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AOS' Joe Shotwell and Novaspect's Hasit Patel, Greg Juchniewicz, and MC Chow present at 2011 Emerson Exchange in Nashville, TN USA.Their abstract:
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State-of-the-Art Automation at
Asphalt Loading/Blending
Terminal
State-of-the-Art Automation at
Asphalt Loading/Blending
Terminal
AOS Chicago Terminal
Workshop# 4-2973
IntroductionIntroduction
Design & Implementation of state-of-the-art Automation for Asphalt Storage, Blending & Loading terminal
Selection process of equipment & integration
Business Results
Path Forward
AOS ChicagoAOS Chicago
Asphalt Operating Services of Chicago, AOSC, LLC, is a liquids terminal service company that provides safe and efficient storage, handling and shipment of bulk liquid products for customers in the petroleum industry.
AOSC Mission: To provide storage, production and terminal services
to the petroleum industry in an efficient and effective manner that provides the greatest value to the customer, utilizing internal and external knowledge, skills, and resources
ECF, IncECF, Inc
ECF, Inc. provides the liquid terminal and industrial manufacturing industries with a source of qualified and experienced construction professionals. ECF is committed to building long term customer relationships based on quality products installed in a safe working environment with customer service second to none
ECF provided Project Management, Design and Construction Management services for this project.
AOS Chicago Terminal ProjectAOS Chicago Terminal Project
Brown field terminal built to provide Asphalt Storage, Blending & Loading
2nd terminal owned & operated by AOS
Construction started in Nov-2010, 1st barge received Jun-2011
AOS Chicago Terminal AOS Chicago Terminal
5 product storage tanks Barge unloading Jetty 6 Rail Car loading spots Hot Oil Heater 4 Truck loading spots with
Weigh scales 6 Ratio blenders with Coriolis
flow meters and VFD’s 18 MOV’s for product lineups Odor Control system for loading spots
Instrumentation & Automation GoalsInstrumentation & Automation Goals
Integrated system which provides– Flexibility in operations & expansions– Compliance to regulatory needs– Meet business needs of AOS– Single point of responsibility– Easy to operate & maintain– Integrate with AOS & its client’s business transaction systems
Meet Aggressive Delivery and Commercial needs System provider to be:
– Local – Posses Domain expertise in Terminals
#1 requirement – KEEP the System simple
Automation Supplier Selection processAutomation Supplier Selection process
Novaspect had experience working with ECF on their previous projects with BP Whiting
Early engagement in the project
Novaspect scope extended to Main Automation Contractor
Leverage learning's from Automation challenges from AOS’s Bartlett, IL terminal
Process Automation System SelectionProcess Automation System Selection
300+ I/O system with distributed I/O at – Tank farm/Blenders (DeltaV Controller and I/O), – Rail Terminal (CHARMS Cabinet) &– Truck Terminal (CHARMS Cabinet)
DeltaV Operator stations at Rail, Truck Terminal & Control Room/Admin Office
DeltaV Reporter for Transaction reports ICONICS BridgeWorx transaction server for data
transfer and reporting
DeltaV System ArchitectureDeltaV System Architecture
Rail Kiosk
CP-701 (DeltaV Cabinet)
MCC-301 BuildingTMS cabinetServer/UPS Cabinet
EEP cabinets
CP-301 (DeltaV Cabinet)
DeltaV Architecture @ AOS Terminal2835 E 106th St,
Chicago, IL 60617
AOSCCTR01DV ControllerFor Chicago
Terminal
VFD’s VFD’s
….
AOSCWIOC01WIOC for
Chicago Terminal
Wireless AntennaModel 781
On Roof of RIE
Wireless AntennaModel 781
On Roof of RIE
Truck Kiosk Admin Office
AOSCCIOC01CIOC for Rail
AOSC-OPR01
DeltaV OperatorStation @ Rail
CP-601 (DeltaV Cabinet)
AOSCCIOC01CIOC for Truck
AOSC-OPR02
DeltaV Operator Station @ Truck AOSC-OPR03
DeltaV OperatorStation @ Admin
Fiber media convertor
RCU3 RCU4
RCU1 RCU2
WeighScale
Controllers
WeighScale
Controllers
WeighScale
Controllers
WeighScale
Controllers
AOSCPRP00DeltaV PROPLUSAMS Server Plus
AOSCAPP01DeltaV App Station
Continuous Historian
AOSCBRIDGETransaction
Engine ServerAOSC-TMS
TMS Server(s)Qty=2
Profibus Fiber
Extender
Patch Fiber Cord
Modbus Serial to TMS Server
Terminal Manager
AOSC-OPR04
DeltaV OperatorStation @ Terminal
Manager Office
To AOSC-Office LAN
DeltaV Area Control Network (Redundant)
Profibus Fiber
Extender
DeltaV Cabinet in RIE & CHARMS cabinetDeltaV Cabinet in RIE & CHARMS cabinet
Field Mounted CHARMS Cabinet with Fiber
DeltaV Cabinet with Mass-Termination
Instrumentation SelectionInstrumentation Selection
Blending skids comprising of – Micro Motion Coriolis flow meters for Mass, Volume, Density
& Temperature measurements– Control Technique Variable Frequency Drives for Flow
Control.– MOV’s for valve line-ups and Odor Control System
Tank Level & Temperature measurement with Saab-Rosemount Radar gauges with multi-spot temperature
Tank Hi-Hi Level measurement with Wireless TT’s Mettler-Toledo Weigh scales with Profibus Interface
Blender Skids with Micro Motion flowmetersBlender Skids with Micro Motion flowmeters
•Pulse Input (for Custody Transfer)
•HART/ Analog
Multiple interfaces
•Density
•Volume/Mass flow
•Totalizer
•Casing Temperature
Multi-variables
(HART)
Level MeasurementLevel Measurement
Multiple
Instrume
nts
•Radar gauge for Level measurement
•Multi-spot RTD for temperature
averaging
•Wireless TT for High-High level
detection
Multi-
variables
(HART)
•Tank Level
•Volume with tank strapping
•Average Tank Temperature
•Temperature rate of change for High-
High
RDU
High High Level MeasurementHigh High Level Measurement
Controls ImplementationControls Implementation
Use of Class based Control Modules
Use of Human Centered Design (HCD) graphics and objects
Use of Equipment Modules (EM’s) and Sequential Function Charts (SFC’s) for loading sequences
SQL server for transaction management
Business Transaction InterfaceBusiness Transaction Interface
BPBDS
Transaction Manager
Rail Car Strapping
Tables
Rail Car Orders & Invoicing Rail Car Transactions
TMS – Truck Loading System
Loaded Weights, Tank Levels
Events
Inventory & Invoicing
middleware
SAPFinancial & Invoicing
Rail Trx
Process Automation
System
Flexible Loading Sequences implemented in DeltaV Control SystemFlexible Loading Sequences implemented in DeltaV Control System
Easy of use – Operator Interface GraphicsEasy of use – Operator Interface Graphics
Easy of use – Operator Interface GraphicsEasy of use – Operator Interface Graphics
Easy of use – Operator Interface GraphicsEasy of use – Operator Interface Graphics
3rd Party Interfaces to Business Systems3rd Party Interfaces to Business Systems
Real time tank levels and truck loading status information to Terminal Accounting System using Serial Modbus interface
Rail car strapping and Rail Transactions interfaced to BDS Railtrack @ YardMaster system for accounting and load tracking
Truck/Rail transactions interfaced to Client’s Accounting system (SAP)
Business Transaction System InterfaceBusiness Transaction System Interface
Business Results AchievedBusiness Results Achieved
Quick Startup
Compliance
Safety
System Performance
Ease in Operations & Maintenance
Business Results Achieved – Quick StartupBusiness Results Achieved – Quick Startup
Terminal Operations started on schedule1) Intelligent devices enabled quick checkout and
commissioning
2) Flexible Architecture allowed for changes during course of construction and startup
3) Ease of use allowed for operations acquaintance
4) Distributed I/O with use of CHARMS allowed for reduced wiring and troubleshooting
Smart Devices & Digital CommunicationsSmart Devices & Digital Communications
HART interface to Micro Motion meters for:– Mass/Volume flow rate & totals– Temperature– Density
Profibus interface to VFD’s– Motor Electrical parameters– Diagnostics & Reset
Profibus interface to Weigh Scales– Scale diagnostic parameters & Zero values
wiHART interface to Tank HIGH level interface
Business Results Achieved - ComplianceBusiness Results Achieved - Compliance
Micro Motion meters for Blend Certification– Pulses used for primary measurement & Control (Mass for
Trucks, Volume for Rail Cars)– HART Totalizers used for verification of batch totals
Wireless HART Temperature transmitters– Provides separate technology (then Radar for Level) and
separate communication path for HI-HI Level on tanks– Field verification and testing setup provided to perform
periodic verification of High level detection
Verification & Test setup for High LevelVerification & Test setup for High Level
Business Results Achieved - SafetyBusiness Results Achieved - Safety
Interlocks configured to prevent inadvertent operations with simple operator communications through Graphics
Checks and balances for Rail & Truck compartment capacities and product compatibilities
Tank Overfill Alarm verification
Tank Low Level for minimizing hot oil coils exposure to atmosphere
Business Results Achieved - PerformanceBusiness Results Achieved - Performance
Terminal Throughput– 32 Rail cars/day– 125 trucks/day
Blend and Shipment accuracy– Rail cars loaded at +/- 6 gallons for 23,000 gals rail car– Trucks loaded at +/-20 lbs for 50,000 lbs truck capacity
Business Results Achieved – Ease in MaintenanceBusiness Results Achieved – Ease in Maintenance
Configuration & Troubleshooting of all Instrument & Controls managed by single tool (AMS)– Micro Motion Coriolis meters (HART)– Saab-Rosemount Radar Level/Temperature (HART)– Control Technique Variable Frequency Drives (Profibus DP)– Temperature Transmitters (wiHART)
AMS Alert Monitor for all “smart” instrumentation
AMS audit trail for revision management
VFD configuration & troubleshooting w/ AMSVFD configuration & troubleshooting w/ AMS
• Perform initial set-up for new drives
• Change parameters on existing devices
• Track runtime data
• Configuration changes are automatically documented in the Audit Trail
• Perform initial set-up for new drives
• Change parameters on existing devices
• Track runtime data
• Configuration changes are automatically documented in the Audit Trail
VFD configuration & troubleshooting w/ AMSVFD configuration & troubleshooting w/ AMS
VFD fault history & runtime with AMSVFD fault history & runtime with AMS
VFD status view through AMSVFD status view through AMS
Automation System accessibility – 55” LCD Monitor in Admin OfficeAutomation System accessibility – 55” LCD Monitor in Admin Office
Automation System accessibility on iPAD through cellular networkAutomation System accessibility on iPAD through cellular network
Path ForwardPath Forward
Expand the system to:– Monitoring process variables wirelessly for
• Hot oil system• Unloading pressure at barges• ….
– Mobile Worker for• Wireless Video Cameras for Surveillance• Operations and Maintenance stations• ….
– Transaction reports for• Material Balance reconciliation• …
– …
SummarySummary
State-of-the-art Automation system allows– Integrated operations & maintenance– Compliance– Flexibility– Room for expansion– Reduced cost of ownership– Simplicity in use and support
Where To Get More InformationWhere To Get More Information
http://www.aoschicago.net/ http://www.aosterminals.com/
http://www.ecfinc.net/
Contact– Joe Shotwell - [email protected]– Al Meitl – [email protected] – Hasit Patel – [email protected]– Greg Juchniewicz – [email protected]– MC Chow – [email protected]