The challenge
Legacy, manual fuelling at rail depots left accuracy, reconciliation and safety to paperwork and human judgment - a costly and hazardous way to move millions of litres of diesel into locomotives every year.
Accuracy
Manual dispensing and hand-written logs made per-locomotive volume hard to verify and easy to dispute.
Safety
Fuelling live locomotives at a depot is a hazardous operation demanding controlled, monitored, interlocked flow.
Reconciliation
Volumes had to tie out across depots, shifts and BPCL's own reporting with a clean audit trail.
What we built
A hardware-integrated fuelling platform that automates, monitors and reports every litre - each capability answering a specific operational stake above.
- ◆Fuelling automationControlled, metered dispensing per locomotive with interlocks and preset volumes - no manual guesswork.
- ◆Hardware / PLC integrationSoftware tied directly to pumps, flow meters and PLCs over Modbus, so the platform commands and reads the physical plant.
- ◆Real-time monitoringLive depot dashboards showing flow, status and alarms as fuelling happens - visibility across all six sites.
- ◆Reporting & reconciliationAutomatic per-transaction, per-shift and per-depot records with an audit trail that ties out to BPCL reporting.
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
In continuous production since 2021 and scaled across the network, the platform turned a manual, dispute-prone process into accurate, safe, reconciled fuelling with a full audit trail - the numbers a prospect can forward internally without a caveat.
"The platform gave us accurate, tamper-resistant fuelling and a clean audit trail across every depot - reliable enough to run without a second thought."
- Operations lead, BPCL depot network (illustrative - attribution pending client approval)
Why it matters
Fuel depots, airports and railways don't get to have an outage. When a system runs 200M+ litres across six sites for years without a major failure, ownership and longevity stop being marketing claims and become the operating record. 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.
