Batch- and loading systems with the Batching Master 110i/210i · Intelligent Batch Solutions.....designed for you mbH Batching Master 110i (intrinsically safe) Batching Master 110

Intelligent Batch Solutions.........designed for you IB

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Batch- and loading systems with the Batching Master 110i/210i

Presentation Batching Master V08 © 2016 IBS BatchControl GmbH Page 1


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Batching Master 110i (intrinsically safe)

Batching Master 110 (non-Ex unit)

- Field housing, IP 65

For wall mounting

(240 x 240 x 120 mm)

- Local installation, direct

at the loading station

- Backlight optional



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- Panel mount

(144 x 144 x 130 mm)

- Front IP 65

- Backlight optional

Batching Master 210i (intrinsically safe)

Batching Master 210 (non-Ex unit)



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Loading system for road tankers

and railway tank wagons Batch system for basic products in

the pharmaceutical production

The Batching Master controls your batching process

at a filling station: in the production:



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Application pictures:

IBC filling: Truck loading:

Mobile filling system for IBC’s with

an Optimass 7300C flowmeter

Truck loading system for bio fuels

with a Promass 84F



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Indication in the field:

- pre-set value

- batched quantity

- actual flow rate, grand total

- temperature, density and

pressure optional

Safe operation in the field

The operator has all important

information for a safe batching

process locally at the filling

station.

In case of a failure, the operator is

able to stop the batch very quick

by the emergency stop switch of

the Batching Master.



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4

20

I [mA]

Start Batchedquantity [kg]

Batch completed

0510152025

4

20

I [mA]

Start Batchedquantity [kg]

Batch completed!

051015

Flow meters:

All types of flow meters can be connected to the Batching Master via single

pulses, double pulses or via a 4-20 mA signal.

Precise batch:

The batching valve can be controlled

by a 4-20 mA output signal which opens

with a soft start-ramp and which closes

at the end of the batch in 5 steps.

Due to these ramps it is possible to get

the highest batch accuracies.

No “pressure hammers” in high

flow rate systems:

They are eliminated because of the

soft-start ramp and the 5-step shut-

down ramp of the 4 - 20 mA signal

to the batching valve.

4-20 mA valve output

ramp for high quantities:

4-20 mA valve output ramp

for small quantities:



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Error messages in clear text

The Batching Master has many safety- and monitoring functions. In case of a

failure the batch will be stopped immediately. After the reset of the failure the

message, the batch can be continued via the start button.

Emergency stop switch

The Batching Master 110i has a proofed emergency stop switch at the front,

which can be delivered optional with a key for interlocking of the device.

When the emergency stop is pressed, then :

- the batch process will be stopped with a failure message

- the 4-20 mA valve output signal will be switched to 0 mA

- the digital outputs 1-3 will be deactivated

- one digital output give the message “emergency stop pressed”.

There is one digital input for an external emergency stop contact available.



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Low flow rate monitoring

If the flow rate during the batch falls below a programmed value, then the

batch process will be stopped after a programmed time. This function

prevents an uncontrolled filling during a failure in the measuring system.

Sensor break- and measuring range overrun monitoring

The Batching Master monitors the 4-20 mA input and the NAMUR contact

input circuit. In case of a sensor break or a measuring range overrun the

batch will be stopped with a failure message.

Error at the flow meter

The error output of the flow meter can be connected to a digital input of the

Batching Master. In case of a failure at the flow meter the batch process will

stopped with a failure message.



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Two release signals

These two custom specific release signals

work via digital inputs. If they are not

activated, then the batch will be stopped

with a failure message.

The texts of the messages can be changed

by the programming.

Terminal function:

The supervisory system is able to use the

Batching Master as a HMI (human machine

interface) to the operator in the field.

The supervisory system is able to show

question texts at the display of the device

and the user is able to make selections or

to enter information like order numbers or

access codes.



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PID controller functions

The Batching Master has two separate controller functions, they are working

parallel only during the batch. The output signals of the two controllers are

working in a min-selection at the 4-20 mA output to the batching valve.

Flow controller

Via the flow controller it’s possible to batch the product with a required

flowrate.

Override controller

The override controller is able to control a second physical value during the

batch, e.g. the temperature or the pressure of the product.



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Pressure keeping of liquefied Gas

Liquefied gas like LPG, Propane or Butane demonstrates out gassing effects

as soon as the pressure falls below the vaporization pressure of the gas.

These vapour locks would cause fail-measurements in the flow meter.

The override control function

of the Batching Master keeps

the pressure during the batch.

The 25-step linearization func-

tion of the Batching Master

delivers the right pressure set

point depending on the

temperature signal.

A parallel PID flow controller

function is also available.

Flow signal

Temperature

Pressure Ou

tpu

t sig

na

l to

th

e

ba

tch

ing

va

lve

Vapour pressure

curve Propan



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Manual filling/purge functions

For the emptying, cleaning or filling of the pipe system it could be

necessary to open the batching valve. This can be done by a digital

input, by the Modbus interface or by the function key F1. During this time

the flow rate signal will not be counted.

Automatic filling/purge functions

It is also possible to fill or purge the system automatically before each

batching process for a programmed time, or until a contact at a digital

input indicates liquid in the pipe.



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Complete batch systems:

IBS BatchControl offers complete batching

systems packages (turn key projects)

Consisting of: engineering support, control

panels, pumps, flow meters, valves, batch

controllers, Exi-interfaces, Exd-housings,

printers and loading software.

Batch systems for ultra pure water:

Used in the pharmaceutical and cosmetic

industries

The continuous water flow in a circulatory

system prevents the formation of germs.

The Batching Master close the circle valve

before the batch start. Different time

functions take care, that only the batched

quantity during the batch will be counted.



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Product way selection via the function keys F1 - F3

With this function 3 products can be batched with one flow meter. The

product way can be selected with the function keys before the start. The

question text and the product texts can be modified by the programming.


Pulse-

input

+15

- 16

4-20 mA

output

+ 29

- 30

+33 -34

Digital-

output 1

Digital-

output 3 Power

supply

+1 -2 +5 -6

24 VDC+24 V

+24 V

+ 31

- 32

Digital-

output 2

Batching Master 110

Product 1

Product 1

Product 1Batching

valve


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Flow conversion functions

for the calculation between mass, volume and

standard volume.

The flow input signal can be mass or volume.

The calculation can be done via the temperature,

pressure and density signal.

Calculation formulas:

- API 2540 / 2004 table for crude oil, refined- and

special products in metric units

- linear correction function

The base density at standard temperature can be

programmed or calculated from the actual values.

All physical values and counters can be indicated

via a special menu at the Batching Master. These

values are also shown via the Modbus interface.



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Loading station with Optimass 7300C in the hazardous area



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Custody transfer loading system with Optimass 7300C in the safe area

Optimass 7300C-CT Batching Master 110

4-20 mA

output

„density“

Pulse

input 1

Batching valve

with position controller

+5

- 6

4-20 mA

input 1

+ 9

- 10

4-20 mA

output

+

-

+ 15

- 16

pulse

output 1

D

D-

C

C-

Power

supply

RS

48

5 M

od

bu

s

inte

rfa

ce

DC

S

24V DC

+31 -32

Digital

output 1Digital

output 2

Sta

rtin

g

the

pu

mp

Pulse

input 2

+7

- 8

pulse

output 2

B

B-

Power

supply

4-20 mA

input 2

+11 -12 +1 -2

24V DC

Interface converter

RS232/RS485

PCC 400 Printer

communication

controllerProtocol printer

Optional monitor,

mouse and keybord

RS232

RS

48

5

RS 485 Modbus Interface to

the next Batching Master

RS232

Modbus

interface1

+39 -41

Data+

Data-

Modbus

interface2

+42 -44

B A

Digital

Input1

+19 -20

Ov

erf

ill

pro

tec

tio

n

Digital

Input2

+21 -22

Re

lea

se

DC

S

+29 -30

24V DC 24V DC

K1 K2

0V DC

K1 K2

Sw

itc

hin

g a

n

On

/Off

va

lve

Temperature

sensor, 2-wire

+ -



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Printing solutions and batch data storage system PCC400

- Custody transfer

proofed

- Storage and print out of

batch reports

- Storage and print out of

log files (alarm lists)

- Connection to the local

Ethernet

Data storage:

- Data base with all batch information

and export function into CSV files.

- PDF copy of the batch protocols on:

- an external USB stick or drive

- a storage path of the PCC 400

Optional:

- connection to external data bases

- Information input by the user before

the start via the terminal function

- Product way selection, controlled

by digital Modbus modules

PCC 400

local Ethernet

Batching Master Batching Master

Alarm printer

Report printer

Maintanance PC workstation Ext. data base



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Communication to an order management software via MYSQL:

- Information exchange between the order management software (TAS) and the

loading system in the field.

- Customers TAS software writes open loading orders into the MySQL table “loadings”.

- The operator enters an order number at the loading station as “Access control” and

the PCC 400 checks if this order is available and valid for the loading station.

- Important loading information will be shown in the field and the batch can be started.

- At the end of the batch the loading results will be written into the table “loadings”

Operation at the

batch controllers:

MySQL table “orders”:

- Order number

- Customer name

- Product name

- Status of the order

0 = order open

2 = order completed

MySQL table “loadings”, written by the PCC 400:

- Order number

- Customer name

- Product name

- TAG number

- Batch number

- Batch start and end time



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Flow computer Pipeline Master 110i/210i

For using at flow metering skids in pipelines or at continuous flow measuring

systems in chemical parks between two companies.

Flow conversion functions available for the calculation to standard volume

flow at 15°C out of the actual flow rate, temperature, pressure and density,

based on the following formulas:

- API 2540 tables A-C for crude oil, refined

and special products in metric units

- Linear correction

6 counter blocks are available with:

- mass, volume, standard volume

- in positive and reverse direction

- failure counters for all values

The PCC 400 is able to store the

counted values in files and to print

them via a connected printer.


Printer

Temperature

Printer Communication

Controller PCC 400RS 485 Modbus

Pipeline

Master 210

Pressure

Flow Rate / Density


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Non-Ex batch controller BC 20 for simple applications

Options:

- 4-20 mA valve output with ramp functions

- PID flow controller for the 4-20 mA output

- RS 485 Modbus interface

Features:

- Back light for the LCD

- Intelligent overrun correction

- Dimensions: 96 x 96 x 120 mm

BC 20-DC

PS = 24 VDC

BC 20-AC

PS = 100-240 VAC

LC-Display

with 2 x 16 caracters

Numeric key path

Batch

Controller

BC 20

24 VDC100-

240 VAC

Power Supply BC 20-DC

24 VDC, 250 mA

Power supply BC 20-AC

100-240 VAC, 47 – 63 Hz

22

PE

23

+24V

24

0V

22

PE

23

L1

24

N

Fuse

400 mA

Fuse

2 A

1 +

2 -

3 +

4 -U

5 +

6 -U

7 +

8 -U

11 +

12 +

13 +

14 -

Pulse input

NAMUR-

contacts

Passive

contacts

DI 1

DI 2

DI 3

Analog input 1

4-20 mA

Analog input 2

4-20 mA

Analog input 3

4-20 mA

Dig

ita

l in

pu

ts 1

-3

U

IP

4-20 mA output

Batching valve

op

tio

na

l

Relay-

output 1

I max = 2 A

19

20

21RS485 A-

B+ RS 485

Modbus-

interface op

tio

na

l

28

29

30

NO

NC

25

26

27

NO

NC

17

18

+

-

15

16

+

-

9+

10-

Optocouppler

output 1

I max = 50 mA

Optocouppler

output 2

I max = 50 mA

Relay-

output 2

I max = 2 A



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Power supply and interface modules

PSC 300i-1:

- One Exi power supply (U=24V, I=50mA)

for the PS1 of the Batching Master 110i/210i

PSC 320i-1:


For the PS2 of the Batching Master 110i/210i

(required for the optional back light of the LCD)

PSC 330i-2:




For the PS2 of the Batching Master 110i/210i

(required for the optional back light of the LCD)

IPC 300i:



- Interface barrier (MODBUS Protocol):

- Exi TTY interface to the Batching Master 110i/210i

- RS 485 interface at the safe area side



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Visualization of the loading:

Software system for Terminal Automatisation (TAS):

- Customer data base with delivery addresses

- Forwarder and truck data base

- Order management and a simple

creation of loading orders

- Visualization of the loading process

- Printout of delivery papers and statistics

- Direct loading without order

Options:

- Data exchange to SAP R/3 (optional)

- Access authorization via card readers

- OPC-Server for the connection to supervisory systems

- User access management and audit trail

- Multi user systems with client- / server architecture



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Trucks

Forwarders

Customers

Products

Order management:

Communication to the user via the

terminal function of the Batching Master:

Software system for visualization and order management

Data bases:



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Order code for the Batching Master 110i/210i:

120-0110 Batching Master 110i, ATEX, IP65 field housing

120-0120 Batching Master 110, non-Ex, IP65 field housing

120-0130 Batching Master 210i, ATEX, panel mount housing

120-0140 Batching Master 210, non-Ex, panel mount housing

120-0145 Back light for the LCD (an additional Exi power supply is required)

120-0150 Modbus interface (the interface and power supply module IPC 300i is required)

120-0160 Terminal function, the price includes the option „Modbus interface“

120-0165 Custody transfer version, the price includes the option „Modbus interface“

120-0170 PID controller function

120-0175 Flow conversion function between mass, volume and standard volume

120-0180 Special function „Automatic filling or empting of the measuring system“

120-0191 Selection of three product ways via the function keys F1-F3

120-0200 Emergency stop switch as a key switch

Exi interface and power supply modules:

A-120-0210 PSC 300i-1, power supply module, 1-channel

A-120-0210 PSC 330i-2, power supply module, 2-channel

A-120-0220 IPC 300i, interface and power supply module



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Some of our Main Clients:

3M, France, Germany

Abbot, USA, Germany

Air Liquide, France, Germany,

Aker Kvaerner, The Netherlands

Akzo Nobel, China, The Netherlands, Germany

Arkema, France, Germany

Astra Zeneca, England

BASF, Belgium, Malaysia, Mexico, China, Germany

Bayer, Malaysia, Spain, Vietnam, Germany

Basell, Germany

British American Tobacco, Germany

Butagaz, France

Clariant, China, Greece, Switzerland, Germany

Ciba, Italy, France, Switzerland, Germany

Christ Water Technology, Germany

Cognis, Germany

Degussa, Belgium, Germany

Dupont, Germany

DSM, The Netherlands, Austria, Germany

Endress+Hauser, worldwide

Emerson, worldwide

Exxon, France, The Netherlands

GlaxoSmithKline, Great Britain, Italy

Kraus Global, Kanada, Korea

KANEX, Russia, Ukraine

Krohne Messtechnik, worldwide

Lanxess, Germany

Linde, Germany

Lukoil, Ukraine

Lurgi, Germany

Merck, Germany

Novartis, Switzerland, Germany

Oiltanking, Belgium

Oval Asia, Singapore

Petroleos de Venezuela, Cuba

Petrobras, Brazil

Rhodia, France, Germany

Roche, Switzerland, Germany

Sanofi-Aventis, France, Germany

Sipchem, Saudi Arabia

Shell, Germany

Symrise, Germany

Tecnicas Reunidas, Spain

Total, France

Toyo Engineering, Japan

Uhde, China, Egypt, Ukraine, Germany

Vopak Banyan Terminals, Singapore

Wacker Chemie, China, India, Germany



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Indicators PID Controllers

Batch Controllers

Process Recorders Flow Computer

Exi Interfaces

IBS BatchControl GmbH

Im Sträßchen 2-4

53925 Kall /Germany

Tel.: +49 2441 9199 801

[email protected]

www.ibs-batchcontrol.de

Documents

Batch- and loading systems with the Batching Master 110i/210i · Intelligent Batch Solutions.....designed for you mbH Batching Master 110i (intrinsically safe) Batching Master 110