Replacing outdated controls with a centralized fuel farm control system to improve visibility, efficiency, throughput, and safety.
A fuel farm containing five storage tanks supported aircraft fueling as well as the loading and offloading of supply trucks. Its aging control system provided limited visibility into equipment status and created operational and safety concerns during fuel handling.
Concept Systems upgraded the fuel farm control system to give operators centralized control, improved equipment monitoring, enhanced alarming, and greater visibility into the fuel handling process.
The Problem: Limited Visibility and Aging Controls
The existing control system provided operators with limited information while transferring fuel. Critical equipment status, including valve positions, was not readily visible, making it more difficult to confirm that the system was configured correctly before and during fuel movement.
The facility also needed better leak detection, equipment monitoring, and alarming. These limitations increased the potential for fuel mishandling and made it more difficult for operators to quickly identify abnormal conditions.
Because the fuel farm operates in a seismically active region, the control system also needed a reliable way to respond to seismic events and other conditions requiring an emergency fuel shutdown.
The Solution: A Centralized Fuel Farm Control System
Concept Systems designed and implemented a centralized control system using an Allen-Bradley ControlLogix PLC and FactoryTalk View SE HMI. The upgraded system gives operators greater visibility into fuel transfer operations and provides a central interface for monitoring equipment and system conditions.
Improved Monitoring and Operator Visibility
The new HMI allows operators to monitor critical equipment and process information from a centralized location. Greater visibility into valves, sensors, and other equipment helps operators verify system conditions during aircraft fueling and truck loading or offloading.
Concept also integrated Allen-Bradley IntelliCenter motor controls and industrial communications, including DeviceNet, ControlNet, and EtherNet/IP, to improve access to equipment status and diagnostic information.
Leak Detection and Alarm Management
A TraceTek leak detection system was integrated into the controls to improve detection and monitoring of potential fuel leaks. Concept also incorporated WIN-911 alarm notification, giving the facility a more effective way to communicate abnormal system conditions.
Together, the upgraded monitoring and alarming capabilities allow operators to identify issues more quickly and respond before they lead to equipment damage or larger operational problems.
Emergency Fuel Shutdown and Seismic Protection
Concept implemented a hardwired Emergency Fuel Shut Off system to provide an independent means of stopping fuel movement when hazardous conditions occur.
Seismic sensors were incorporated into the emergency shutdown system so the facility can respond appropriately during a seismic event, adding another layer of protection for personnel, equipment, and the surrounding operation.
The Results
The upgraded fuel farm control system gave operators centralized visibility and control over fuel handling while improving monitoring, alarming, and safety throughout the operation.
- Improved operator visibility into fuel transfer equipment and system conditions
- Increased fuel-handling efficiency and throughput
- Enhanced leak detection and equipment monitoring
- Improved alarm notification and response capabilities
- Added hardwired emergency fuel shutdown and seismic protection
- Increased automation capabilities while retaining the facility’s existing equipment
- Achieved a return on investment of approximately 12 months
Project Details
ROI
About 12 Months
Team
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 FactoryTalk View SE
WIN-911 alarm notification software
TraceTek Leak Detection System
Modernize aging controls to improve system visibility, reliability, safety, and performance.