http://www.yokogawa.com/success/

Success Story

Executive Summary

Hazira LNG Private Limited (HLPL), a joint venture

between Shell Gas B.V. and Total Gaz Electricite

Holdings, operates an LNG receiving terminal in

Hazira, which is a major port and industrial hub in

India's Gujarat state. Commissioned in 2005, the

terminal has two 160,000 m3 storage tanks along with

re-gasification and auxiliary facilities that are capable

of handling 3.6 million tons of LNG per year. This is

the first LNG terminal in India to be built by global

energy companies.

A 22 km pipeline connects the Hazira terminal to the

national gas grid at Mora Station. The pipeline has

sectionalizing valve (SV) and LNG custody transfer

metering (CTM) stations that are located 4 km and 14

km from the terminal, respectively.

The control systems for the Hazira terminal are

installed in its main control room (MCR), which

handles all re-gasification processes and utilities, and

at the jetty facility, where arriving LNG carriers are

unloaded.

Original configuration

The Hazira terminal's process, utility, jetty, and

pipeline operations were all originally automated with

a Yokogawa CENTUM CS 3000 process control

system (PCS), a ProSafe-PLC safety instrumented

system (SIS) with emergency shutdown (ESD) and

fire and gas detection (F&G) functionality. The

ProSafe-PLC was connected to the PCS via a

MULCOM multiple protocol communication interface

unit, an M-net bus (SIS control bus), and a V net bus

(PCS control bus), with all these systems sharing the

same human machine interface (HMI).

New configuration

As the legacy ProSafe-PLC system was costly to

maintain and was reaching its end of support date,

Yokogawa India proposed that HLPL upgrade to

Yokogawa's latest SIS offering, ProSafe-RS. After

considering the merits of adopting the latest hardware

and software, which included the use of a single

control bus for all terminal facilities, the seamless use

of the same HMI for both PCS and SIS, and improved

safety and integrity, HLPL opted to go with Yokogawa

India's migration proposal.

The Challenges and the Solutions

Migrating application logic while keeping

existing engineering philosophy

HLPL was specific in its requirement that the ProSafe-

RS system had to retain the same engineering

philosophy used with the ProSafe-PLC system. HLPL

also insisted that the migration project should

leverage the latest advances achieved in the ProSafe-

RS system software blocks.

Yokogawa's PLC2RS tool for converting from

ProSafe-PLC to ProSafe-RS applications proved to be

extremely effective in fulfilling the client's requirement

to retain the essential engineering features of the

terminal's existing systems. The base application

output by the conversion tool implemented all the

latest features of the ProSafe-RS software. The

engineering output was a perfect blend of the original

engineering philosophy and the latest software

features, and engineering time was drastically

reduced.

Legacy ProSafe-PLC SIS Replaced with ProSafe-RS to Improve

Sustainable Lifecycle Support at LNG Terminal

Location: Hazira, Gujarat, India

Order date: September 2012

Completion: March 2013

Industry: LNG

ISD-SP-R189

Hazira LNG Private Limited

Network migration and integration with

existing components

The key point was the need to replace just the SIS

(ESD & F&G) while keeping the existing PCS and F&G

mimic panel as is. This involved the removal of the

MULCOM interface unit and ProSafe-PLC components

and their replacement with ProSafe-RS components

on a Vnet/IP control bus. To enable the use of the

existing PCS network (V net), Yokogawa India

installed an AVR10D V net router.

The most challenging aspect of this migration was the

software, which included special logic on the PCS for

controlling the MULCOM interface unit. To reduce

network load, Yokogawa India conducted a thorough

investigation and was able to remove this logic without

impacting the PCS logic.

In addition, the MULCOM interface unit had ISA-F3A

alarm indication logic for the F&G mimic panel. All of

this functionality was successfully embedded in the

ProSafe-RS system, and HLPL continues to use the

mimic panel as an operation interface.

Continued operation of BOG and MSO

compressors during migration

For the project execution phase, HLPL inquired

whether it would be possible for safety reasons to

continue operating two boil off gas (BOG)

compressors and a minimum send out (MSO)

compressor. Yokogawa India took up this challenge in

spite of the fact that the running/trip logic for this

equipment resided on the existing ProSafe-PLC

system, which needed to be disconnected as part of

the migration. The company offered an innovative

workaround by implementing this logic on a stand-in

ProSafe-RS system that was temporarily hooked up to

the existing PCS for the duration of the migration

process. Following the completion of all migration

activities, the data on the stand-in system was merged

with that on the main ProSafe-RS system.

Exhaustive planning coupled with clinically perfect

execution helped Yokogawa India meet this client's

demanding requirements with a minimum of disruption

to terminal operations. As a result, both the BOG and

MSO compressors were able to continue operating

throughout the migration process.

Maintaining the same hardware footprint

Given the limited amount of space available in the

control and rack room, HLPL stipulated that the

ProSafe-RS system must have the same footprint as

the system that it replaced. It was indeed a challenge

to fit the ProSafe-RS terminal boards into this space

without compromising Yokogawa's high engineering

standards.

Success Story – Legacy ProSafe-PLC SIS Replaced with ProSafe-RS to Improve Sustainable Lifecycle Support at LNG Terminal