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

PresentersPresenters

Joe Shotwell

Hasit Patel

Greg Juchniewicz

MC Chow

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 - joe.shotwell@aosterminals.com– Al Meitl – AJMeitl@ecfinc.net – Hasit Patel – hpatel@novaspect.com– Greg Juchniewicz – Gjuchniewicz@novaspect.com– MC Chow – MCChow@novaspect.com