Batch Control System

Overview

Based on batch controllers, the system is designed for auto-control and information transmission of production process in refinery, LNG/LPG receiving station, liquid chemical/gasoline/diesel terminal and others.

By "all-in-one” card , the system integrates electronic, network, explosion-proof, radio frequency identification and other technologies to achieve management such as monitoring, bill of lading, access control, weighing, batch control and etc..

Parameters setting, data collection, safety interlocking, automatic control, chart printing and other functions ensure information transmission rapid and accurate during the loading /unloading operation, and ensure the entire production process efficient and safe.

Composition

The system consists of computers and software, communication servers, weighbridges (optional), batch controllers, electric/pneumatic control valves, electrostatic/oil spill protectors, volumetric/mass flow meters, explosion-proof screen displays and other equipment.

Loading /unloading process can be operated by the computer issuing instructions to batch controllers and also can be operated directly on batch controllers.

Each batch controller collects data and signal such as quantity, flow rate, temperature, electrostatic/oil spill alarm, valve feedback and etc., to control valves opening/closing and pumps starting/stopping, then realize batch control.

Comparing the weight by weighbridge and the quantity by batch controller, System completes the oil delivery task.

Architecture and Functions

Control Room

One loading engineer station for back-office management, process monitoring and data interfaces to other systems;

One loading business workstation for ticketing, card issuing and document printing;

Card reader/writers and management software deliver the one-card function; paperless operation removes the errors manual handling introduces;

A communication control cabinet links the management computers to the batch controllers, handling system communication and controller power distribution.

Loading Area

Batch controllers automate the loading process;

Volumetric or mass flow meters are selected, with accuracy set to requirement;

Electric or pneumatic control valves are the actuating element that keeps loading steady;

Overfill and static protection keeps the loading operation safe;

Explosion-proof large-screen displays and card readers are configured to requirement.

Weighbridge (configured as required)

Captures tare and gross vehicle weights automatically and alarms when the deviation exceeds tolerance;

Calculates the loaded quantity automatically and reconciles it against batch controller data to complete custody transfer.

Supervisory Software Functions

Supervisory monitoring

Overview, section and single-bay screens show the status of pumps, valves, static clamps and loading-arm position alarms, and display instantaneous flow, totalised quantity, flow coefficient, pre-set lead, temperature and pressure in several formats;

Alarming

When a site alarm or equipment fault occurs, the software notifies the operator on duty and logs the alarm automatically;

Data acquisition and processing

Acquires and processes field data in real time, commands the controllers, collects their data, and stores and classifies historical loading records;

Data storage

Retains more than three years of history, including loading and alarm records;

Query and statistics

Queries loading records on combined criteria and generates statistical reports;

Parameter configuration

Maintains products, tanks and bays, and sets controller parameters.

Business operations

Ticketing and card issuing, remote unlock, order cancellation and emergency dispatch;

Operator protection

Permissions confine each operator to their own scope, keep unauthorised users out and add password protection;

Interfaces

A standard industrial bus (MODBUS RTU) allows direct data communication with the DCS.

Equipment Configuration and Performance

XY242 Explosion-Proof Batch Controller

The XY242 is an explosion-proof controller combining an advanced programmable logic controller with a keypad human-machine interface, and offers a fully open communication protocol (MODBUS RTU). Advanced control algorithms give it high control accuracy, dependable performance and easy maintenance. Connected to management computers, weighbridges, flow meters, thermometers, level switches, earthing switches and control valves, it forms a complete batch loading system.

Key Capabilities

10-inch high-brightness TFT colour display
Live readout of mass/volume, flow, temperature, density and time
Online or standalone operation
Operator and administrator password protection
Interlocks including anti-static and overfill protection and abnormal flow-rate alarms
Precise control of solenoid, multi-stage and modulating valves
Coordinated pump and valve control
Overfill alarm
Presence interlocks for the site supervisor and driver
Temperature compensation to API standards
Self-diagnostic testing
Surge and lightning protection

Specifications

Explosion-proof marking

ATEX: II 2G Ex db IIB+H₂ T6 Gb; IECEx: Ex db IIB+H₂ T6 Gb
Ingress protection

IP66
Accuracy

±1 pulse
Supply voltage

AC 220V or AC 110V
Ambient temperature

-40 to 60℃
Pulse input

Vp-p ≥ 2V, frequency ≤ 30 kHz (2 channels standard)
Digital input

Valve and pump feedback, overfill and anti-static switch signals (10 channels standard)
Digital output

Pump and valve control and other uses (8 channels standard)
Analogue input (4–20 mA)

Temperature, pressure and control-valve feedback (2 channels standard)
Analogue output (4–20 mA)

Control-valve actuation (1 channel standard)
Communication bus

1 × RS485
Keypad

24-key stainless steel Hall-effect keypad
Reader type

IC card reader or QR code reader

XY400 Explosion-Proof Card Reader

The XY400 explosion-proof IC card reader combines electronics, networking, explosion protection and RFID. IC card technology digitalises ticketing, depot entry and exit, automatic loading and weighbridge operations, so information moves efficiently and accurately at every stage, manual entry uncertainty disappears, throughput rises and vehicle management gets simpler.

Features

Equipment status display
Automatic card data capture
Cardholder account and record management

System Benefits

Stops fraud, closes gaps, prevents loading errors

Saves RMB 0.5–5 million per weighbridge each year and removes the safety risk of loading the wrong tank.

Faster logistics and tank storage

5–15 seconds per vehicle — ten times the weighing throughput.

Process design that keeps every step safe

Online training and safety assessment; intelligent guidance and safety checks; equipment interlocks and protection.

Fewer staff,more output

80% fewer weighing staff, with lower labour and management costs.

Mobile app

Delivery booking, online assessment, delivery-note review and safety inspection.

Interfaces across systems

Integrates with ERP (SAP, Kingdee, Yonyou), LIMS and DCS.

Case Studies

CNOOC Huizhou Petrochemical — XY-TMS Intelligent Storage and Loading Management

Unit 228 at CNOOC Huizhou Petrochemical deployed XY-TMS to replace manual ticketing, repetitive vehicle checks and risky document verification. The system supports online booking and registration, self-service ticketing and settlement at kiosks, unattended weighing and end-to-end loading supervision, making the whole flow self-service. During trial operation it handled over 5,500 vehicle movements and more than 145,000 tonnes of product, saving over RMB 2 million a year in operating costs and closing the loop on digital loading control across the depot.

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Oil & Gas Industry
Batch Control System