International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056

Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072

Design of TAS using PLC and Batch Controller

Sreeraj S1
1Software Engineer, ADAS Business Unit, Continental AG, Bangalore, India
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Abstract – In this paper, the design of sequential process like ESDs. The second one controls the barrier gates, DBBVs,
involved in the automation of oil and gas terminals is pumps etc.
explained. This paper talks about various levels included in the
TAS or Terminal Automation System as subsystems, the 2. SUBSYSTEMS OF TAS
different mechanical and electronics equipment used and how
they are designed. The Terminal Automation process starts with the truck
enters the terminal and ends with the truck leaving the
Key Words: TAS, Batch Controller Unit (BCU), PLC, terminal after the tank compartments are filled with fuel.
SCADA, Digital Control Valve, LOAD RACK During this time there are several processes like generation
COMPUTERS of fan, interfacing SAP with TAS, entering into licensed area,
batch controller functioning, loading, cancellation of truck,
1.INTRODUCTION bypassing, aborting truck etc. All these operations will come
under eight main subsystems and they are briefed below.
One of the most relevant economic sectors in India is the
petroleum industry. Due to its highly inflammable nature, 2.1 TAS-SAP INTERFACE
dealing with both oil and gas is of very high risk. Because of
the mistakes and carelessness done by humans, so many TAS-SAP interface is developed in a view to automate the
deadly accidents have occurred in the oil and gas field. transfer of data between server and client TAS system. It has
Products which are refined from refineries are stored in in built control and executable algorithms for its proper
places called Terminals. These products are despatched to working.
oil pumps from the terminals only. Many of the petroleum
products are highly inflammable and their cost is also very 2.2 GANTRY AUTOMATION SYSTEM
high. So, we require a safe, hazard free, at the same time a
commercially successful environment. This is the scenario The heart of TAS is gantry automation system [2]. The
where automation of the oil and gas terminals is of high transfer of fuel products is mainly controlled by this unit. It
importance. Here the automation process of the oil terminals consists of batch controller, Overspill Preventing Device
is discussed. Proximity Card reader, Static charge grounding device,
Loading Arm position detector, Loading Arm, DCV, Flow
The entire process can be divided into three fields. meter, Strainer with Air eliminator, Pressure and
 Programmable Logic Controller (PLC) Temperature transducers and Pulse transmitter.
 SCADA and Control room
 Field devices 2.3 BLENDING AND ADDITIVE INJECTION SYSTEM

All the pipe lines, trucks, tanks, batch controllers, wagons, Selecting the optimal combination of components to produce
card readers, radar gauges, sensors, air eliminators, RTDs, the final finished product is one of the most critical economic
valves, strainers etc. comes under field devices. issues for both traders and refiners. Blending is much more
complicated than a simple mixing of components. This
Control room has the communication devices such as mod system will allow to feed different products from a single
buses, servers, PCs, RTUs, switches etc. Signals from the field loading arm and thereby reduces dependency on more than
are received by these devices through RS 232/485 cables. one tank. This helps in flexibility in operation.
LAN interconnects all the devices in the control room. The
processes are remotely controlled from the control room 2.4 TFMS SUBSYSTEM
through SCADA.
The product which is stored in each tank and its level are
The PLC will get energised by the control signals which constantly monitored by TFMS or Tank Farm Management
SCADA gives and the PLC will control the field devices. PLCs subsystem [2]. It also watches other related information like
used in terminal automation are two in types. Safety PLC and temperature and density. Tank gauges, tank slide indicators,
the Process PLC. The first one is used for safety applications temperature sensors, communication interfacing units,
TFMS software and water bottom sensors are the major

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072

components of this subsystem. Mainly it has all the functions for loading/unloading/blending of products such
measuring equipment and the TFMS software to control that. as fuel, biofuels, chemicals, bitumen, asphalt and LPG. This
intelligent loading system offers numerous functions,
2.5 TTES SUBSYSTEM including flow measurement with pulse verification to API
and ISO standards, temperature and volume correction and
Filling Advisory Note (FAN) generation process is managed digital valve control.
by TTES or Tank Truck Entry Subsystem. FAN is generated
from the data coming from client to server. Tank Truck Entry CARD READER UNIT
System will be provided for authorizing the TT for loading
product, for a consignee, by allocating loading bay and to The card reader is installed at each bay to restrict the access
issue access entry card. of unauthorized vehicle / person to a hazardous or
nonhazardous harsh area [2]. The card reader is highly safe
2.6 TTRS SUBSYSTEM and so it is being used in areas certified as Zone 0 and any
other hazardous area, where there are more chances
All TTs at the locations will be provided with configured explosion. It is configured to read cards of different
RFID tag on the wind screen of the TT as part of Registration technologies. After the truck is parked inside the bay, the
requirements. RFID readers will be provided at the entrance driver has to flash the card at the bay card reader. On
of TT Parking area. RIFD reader to read the TT flashing card at the bay, the truck appears in the SCADA
Registration no. of incoming TTs from RIFD tag pasted on the screen in control room. Upon successful completion of
wind screen and convey to Server. Registration number of identification, and if card is valid then TAS will
the TT entering the designated TT parking area will get check for all safety permissive interlocks.
logged on the Server in S&D automatically and also flashes
the same on the Queuing Display Board (QDB) which will be SCADA SOFTWARE
provided in the parking area. Server will communicate with
the LRC and SAP. SCADA controls the whole operation in depot which starts
from the arrival of the truck till the exit from the terminal
2.7 CONTROL ROOM SUBSYSTEM [1][3]. With SCADA one can see the complete loading
operation at the gantry area. The graphical representation of
The TAS system is operated and controlled in remote mode the loading process is shown through iVision max software.
in this subsystem. LRCs (Load Rack Computers) which are Details regarding each compartment in a truck such as which
redundant in nature, printers, PLC, networking devices, compartment is to be filled by which fuel by what quantity,
panels, UPS units, consoles etc are the main components in are either given to the device locally or can be given from the
this subsystem. LRCs will have the SCADA software installed SCADA. One can cancel or abort a truck from the SCADA.
in it. SCADA energizes PLC to control the field equipment.

2.8 CONTROLLED ACCESS SUBSYSTEM DCV

The entry of trucks and its exit at the terminal is controlled Digital control valve(DCV) is used to limit the product flow
by this subsystem. Barrier gates, traffic lights, RFID readers, , as per instructions programmed in Batch Controller.
various sensors for identifying vehicle, security station etc Diaphragm Digital Control Valve is an electrically actuated,
are the components of this subsystem. hydraulically operated multi-function control valve. It can be
used for local as well as remote controlled batching
BCU operations with electronic batch controller. When the
Diaphragm Digital Control Valve is used with an electronic
The proper functioning of Terminal Automation System is batch controller, it can be digitally controlled by operating
mainly dependant on BCU [1][2]. A Batch Controller Unit the solenoid valves through any of these three stages.
(BCU) is a loading system designed for loading gantries of  when NO and NC solenoids are energized, the valve
petroleum refineries and oil marketing terminals to control opens gradually.
and manage the custody transfer of petrochemical products  when NC solenoid is de-energized (keeping NO
onto railcars and road tankers. It is a powerful and solenoid energized), the valve locks at its current
intelligent loading system, capable of controlling and position.
managing the loading procedure simultaneously via multiple  when NO and NC solenoids are de-energized, the
loading arms. The loading system is available in two valve closes gradually.
versions: 1010CJ for straight product loading and 1010CB
for MID-compliant integrated loading, blending and addition.
It has standard provision for all measurement and control

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072

PD - POSITIVE DISPLACEMENT METER

A positive displacement meter is a type of flow meter that

requires fluid to mechanically displace components in the
meter in order for flow measurement. Positive displacement
(PD) flow meters measure the volumetric of a moving fluid
or gas by dividing the media into fixed, metered volumes
(finite increments or volumes of the fluid). A basic analogy
would be holding a bucket below a tap, filling it to a set level,
then quickly replacing it with another bucket and timing the
rate at which the buckets are filled (or the total number of
buckets for the “totalized” flow). With appropriate pressure
and temperature compensation, the mass flow rate can be
accurately determined.

PLC

PLC controls all the operations involved in the automation

process. The logic for the sequential process is either written
in functional blocks or in the form of ladder logic. The logic is
derived from the functional operation shown in the P&ID
diagrams and it is converted in the form of logic gates and
the ladder logic is then programmed out of it. PLC programs
shall control
 The pump functioning including start and stop from
the Operator Interface Console(OIC), Processing
demand which the pump raises; sequencing of
pumps, controlling the pump locally or remotely etc.
 The opening and closing of control valves from the
OIC, control locally or remotely etc.
 Fire Alarm functioning for the entire plant by
operating the Fire alarm pumps if fire is spread
across the plant.
 PID controllers installed at different areas of the
plant as per the configured set point.
 IF any Emergency Shutdown required, PLC will stop
the whole plant operations by stopping the pumps
which load the product, closing all the Valves,
Opening the Barrier gates, stopping all BCUs etc.
 Process the analog data such as signals from Density
meter, Pressure transmitter, product level in tanks
and temperature signals to pipeline division.

The process of terminal automation system is detailed below

in a flow chart. It includes each step that comes in the
loading process.

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072

START

From TTES, the New Day is opened by the

planning officer. *

TT is arrived at Terminal and driver will report

at the MARKETING Room. Authorization is
performed by JDE operator and a Load is
generated in JDE. **
*In a day, Open New Day needs to
be done only once.
LRC will read Load Data given by Gateway
Server. *** ** FAN can get generated from
TTES in case SAP system is down.

Load Data is updated in Database by LRC and the *** JDE will create FAN in manual
LRC maintains a FIFO list of all the TT which JDE mode in case LRC is down.
authorized.
#LRC applies priority system
while queuing the Truck for a bay.
TTES will display the assigned bay on the screen The truck which is having more
with the list of bays which are available. # priority will be filled first. The
other trucks will wait until then.

Card No is assigned manually by TTES operator

or read from card reader at Marketing Room
and also if applicable the seal number is entered.

The FAN can be generated by TTES operator. LRC

will get updated with details of comps, bays, FAN,
card ID and Seal Nos. by the TTES program. It
takes care of printing FAN also. Then truck is
allocated with a card.

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Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072

*Conditions for a card to be valid:

In the display boards placed at parking area, first Should be a valid ID,
four Trucks will be displayed for some time which is Card should have a FAN printed.
configured. It should not be an expired card and must be a
registered card for loading.

The truck driver waits till his Truck number is

displayed. Once displayed, the driver will collect his
FAN from the marketing room.

The operator at TTES will provide the card and

FAN no to the driver.

Driver moves to TLF Entry Barrier Gate.

Truck driver displays the card at the card reader

kept at entry barrier gate.

Card is validated by Load Rack Card will get again

Computers. * authorized by operator.

No Barrier will remain closed

IF Card is Valid? and the driver reports at
operator at TTES

Yes

Whether Truck
Time out?
Yes

No

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 International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072

No Bay with multiple

products?

Yes

Is truck permitted No One bay BC displayed “Not

to load multiple in Use”
products?

Yes

Preparation for loading.

Warn driver to attach Grounding

Is Truck clip. Message “CONNECT
earthed? EARTH” displayed on Batch
No
controller.

Yes

Warn driver to place the loading

Is Loading arm Arm properly. Message “ARM
placed correctly? NOT IN POSITION” displayed on
No BC.

Yes Warn driver to place the

loading Arm properly. Message
“ARM NOT IN POSITION”
displayed on BC.
Compartment Number, Product Quantity displayed and
“PRESS ACK” on Batch Controller telling the driver to press
button in Amber color on RIT.

ACK is
pressed? No

Yes

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Volume: 06 Issue: 03 | Mar 2019 www.irjet.net p-ISSN: 2395-0072

LRC instructs PLC to open the exit gate. Card

can be reused for another truck

The card and gate pass are surrendered at

security gate by the driver

Truck exited from the terminal.

STOP

3. CONCLUSIONS REFERENCES

In this project, whole process right from the entry of a [1] D.J. Gaushell ,H.T. Darlington, “Supervisory control and
Tanker Truck into the oil terminal, filling of fuel, its billing, data acquisition ” Proceedings of the IEEE ( Volume:
controlling the loading operations, its safety checks till exit 75 , Issue: 12 , Dec. 1987 ).
from the terminal is designed and implemented with
minimum manual interruption. [2] Wang Gunawan, Francisco Gunawan Saputra Johnson,
Benefits of Terminal Automation System are as follows: “Terminal Automation System: Automation Solution in the
Oil and Gas Industry” in 2018 Indonesian Association for
 Improves Productivity
Pattern Recognition International Conference (INAPR)
 Reduces Loss
 Prevents Accidents & Improves Safety [3] M.R. Ab. Ghani, “Remote terminal unit (RTU) hardware
 Protects the Environment
design and implementation efficient in different
 Reduces Paperwork
application” 2013 IEEE 7th International Power
 Expedites Billing Process
 Enhances Product Security Engineering and Optimization Conference (PEOCO)
 Terminal Security
 Loading Sequence Control [4] All TAS manuals in L&T Mumbai.
 Inventory Management
 Stock Balancing
 Order Management
 Transactions Storage

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