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 jointly with Spectrum Technology.
Delivery model: Spectrum handles the hardware and field integration; Silex builds the software, SCADA/HMI and dashboards. The same blue-chip partnership behind 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.
