The challenge
An LPG terminal handling bulk receipt, pressurized storage, and dispatch is inherently hazardous - it must continuously watch fire-protection, gas-leak detection, emergency-shutdown, and valve systems. Control-room operators needed a single, real-time view of all that equipment, with a historical record of alarms for incident review, rather than fragmented panels.
Hazard
Bulk receipt, pressurized storage and dispatch of LPG demand constant, watchful monitoring.
Single view
Operators needed one real-time picture of every subsystem, not fragmented, isolated panels.
Traceability
A historical record of alarm state-changes was needed for incident review and follow-up.
What we built
A web-based SCADA/HMI for the Jhansi terminal - each capability answering a specific operational stake above.
- ◆Live mimic screensColour-coded status for valves, emergency-shutdown devices, gas detectors, fire-protection systems, storage vessels ("bullets"), pumps and compressors, refreshed roughly once per second.
- ◆Direct plant integrationLive values read from plant PLCs over industrial Modbus TCP; a background Windows service polls the tanker-filling gantry every second and snapshots readings.
- ◆Supervisory controlOperators can acknowledge alarms, set maintenance/operational modes, and issue a controlled set of commands.
- ◆Historical alarm logAlarm state-changes recorded for review and incident follow-up.
The stack
Industrial-grade software on a hardware foundation — delivered as a complete integrated solution.
Delivery model: Silex builds SCADA software, HMI systems and dashboards, with hardware and field integration handled as part of the integrated solution. The same approach powers BPCL, Indian Railways and both airport projects — which is how a senior ~15-person software team delivers hardware-integrated systems at national scale.
Results
Deployed June 2024 and live in production, with active development continuing (pipeline-overview and tanker-filling capture being extended) - a single-pane, real-time operational view of a safety-critical LPG terminal, with direct, sub-second visibility into ~15 plant subsystems.
Why it matters
This is monitoring where a missed alarm has real consequences. Silex builds the software that gives operators of hazardous industrial facilities live, reliable visibility - integrated straight into the plant hardware. That is the same discipline Silex brings to a B2B ordering platform or a retail stack - engineered to your business, owned by you, and supported for the long run.
