Every signal in the plant, from bullet level to carousel count, in one control system with the safety interlocks built in.
LPG arrives either through a cross-country pipeline, where it passes a custody-transfer metering skid, or by tank trucks unloaded at the gantry into the receipt header.
We automate:Flow and pressure supervision on the receipt line, interlocks with the pipeline terminal, receipt metering totals and OISD-214 data exchange with pipeline control.
Product is held under pressure in horizontal bullets and a sphere, each isolated by remote operated valves on the outlet.
We automate:LT, PT and TT on every vessel, high and low level and pressure alarms, ROV open and close commands with position feedback, and emergency isolation from the control room.
LPG pumps draw from the storage manifold and feed the filling shed; an LPG compressor returns vapour to the gantry so trucks can be unloaded.
We automate:Start and stop sequences, duty and standby rotation, run hours, dry-run and low-suction protection, and ESD interlocks that trip pumps and close ROVs together.
Empty cylinders travel by conveyor onto the filling carousel, are filled by weight, then pass a check-weigh and leak test station before leaving the shed.
We automate:Carousel status, cylinders per hour and shift production counts, check-weigh and leak-test results logged against each run, and shed gas detection tied to the ESD.
A fire water ring main with deluge sprays over the vessels and shed, gas detectors around storage and filling, and fire water pumps kept pressurised by a jockey pump.
We automate:LEL detection and zone alarms, deluge valve actuation, fire water pump sequencing on ring-main pressure drop, jockey pump pressure control, and zone annunciation at the gate.
Filled cylinders are loaded onto trucks for dispatch, and the plant's opening and closing stock must be reported to the corporate ERP every day.
We automate:Tank levels converted to quantity and posted to SAP automatically at 6 a.m. (auto dip posting), dispatch counts, and OISD-214 data sharing with the pipeline.
An LPG bottling plant receives product from a pipeline or tank trucks, stores it in bullets and spheres, pumps it to filling carousels and dispatches cylinders. The control system has to see all of it at once: storage levels, pressures and temperatures, pump and compressor status, valve positions, gas detection and the state of every interlock, so the operator can run the plant from the control room and the safety logic acts before a person has to.
Our largest IOCL engagement was a turnkey automation of the Kalyani plant in West Bengal. We delivered the same scope at BPCL Mangalore with a full fire and gas system, and at IOCL Khorda. Across about 22 IOCL and BPCL plants our auto dip posting system sends measured stock to SAP every morning.
One control room screen runs the whole plant. Operators see every tank, pump and valve, the safety logic trips before anyone has to react, and the stock figures reach SAP without a clipboard.
OISD audits, pipeline coordination and SAP stock accuracy all depend on the control system. Manual logging and standalone panels fail each of them.
Four to six months for a complete plant; shorter for an upgrade of one system.
Attach these to your enquiry. The three marked essential are enough for us to start a budget.
We count instruments and valves from it and draw the tank farm, pump and carousel logic on it.
The I/O count sets controller size, panel count and most of the engineering hours.
It fixes the PLC and SCADA make, redundancy and documents we must quote to.
It decides barriers, Ex-rated field devices and where panels can stand.
We code the interlocks from it; without it we draft one for your approval.
It decides which tank and receipt data we exchange and over which link.
It tells us whether we extend, migrate or replace.
The auto dip posting needs one SAP code per tank before we can configure it.
Do not have all of it? Send what you have; we work from a site visit for the rest.
Overall: Four to six months for a complete plant; shorter for an upgrade of one system.
Every plant is different, so we price from the I/O list and scope rather than a rate card. Send the documents above and you will have a budget figure within a week, and a fixed price after the scope call.
Our largest IOCL engagement: complete automation of the LPG bottling plant with every real-time signal and safety interlock in one control system.
Level, temperature, pressure, valve status and alarms integrated in GE iFIX; full plant operation from the control room; live terminal data pushed to the connected pipeline as OISD-STD-214 requires.
Complete LPG plant automation plus the full fire and gas system, executed in about five months.
Deluge valves, break glass units, sequenced fire engines, jockey pump and ROV control. A digital fire clock at the gate lights the zone where fire is detected, mapped across admin, MCC, sheds, pump house, gantry, sphere and bullet areas.
Measured tank levels posted into SAP automatically, removing manual stock entry.
SCADA collects live levels; every morning at 6 am a Java routine posts them to SAP through a remote function call. Running at about 16 IOCL plants since 2017 and 6 BPCL plants.
OISD-STD-214 covers cross-country LPG pipelines. Bottling plants connected to a pipeline share live data such as tank levels and receipt status with the pipeline control system so both ends operate in coordination. We implemented this at IOCL Kalyani and GAIL Vizag.
GE iFIX, with GE PLCs. iFIX gives the alarm management, trending and audit trail that oil marketing companies specify, and we have standardised on it since 2005.
Metering skids, flow computers and meter provers, where the measurement settles money and has to stand up to audit.
Detection, deluge valve control, sequenced fire water pumps and jockey pump pressure management to OISD-144.
Dispatch and receipt terminals on redundant PLC and SCADA, so a single failure never stops the line.
Live tank levels posted to SAP every morning without manual entry, running at about 22 IOCL and BPCL plants.
Tell us what you are planning, even if the details are still rough. We reply with a technical approach and an offer.