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 sales@masterintegrators.co.in  +91 9833 9303 87
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LNG Station Automation Across Multiple Locations

About the Company

A clean-tech infrastructure provider committed to the global environmental and sustainability agenda. They're building a nationwide network of "Green Fuel Hubs" to serve industries and the transport sector across India.

Requirements

  • The company needed to set up safe, reliable control systems across multiple LNG stations that met strict SIL-2 safety standards.
  • They required a complete solution—from design to installation—that would enable remote monitoring of all sites and ensure fail-safe operations for handling LNG.

    The Challenge

  • Multi-Location Coordination Mobilizing skilled teams, arranging logistics, and synchronizing deliveries across five geographically dispersed sites under tight timelines.
  • SIL-2 Safety Implementation Designing, testing, and validating SIL-2 emergency shutdown and interlocklogic with redundant control paths to meet stringent safety standards.
  • Diverse Site Conditions Adapting control panel designs and network configurations to varying on-site electrical, mechanical, and civil conditions without disrupting existing operations.
  • Secure Remote Connectivity Ensuring reliable, encrypted data flow from edge devices through client firewalls and over public networks to the central monitoring system.
  • Resource & Schedule Flexibility Managing unexpected site delays, last-minute scope changes, and reallocation of field resources without impacting overall project milestones.
  • Third-Party Integration Establishing smooth communication over Modbus protocol with third-party systems like LNG dispensers and gas generators (GEGs)

The Solution

  • Control Panel Supply - Supplied SIL-2 certified safety panels with reliable controllers and pre-configured gateways for secure communication across all stations.
  • Safety PLC Programming - Programmed the control logic for SIL-2 safety shutdowns, interlocks, and automated sequences to ensure fail-safe performance at every step.
  • Edge Gateway & Remote Monitoring - Set up devices to stream real-time safety and process data, enabling live dashboards, alerts, and data logging from a central location.
  • Complete Installation - Commissioned systems at 5 LNG stations, including all wiring, testing, system power-up, and full field testing of safety functions.

Our Approach

Design Phase
Created standard control system designs with built-in redundancy and fail-safe logic. Prepared detailed specifications for programming, interface screens, network setup, and remote monitoring.
Build Phase
Built control panels with certified safety controllers and communication devices. Developed programs according to design specs and configured devices for secure, real-time data transfer.
Installation & Testing
Installed and connected all panels and gateways on-site with thorough testing. Validated all safety features and set up remote monitoring with dashboards and alarms.

Key Outcomes

Enhanced Safety
SIL 2 safety PLCs made shutdowns and interlocks more reliable at all LNG stations.
Better Accuracy & Control
Automation reduced manual work and errors, ensuring smooth and consistent LNG loading, unloading, and dispensing.
Remote Visibility
Real-time data sharing enabled central monitoring of all sites for faster problem detection and decision-making.
System Reliability
Trusted Rockwell hardware and field-tested configurations ensured smooth and stable operations after setup.