A pipeline dispatch terminal cannot stop because one controller fails. We build them with two of everything.
At a pipeline head, a controller failure stops product flow for an entire region. A redundant architecture runs two PLCs and two SCADA nodes in a master and standby pair with the same live database. If the master fails, the standby takes over within the scan time and the operator sees a role switch, not a shutdown.
The GAIL dispatch terminal at Visakhapatnam, head of the Vizag to Secunderabad LPG pipeline, where we replaced the existing PLC with GE in a fully redundant configuration and delivered about twenty operator screens.
Two controllers and two servers run side by side. If one fails, the other is already running, and the operator sees a notice, not a shutdown.
At a pipeline head or a receipt terminal, an hour of downtime costs more than the redundant hardware. Redundancy is also what the oil companies specify.
Four to six months for a terminal; cutover itself in planned windows of hours, not days.
Attach these to your enquiry. The three marked essential are enough for us to start a budget.
It shows what actually fails today, so redundancy goes where it earns its cost.
Not every controller can be paired, and some need a replacement first.
It sets how fast switchover must be and how much of the system is duplicated.
A redundant controller on a single switch is still a single point of failure.
We migrate your screens and tag database instead of redrawing them.
They set how we stage the changeover and how long each step may take.
Every external link has to survive a failover, and we test each one.
These stay single, and we need to say so in the offer.
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 terminal; cutover itself in planned windows of hours, not days.
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.
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.
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.
Yes. We pre-build and test the new system against the existing I/O list, then cut over in planned windows area by area. The GAIL Vizag PLC swap and the ExxonMobil Nigeria upgrade were done this way.
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.
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.