Advances in Terminal Automation Systems

Abraham Samson Senior Manager Larsen and Toubro Limited Automation Systems Centre Navi Mumbai, Mah., India

Kishore Raheja Manager Larsen and Toubro Limited Automation Systems Centre Navi Mumbai, Mah., India

KEYWORDS
Terminal Automation, Oil and Gas, Terminals ABSTRACT The article describes the advances in Terminal Automation Systems. Instrumentation & Automation is used in all the areas to co-ordinate the entire terminal operations for a virtual unmanned fashion. The controlling system needs to take care of product movements, fast turnaround times , vehicle queue optimization, product reconciliation, safety , fraud & loss prevention, allow controlled access and interact with business systems for order fulfillment and invoicing. The article describes the typical architecture , features, experience and benefits of such a control system and is based on the experience of many such similar projects executed in India by Larsen and Toubros Automation Division, where an integrated software package (LnTAS) which covers all aspects of terminal operation has been deployed. INTRODUCTION Terminals are an important component in the distribution network of oil and gas. These terminals have large capacities to store products, which are distributed using truck or rail wagons or barges. These terminals are a source for retail outlets. Traditionally these terminals were manually operated but with new supervisory and control software these are now being better leveraged to provide virtually unmanned operation. Primary function of Terminal Automation System (TAS) is to increase accuracy, efficiency and safety of the distribution process. It also enables terminals to increase availability and throughput while reducing risks and cost. System provides terminal security, Vehicle identification, inventory management, and safety interlocks, Filling Advice Note (FAN) printing, audit trail, event and alarm logging and extensive reports.

These integrated solutions consist of flow measurement and control equipment, Vehicle identification devices and other hardware and software, which are fully integrated with custom or commercially available enterprise management systems (ERP).

OVERVIEW OF SYSTEM FUNCTIONAL REQUIREMENTS:

Terminal facilities comprise of loading bays. The facility is designed to typically operate two shifts throughout the year, demanding a highly reliable system. Loading bays incorporate loading arms, which are manually positioned and a pre-set metering system to control the delivery of various Products. The metering and interlock system includes card readers for customer identification. Each product is supplied to the loading bay from a common header from Tank Farm system. Blending and Dosing systems may be also provided at the header or bay level. These are typically for ethanol or high-performance additives. Each loading bay is supplied as a integrated module interfaced to a centralised Loading TAS for monitoring and supervisory control. The loading and tank-farm area are hazardous areas and equipment conforming to the area classification needs to be used. A centralised control room is provided to accommodate all safe area loading bay equipment. Operation is done via Windows based workstations. The loading bays are totally automated with load details set by the TAS. Standby manual operating facilities permit loading from the Batch controller in case of a communications breakdown. Tankers are identified and logged on entry to the facility. Drivers are issued with a token for automatic identification, typically a proximity or touch-key card. The system is used to monitor the progress of the truck from entry through the loading area to exit. Each entry barrier gate, loading bay and weighbridge will have a card reader, interfaced to the central loading computer. The system ensures that queuing at each bay is dynamically minimised. As each tanker enters the loading area the TAS identifies the customer, product and capacity of the vehicle. This is used to produce a Filling Advice Note (FAN), which will advise the driver of the bay to be used, product and volume. On arrival at the bay the driver again identifies himself to the system and complete connection of loading arm and safety devices, which includes the Grounding systems, and loading arm position switches. Once all interlocks are satisfied a green lamp will illuminate. The driver will then press a button to initiate loading. Loading will stop automatically when the programmed load has been delivered. In case of an emergency loading may also be stopped by loss of interlocks or by a button on the gantry. As the tanker leaves the Loading area it is again identified at the exit security barrier. Facility is available to collect and recycle the identification cards at this point. The TAS continuously reads Storage Tank levels and inventories from the Automatic Tank Gauging system. This system displays these parameters to loading operators in both graphical and tabular formats. Data available include available inventory, ullage and allocated inventory for both

individual tanks and a given product. The system also controls various motorised valves on tank receipt and outlet pipelines. On receipt of a loading request the TAS interrogates the inventory of the Loading Storage Tanks to ensure sufficient inventory is available. Product volumes are marked as allocated to a given customer within the system as soon as an order is entered to identify inventory deficiencies as early as possible. As tankers are filled the allocated inventory shall be automatically adjusted.

SYSTEM CONFIGURATION: A typical TAS configuration has the following main components:
ERP System MARKETING CONTROL ROOM TRUCK/WAGON LOADING E-Logistic Work Stations

100 MBPS LAN (ENTERPRISE NETWORK)

TAS/TFMS
CLIENT CLIENT SERVER SERVER TTES SYSTEM

IT ROOM

Router (Gateway)

Print Server

100 MBPS LAN (CONTROL NETWORK)

ESD Configurator

Terminal Server Terminal Server Dual Dual

From Data Entry Terminal

From Prover Computer

Redundant PLC
LRC Server ( HOT BACKUP)

ATG CIU RAID 5 External Storage

Batch Controller + Card Readers Weigh Bridge

MOV Master Station

Fig 1: Typical TAS configuration

LEVEL 2 (Supervisory Level)

Loading Rack Computers (LRC) Tank Truck Entry System (TTES) Operator Interface Computer (OIC) Terminal Managers work station ERP Interface e-Logistics / Web Interface Redundant Link TCP / IP Ethernet network connecting all the above terminals Programmable Controller (PLC) in Hot Standby configuration Redundant Master stations for Motor Operated Valve (MOV) controls Communication Interface unit (CIU) for Radar Level Gauges Communication processors for Batch controllers, Gate displays, Densitometers Optional Emergency Shutdown (ESD) PLC. Networked Batch Controllers with corresponding Positive Displacement (PD) / Mass Flow meters , Pulse Transmitters, Control Valve, Earthing (Grounding) device, and Remote Interaction Terminal (RIT) Card readers in each loading bay MOV system with Field control units (FCU) and corresponding Actuators One on each MOV and all FCUs networked using twisted pair cable in redundant configuration Radar level gauges with respective display units one on each product tank and all gauges networked using twisted pair cable Densitometers , networked Pressure transmitters , networked or connected to PLC I/os Large Sized Display in TT area Data entry terminal at TT area

LEVEL 1 (Control Level)

LEVEL 0 ( Field level)

Data Processing Print Server Alarm/Event Handling

Real-time Database

Inter Process Communication Sequence Control Man Machine Interface

TAS Core
Data Acquisition and Control

TERMINAL AUTOMATION SOFTWARE

Applications Tank Truck Registration Truck Terminal Automation

TAS Core
Product Receipts/Dispatch Tank Inventory Pipeline Monitoring/Plant Control

Fig 2: TAS Software Modules

Terminal Automation Software is a software application that seamlessly integrates various components of the existing automation system to achieve the following terminal automation related functionality.
a) Tank Truck (TT) Registration

Tank truck registration can be understood as a formal acceptance of request from the customer computer by the server to authorize a tank truck to fill the requested product from the terminal.
b) Truck Terminal Automation

Truck terminal automation involves the following functions: Truck entry & exit validation Communication with the devices that control loading at the Bays Perform a controlled truck filling operation Provide monitoring of safety Inputs Record and store truck loading information Log events and generate alarms. Support blending of products and additives Produce Filling Advice Notice (FAN)

Print Bill of Lading (BOL) and invoices Manual bay allocation changes by authorized personnel Credit invoicing and pricing End of shift/day/month/ processing Product gain/loss report System reports Truck movement reports

c) Product Receipt/Dispatch, Tank-Farm Inventory

Product receipt/dispatch, Tank Farm Inventory supports the following functionality: Terminals product receipts/dispatch monitoring. Products details, e.g. Density range Tank levels and volumes Tank level alarms Tank Details Display Loss Gain Calculations and Reconciliation

d) Pipe Line/Tank Farm/Pump Engine/MOV Control Automation

Incoming/Outgoing Pipeline monitoring and control Batch tracking and cutting Batch Scheduling Data Acquisition for input to maintenance management Main line Pump Start/Stop Sequential control

SYSTEM SOFTWARE components:

Loading Rack Computer Software Tank Truck Entry System Software Tank Farm Management Software Plant Control System Software

LRC Software Architecture

The LRC computer consists of following software applications as detailed below 1 The communication interface to ERP in Hot Standby

2 3 4 5

The Real Time Synchronized Replication Database Application. Alternately a Clustered configuration may be used. The Communication link to Plant Control System in Hot Standby Configuration Database server for Client Applications like TTES, OIC & TFM for Data retrieval and update. The server also serves as Integration platform for Enterprise Information System such as SAP or other systems

Over view of LRC software

The Redundant LRC is based on an RDBMS (ORACLE) Real Time Synchronized & Replicated Database communicating to Terminal Documentation Module (TDM) on Dual Ethernet LAN. This system ensures real time database replication. The LRC being a nodal point for data upload from and download to ERP computer. This is based on Windows NT operating system.
ERP Interface Functions

The LRC-ERP interface supports all function calls such as Authorize Truck, Get Load Completion Data, Get Truck status, Cancel Truck, Reconcile Inventory, Open New Day, Get File and put file for Tank Wagon Loading Operations.
Data transmission and Control Link to plant Control System HMI

The data transmission to the Plant Control System takes place through the HMI software through an ODBC driver. This software also runs in real time redundant configuration enabling thereby an online backup system in the LRC computers. The plant Control functionality is tightly interwoven between LRC system software and HMI system software. Both these software are in client server architecture.

Figure 3: LRC software architecture block diagram /Database Configuration.

TTES System Software The TTES is configured in Client Server architecture. The TTES computer acts as client to the LRC. The FAN data is stored in the LRC. This data is referred and processed by Bay Allocation logic in the TTES client and subsequent update takes place in LRC that acts as the server for this data. The GUI and Plant Control system data as well is maintained in client server architecture in the LRC acting as server. The link between the two is on TCP/IP on dual Ethernet LAN hardware. The following functions are offered to the TTES computer. Automatic Download of pending FANs This function is automatically performed at the launch of TTES operations. All the pending FANs are displayed to the operator and a particular fan can be selected for Bay Allocation by clicking on the respective FAN. Any FAN from the showed list can be selected. By default the first FAN displayed is selected for Bay Allocation. Bay allocation logic While authorizing a Truck for filling the LRC automatically assigns appropriate Loading Bays for filling various products to be filled into the Truck. When the TTES operator generates the FAN for a truck, the PMS software invokes the "Bay Allocation logic" built into it. The following are the key requirements of the Bay Allocation logic. Optimum utilization of all the Loading Bays available at the Terminal Bay with minimal movement of the truck within the loading area.

Restrict the number of Trucks inside the loading area. Dynamic Queue Optimizations to reduce truck turnaround and waiting times

The following information about a Truck is available to the LRC from the ERP computer. a) No of products to be filled and the quantity of each of the products to be filled. b) No. of compartments in the Truck and the capacity of each of the compartments The following status information about each of the loading Bays at the Terminal is already available to the LRC: a) No of loading Bays available at the Terminal for loading each of the requested products. b) No of Loading Bays currently declared good for use c) No. of Trucks already queued up at each of the Loading Bays. Normally the Bay allocation logic will attempt to assign a single Loading Bay so that all compartments of the Truck can be filled at the same Bay. However, if the combination of products is such that filling cannot be completed at a single Loading Bay, then the Bay allocation logic will assign appropriate Bays for filling all the products. The result of this Bay allocation logic will be transferred to the TTES Terminal and the same will be displayed on the TTES terminal for operator review. The TTES operator, if needed, can override the automatic Bay allocation performed by the LRC. If the Bay allocation logic fails to assign loading Bays, then all Bay assigned fields in the FAN display on the screen will be empty and the Bay operator can assign desired Loading Bays for filling various products. Card assignment and FAN printing Every Proximity Card is embossed with a unique serial number. It also has an encoded serial number, which is not visible, but may be read by the PCR. The proximity card label is identified by the serial number embossed on it. This is also called the ID number. When the TTES Operator confirms the above, the Proximity card ID and loading Bays assigned for filling will be downloaded to the LRC. The complete FAN with the card ID number is then printed out on the printer attached to the TTES Terminal. Simultaneously the TT no. is displayed in the Gate VDU for the driver to proceed to S&D for collecting FAN

Plant Control System (PCS) Software

The PCS software consists of two components : PLC and HMI software implemented in computers of LRCs, OICs and a tightly integrated dual Ethernet LAN connecting the Computers and Control Network in a full redundant architecture. PLC Software The PLC system software offers following control functions.

Hot Standby System Software for redundancy implementation. Automatic starting of the Product Loading Pumps through the LRC / PLC depending on the demand of the product. The pumps work in standby mode to ensure starting of standby pump in case the primary pump fails. The no of pumps working shall depend on flow demand. The pumps can also be operated manually from the OIC. Entire functionality of pump control is achieved through PLC application software for necessary interlocking. Alarm Annunciation displays all the critical alarms in the Product Control Rooms. These alarms are grouped for Valve failure , Pump Failure , Tank Alarms , TLF line pressure, Density out of range etc. The annunciator alarms are implemented in the PLC application software. GUI Software

The GUI (HMI) software residing in LRC, OIC & TTES provides various functions for Plant Monitoring and Control. Data transfer to & between the Batch Controllers and the LRC. The GUI facilitates Remote control of actuators through PLC and Master Station Automatic and Manual Controls for Batch Controller stop and start , pump auto/manual selections and for tank farm management are available through GUI/PLC software. Graphics, Alarm management and data trending

Tank Farm Management Software

Tank Farm management System (TFMS) software package is a powerful and versatile inventory management program for bulk storage tanks. The versatility lies in the options provided to cater to the various methods of inventory calculations followed in oil industry. Very high accuracy in volumetric inventory for various products are obtainable. Main functions are : Acquiring Tank gauging Information The package acquires data like Level, Density, and Temperature from instruments mounted in the field. The package serves any combination of instruments like smart Transmitters fitted on any type of tank and having different inventory (by volume or by mass) requirements. Remote Time Monitoring of Tank data Continuous real time monitoring (single tank or logical group of tanks, e.g., all tanks, product wise, group wise, customized etc.) of upto 32 tanks. TFMS package scans 32 tanks less than 3 sec. Real time pumping rates can also be monitored and are used for detecting leak alarms. Inventory Calculation / Presentation Computing inventory using calibration charts, using standard compensation and conversion tables and tank strapping table data and presenting it in different logical formats for the user to work with. Current and Historical Report Generation Automatic Logging at preprogrammed dates / times. Logged data used for trending information, histograms and variation reports.

Integration with Terminal Automation server In this method of integration, TFMS package installed on one node of Local area Network generates a current tank data file on the server. This file can be shared by TAS program installed on other nodes. OPC connectivity is also being offered by many tank gauging vendors for on-line data access Automation System Redundancy Architecture

In a TAS, failure of control hardware or software is not acceptable. This is because such a failure not only hinders operations, but also compromises safety. In real life, hardware and software do fail due to various reasons. TAS implements redundancy in such a way that no single component failure causes any loss of data or functionality. This is achieved by providing redundancy at each level. Hardware redundancy is provided at every sub-system level to ensure that failure of any sub-system hardware does not affect the loading operations at the terminal. In addition to provide entire sub-system hardware as a backup, critical communication links listed below are also duplicated to provide redundancy. Ethernet LAN over which the LRCs, IMS, TTES and the OICs communicate with each other. Serial ports through which the PLCs communicate with LRCs

USER BENEFITS & KEY FEATURES Complete, ready-to-run solution Optimized for terminal performance and availability Traffic management- Provides systematic and efficient handling of filling operation. Reduction in labour possible. Reduction in waiting time for documents. Eliminates the tiresome task of collecting and manual sorting of loading tickets. Security Makes depot safer since dangerous actions (e.g. improper connection of grounding device at the loading bays) can be eliminated. Reduction in Fraud- Filling can be done only after driver is identified at gantry. Real-time control of amounts delivered. Sophisticated audit functions allow events to be explained and fraudulent operations to be avoided. Flexibility-The flexibility of the system allows physical changes in the depot layout to be taken into account without modifying the software or interrupting the operations. Remote maintenance, with access to the various stations in the depot from our computers either via a modem link or through the client (TCP/IP) network allows swift, precisely directed intervention. Inventory management- Manage and provide detailed and accurate information of the available and dispatched products. Direct surveillance of the movement of each product for an efficient control over losses. Commercial Management- Smooth interface between Process and Business system for accurate invoicing and real-time integration. Loading schedules can be uploaded from different sources. Automation makes available up to date and reliable information on quantities of products delivered, either globally or by client, which can be exploited by marketing, customer services, or purchasing departments. Scalable- Expandable from a single-arm bay to Multi-arm bay. Open In built standard interfaces (usually OPC/ODBC) allow seamless integration with various systems.