Improving safety and operational reliability in a tank terminal facility
A liquid storage and distribution terminal located in the Port of Antwerp, Belgium, required an upgrade of its control system to support the operation of newly installed tank pits. The project focused on redesigning the automation program responsible for controlling storage, loading, unloading, and circulation processes across the tank terminal infrastructure.
Contec delivered an automation solution that modernized the control architecture while ensuring safe and reliable tank operations. The new system provides improved equipment control, enhanced alarm management, and clear operator diagnostics, supporting efficient terminal operations and regulatory compliance.
Implementation Overview:
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Redesign of control programs for multiple tank pits within a tank terminal
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Automation of tank loading, unloading, circulation, and storage operations
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Alignment with site-specific electrical standards
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Integration of safety systems and industrial communication networks
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Standardized control modules for pumps, valves, and instrumentation
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Improved operational visibility through modern HMI diagnostics
The challenge
Ensuring safe and reliable operation of tank storage infrastructure
Tank terminals handle large volumes of liquid products that must be transferred, stored, and circulated safely and efficiently. The control system responsible for managing these operations must ensure reliable equipment sequencing, proper interlocks, and full visibility of system conditions.
The terminal required a redesigned control program capable of supporting new tank infrastructure while maintaining operational safety and regulatory compliance. The system also needed to integrate with existing equipment such as pumps, valves, drives, and safety systems.
Another important requirement was the implementation of clear operator interfaces and alarm management, enabling terminal operators to quickly identify abnormal conditions and respond effectively.
Our approach
Developing a standardized control architecture for tank terminal operations
Contec implemented a redesigned automation solution based on the Rockwell ControlLogix platform.
PLC logic was developed for a Rockwell 1756-L85EP controller using Studio 5000. The control program includes standardized equipment modules and sequences for pumps, valves, and instrumentation used throughout the tank pits.
Operator interfaces were developed in FactoryTalk View SE using the PlantPAx V5 architecture, providing structured visualization and control of tank terminal operations. Standardized faceplates were implemented to simplify operation and maintenance of field equipment.
The system integrates multiple industrial communication protocols including Profibus, Modbus, and PIO, enabling communication with field devices and terminal equipment.
Additional configuration included Emotron drives and a PnozMulti safety PLC, ensuring safe operation of equipment and proper management of critical interlocks.
To ensure reliable project delivery, Contec conducted Factory Acceptance Testing (FAT) with simulation of I/O, sequences, and alarms. This was followed by Site Acceptance Testing (SAT) including I/O checks, network validation, and verification of operational interlocks with terminal operations.
Start-up support and follow-up services were also provided to ensure stable system performance after commissioning.
