Case Study by Yokogawa: 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.

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Many process facilities have an outdated Distributed Control System (DCS) currently in place. As a DCS reaches the end of its useful life, migration to a new automation system is required. Three new white papers from Rockwell Automation, “Justification for Migration,” “DCS Migration Strategy and Implementation,” and “Automation System Optimization,” examine the different financial, strategic and optimization advantages associated with migration, and address valuable plant inquiries that usually accompany the topic. The three papers focus on different steps within the migration process and give detailed insights into migration.

Justification for Migration – This paper examines how to accurately analyze the total cost of ownership for continued operation on an outdated DCS and how to justify the benefits of replacing it.

DCS Migration Strategy and Implementation – This paper shares strategies for upgrading an existing legacy DCS to a new automation system, and focuses on how to implement the chosen strategies while maximizing uptime, and minimizing cost and risk.

Automation System Optimization – This paper examines the specific ways in which a new automation system can deliver superior performance as compared to a typical legacy DCS.

“Many companies may not realize that the very same DCS system installed years ago to improve productivity and reduce costs, is actually negatively affecting productivity and the bottom line today,” says Mike Vernak, DCS marketing manager, Rockwell Automation. “Much of the expense is due to the difficulty in maintaining technical expertise and finding spare parts for the 25- to 30-year-old legacy systems.”

The white papers, “Justification for Migration,” “DCS Migration Strategy and Implementation,” and “Automation System Optimization,”. Rockwell Automation has conducted three webinars on DCS migration to accompany the white papers.

Siemens' Dairy Functional Toolset (DFT) complements the Simatic PCS 7 process control system by adding various important functions for milk-processing enterprises. DFT allows specific workflows such as milk sampling, pasteurization, separation, cheese and yoghurt production and the end-of-process cleaning of pipes and tanks to be accurately and easily controlled via Simatic PCS 7.

The new DFT software contains all necessary visualizations (faceplates) for displaying plants and processes controlled by Simatic PCS 7 on the screen. Important process steps are pre-installed to the most up-to-date industry standards and can easily be configured to suit any application. Moreover, this Siemens DFT toolset continuously captures and archives production-related data such as temperature, agitation time, pH, and storage location. These data can then be exported to a superimposed MES (Manufacturing Execution System) or an ERP (Enterprise Resource Planning) system. This integrated data management concept ensures consistently high product quality and product traceability from the raw milk to the processed, saleable product.

Functions related to specific process steps and workflows are pre-consolidated within the DFT software. For example, modules for the management of materials, system parameters, orders and storage locations are pre-installed. These support the automation of production processes from the delivery of the raw milk to the signing off for bottling and packaging. Further modules such as those for tank management, piping system management, process line management, follow-up material testing and a CIP (cleaning in place) sequencer have been optimized within the new software with a view to automating processes such as transfers, mixing and cleaning.

Milk processing today calls for extremely efficient and perfectly interacting processes from the delivery of the raw milk and its sampling and initial preparation through the various operations in the dairy processing plant to its packaging, storage and shipment. With its customized solutions such as the DFT software and an extensive product portfolio of integrated automation and drive solutions, Siemens is helping milk-processing enterprises to optimize their production processes and thus enhance their competitiveness.

Idemitsu Kosan Co., Ltd. (Idemitsu) is a leading producer and distributor of oil, lubricants, and petrochemical products, and is also engaged in the research and development of functional and electronic materials as well as agricultural biochemicals. At the company’s Technology & Engineering Center, technical experts are carrying out research in the refining and petrochemical fields, focusing on topics related to development, design, construction, operation, quality control, maintenance, and systems.

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