Gas in the Tank: Replacing outdated controls for more efficient, safe fuel handling.

A Control Systems Upgrade Case Study

Replace Outdated Controls For More Efficient, Safe Fuel Handling

A control upgrade leads to a safer and more efficient system.

A Fuel Farm contained five storage tank, as well as equipment to transfer fuel to aircraft and load and offload supply trucks. Its outdated control system design was cumbersome and unsafe. Concept was called on to improve efficiency of fuel handling and reduce risk.

The Problem

Older controls did not provide operators with enough information when fueling aircraft, e.g., they could not see the position of the valves. Other issues were unsatisfactory leak detection, the potential to mishandle fuel, insufficient monitoring and seismic vulnerability.

The Solution

Concept Systems enabled greater fuel throughput, increased efficiency through a Human-Machine Interface (HMI), improved equipment monitoring and enhanced alarming and safety systems. With the upgraded control system, various sensors can now be easily monitored avoiding system damage. A hard-wired Emergency Fuel Shut Off (EFSO) system was implemented, including seismic sensors.

The Results

The Fuel Farm Control System upgrade increased the usability, efficiency and safety of the existing equipment. We provided a centralized control system for ease-of-use. The bottom line: improved operator control, increased capacity to handle more fuel throughput, enhanced automation capabilities, and increased productivity.

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Project Details


About 12 Months


Client: 1

Concept Systems: 2 engineer

Services Provided

Control engineering and design

PLC/HMI programming

O & M and AutoCAD documentation

Start-up and commissioning

Technology Used

Allen-Bradley ControlLogix PLC

Allen-Bradley MCC IntelliCenter

DeviceNet, ControlNet and EtherNet/IP

Rockwell FactoryTalkView SE

Specter Instruments WIN-911 for alarm notification

TraceTek Leak Detection System