Efficient and flexible pump control for high-throughput truck unloading
At a liquid storage terminal, in Belgium, an expansion project required extending the pump plate infrastructure to support increased transfer capacity. With frequent truck unloading operations, higher traffic volumes created the need for a more efficient and flexible pumping system.
Contec enabled simultaneous unloading of multiple trucks into the same storage tank, reducing waiting times and improving terminal throughput. The new pumps were fully integrated into the existing control environment, ensuring reliable and safe operations.
Project Highlights:
-
Automation of an extended pump plate with multiple new pumps
-
Implementation of simultaneous truck unloading functionality
-
Integration with the existing tank terminal automation system
-
Enhanced operator visibility through alarm, event, and trending screens
-
Improved truck throughput and reduced terminal congestion
The challenge
Managing increased truck traffic and pumping capacity at the terminal
The terminal expansion introduced additional pumps to support increased liquid transfer capacity. However, the existing system allowed only sequential truck unloading into storage tanks, which created waiting lines when multiple trucks required access to the same tank.
The facility required an automation upgrade capable of managing the additional pumps while introducing more flexible unloading functionality.
Another challenge was integrating the new equipment within the existing control architecture while maintaining safe and reliable operations in a tank terminal environment. The solution also needed to provide operators with better visibility of system status, alarms, and process data.
Our approach
Extending control capabilities for flexible and safe pumping operations
Contec implemented an automation upgrade based on Rockwell ControlLogix, developed in Studio 5000, to control the new pumps and integrate them into the existing infrastructure.
The project started with a detailed functional analysis and customer workshops to define system behavior and operational requirements. Operator interfaces were developed in FactoryTalk View SE (PlantPAx), providing clear visibility of pumping operations, alarms, and system status.
To ensure safe operation in a hazardous environment, the system integrates ATEX badge readers for secure operator access.
Additional functionalities included alarm management, event monitoring, and trending, along with configuration of process data in the plant historian for analysis and reporting.
The solution was validated through Factory Acceptance Testing (FAT), followed by operator training and on-site commissioning to ensure a smooth and reliable start-up.
The solution enhances operational efficiency and reliability while maintaining safe operation within the terminal environment. The client expressed strong satisfaction with both the system performance and the engineering support provided throughout the project.
