LPG bottling plants, pipeline terminals, custody transfer metering and fire and gas systems for India's oil marketing companies and international operators.
Product arrives by pipeline or tank truck, is stored in bullets and spheres, pumped to filling carousels and dispatched as cylinders. Around that core sit the fire and gas system, the custody transfer measurement where product is received, and the stock accounting that feeds SAP. We automate each part and connect them. Follow the numbers on the drawing from receipt to dispatch; the control room at the top sees all of it, and the cards below say what our system does at each stage.
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.
The equipment our control systems run, photographed on client sites.
Complete plant control from one control room: tank farm, pumps, carousels, interlocks and OISD-214 data sharing with the pipeline.
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.
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.
Upgrade of the dispatch terminal at the head of the Vizag to Secunderabad LPG pipeline from another PLC make to GE, in a fully redundant configuration.
Two PLCs and two SCADA nodes in master and standby. About twenty screens: harbour receipt, receipt lines for HPCL, EIPL and GAIL, mainline pumps, interlocks, fire water, gas chromatography, rack diagnostics, vibration and power distribution.
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.
Upgrade of the fire and gas automation at the HPCL LPG bottling plant.
Detection loops trigger the area deluge valve; ring main pressure drop starts fire engines in sequence; a jockey pump keeps the main above about 7 bar, to OISD-STD-144.
PLC, SCADA and flow computer integration for a fiscal gas metering skid, executed with Nirmal Industrial Controls.
Emerson FloBoss S600+ flow computers calculate flow to AGA, ISO, GPA and GERG; the GE PLC handles skid logic and valves; Cimplicity shows meter runs and totals. Panels built in Mumbai to our specification.
PLC and SCADA for the augmented gas receiving and metering station that supplies the cement plant and its power plant.
Redundant PLC A and PLC B, with SCADA screens for the filter separator skid, the orifice metering skid, the line heaters, the PRF skids for the cement and power plants and the instrument gas system, plus ESD status, fire and gas alarms, event history and reports.
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.
SCADA built with Emerson ROC364 and GE iFIX, and a GE Fanuc PLC and SCADA upgrade on a running facility.
Remote monitoring and control through the ROC364 with iFIX; brownfield migration of the existing control system without taking the facility down.
Metering automation for multi-product fuel receipt stations.
Per-line temperature, pressure and flow with meter totals for petrol, diesel and jet fuel, plus alarms, trends, reports and diagnostics.
An automated prover that verifies custody transfer meters read true.
The HMI routes flow through the prover, compares master meter and test meter volumes across repeat passes, sequences the valves and computes the meter factor.
OISD-STD-214 covers cross-country LPG pipelines. Bottling plants and terminals share live data with the pipeline control system so both ends operate in coordination. We implemented this at IOCL Kalyani and GAIL Vizag.
A terminal at the head of a pipeline cannot stop because one controller fails. With two PLCs and two SCADA nodes in master and standby, the standby takes over without interrupting the process.
Tell us what you are planning, even if the details are still rough. We reply with a technical approach and an offer.