Project NamePCS 7 DCS for High Pressure Air Injection Plant
Case Study: Oil & Gas
Siemens PCS 7 DCS for High Pressure Air Injection Plant - ONGC, Ahmedabad
Full lifecycle DCS delivery - engineering, procurement, manufacturing, installation and commissioning - for ONGC's critical High Pressure Air Injection Plant using Siemens PCS 7.
Project Overview
Project Information
Hive Automation delivered a comprehensive, full-lifecycle Distributed Control System (DCS) solution based on Siemens PCS 7 for the High Pressure Air Injection Plant of ONGC in Ahmedabad.
Our scope covered the complete project lifecycle - detailed engineering, procurement, manufacturing, installation, and commissioning - making this a true single-source, end-to-end turnkey delivery for one of India's most critical oil and gas operators.
The system architecture was designed for maximum reliability and safety, incorporating three separate redundant control setups on a common plant network, two Operator Stations (OS), one Engineering Station (ES), and a dedicated HART Asset Management System for field device diagnostics and calibration management.
Project Details
Project Delivery Snapshot
Completion DateMarch 2025
Scope of WorkEngineering | Procurement | Manufacturing | Installation | Commissioning
LocationAhmedabad, Gujarat, India
System Architecture
Technical Architecture
Siemens PCS 7 with three separate redundant DCS setups on a common Profinet network: Compressor Control System, Process Control System, and SIL-3-rated Fire & Gas Detection System.
Plant network architecture included 2 Operator Stations (OS) and 1 Engineering Station (ES) for centralised monitoring, engineering access, and process visibility.
A dedicated HART Management System was integrated for field instrument lifecycle management, remote diagnostics, calibration tracking, and predictive maintenance support.
Delivery Scope
Scope of Work & Key Deliverables
- Detailed engineering - P&ID review, control narrative, FDS, and instrument loop documentation
- Procurement - Siemens PCS 7 hardware, field instruments, and panel components
- Panel manufacturing - in-house fabrication of DCS cabinets, marshalling panels, and junction boxes
- Compressor Control System - PCS 7 configuration for reciprocating and centrifugal compressor unit control
- Process Control System - full plant process variables, interlock logic, and process SCADA graphics
- SIL-3 Fire & Gas Detection System - gas detectors, flame detectors, and ESD integration
- HART Management System - field device diagnostics, calibration management, and asset health monitoring
- Factory Acceptance Testing (FAT) of the complete integrated system
- On-site installation, loop checking, and commissioning at ONGC Ahmedabad
Project Impact
Challenge & Outcome
Challenge
Designing and delivering a SIL-3-rated, triple-redundant DCS for a live oil and gas operator like ONGC required certified functional safety engineering, rigorous FAT documentation, and precise coordination between mechanical, electrical, and process engineering teams - all executed under a fixed project schedule.
Outcome / Result
Full system commissioned at ONGC Ahmedabad in March 2025. Three redundant DCS subsystems - compressor, process, and fire and gas - were integrated on a common PCS 7 network with HART management, delivering real-time plant visibility and SIL-3 safety coverage from day one.
Process Coverage
Processes Automated
- Compressor Control System - redundant controllers managing injection compressor train sequences, anti-surge control, and vibration monitoring.
- Process Control System - plant-wide process variables, flow, pressure, temperature, and utilities automation.
- SIL-3 Fire & Gas Detection System - certified SIL-3 logic solver with mapped fire and gas sensor coverage zones, voting logic, and ESD activation.
- HART Management System - connected to HART-capable field instruments for remote calibration, diagnostics, and predictive maintenance alerts.
I/O Summary
I/O Capacity & Configuration
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Frequently Asked Questions
Oil & Gas Automation Questions, Answered
Yes. We delivered the complete Siemens PCS 7 DCS - including compressor control, process control, SIL-3 fire and gas, and HART management - for ONGC's High Pressure Air Injection Plant in Ahmedabad, commissioned in March 2025.
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