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SUCCESS STORY
Hazira, Gujarat, India
September 2012
March 2013
LNG
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 m
3
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.
Legacy ProSafe-PLC SIS Replaced with ProSafe-RS to Improve
Sustainable Lifecycle Support at LNG Terminal
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.
ISD-SP-R189
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SUCCESS STORY
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.
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.