XY6000 Batch Control System

Overview

Based on batch controllers, 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 , 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

System consists of computers and a set of 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 signal, valve feedback and etc., to control valves opening/closing and pumps starting/stopping, then realize batch controlling. Comparing the weight by weighbridge and the quantity by batch controller, System completes the oil delivery task.

Architecture and Functions

Control Room

One set of engineer computer for loading/unloading management, and connecting with other system;
One set of service computer for information key-in, card issuance, document printing and other operations;
One set of card reader and management software for “all-in-one” card, paperless functions;
One set of control cabinet for communicating and power supplying with batch controllers.

Loading/unloading Platform

Batch controller automatically controls loading/unloading process;
Volumetric or mass flow meter calculates loading/unloading quantity; Accuracy is determined according to need;
Control valve ensures loading/unloading process smooth;
Electrostatic oil spill protector ensures loading/unloading process safe.

Weighbridge (configured as needed)

Collect the weight of loaded/unloaded tank truck, and if exceeding the standard;
Compare the weight by weighbridge and the quantity by batch controller, and occur alarm if exceeding the standard.

Topology diagram

Flow Chart

Equipment introduction

XY242 Batch Controller

XY242 batch controller is an explosion-proof operation panel that integrates an advanced programmable logic controller and a button-type human-machine interface. With advanced control algorithms, it has the characteristics of high control accuracy, reliable performance. By providing standard communication protocol (MODBUS.RTU), it is connected with management computers, weighbridges, flow meters, thermometers, electrostatic/oil spill protectors, control valves, etc., to constitute a complete batch control system.

Basic features

True color 10-inch TFT high-brightness screen
Real-time display of mass/volume, flow rate, temperature, density, and time
Online or offline working mode
Operator password, system administrator password setting
Anti-static and oil spill protection, abnormal flow rate alarm and other interlocking protection functions
Precise control to solenoid valve, multi-stage control valve, regulating valve, etc.
Pump and valve logic control
Overloading alarm
Detective function of operator/driver on-site (optional)
API standard temperature compensation function (optional)
Self-diagnosis test
Surge protection

Basic parameters

Explosion-proof mark: ATEX: II 2G Ex db IIB+H2T6 Gb; IECEx: Ex db IIB+ H2T6 Gb
Protection level: IP66
Accuracy: ±1 pulse
Power supply voltage: AC220V or AC110V
Ambient temperature: -40～60℃
Pulse signal input: Vp-p≥2V, frequency≤30KHz (standard: 2 channels; up to 4 channels )
Digital signal input: for valve/pump, electrostatic/oil spill protectors feedback (standard:10DI; up to 16DI)
Digital signal output: for pump control, valve control and others (standard: 8DO; up to 12DO)
Analog signal input (4-20mA): for temperature, pressure, and valve feedback (standard: 2AI; up to 4AI)
Analog signal output (4-20mA): for regulating valve control (standard: 1AO; up to 2AO)
1-RS485 communication bus: for PC
24-key Hall stainless steel buttons
Recognizer type: IC card reader or QR code reader

XY400 Explosion-proof Card Reader

The XY400 explosion-proof IC card reader integrates electronic, network, explosion-proof, radio frequency identification and other technologies，to realize the information management of production processes such as card issuing, tank truck enter/leave recognizing, automatic loading/unloading operations, and weighbridge weighing, to ensure efficient and accurate information transmission and improve production efficiency and tank truck management.

Features

Explosion-proof mark: ATEX: II 2G Ex db IIB+H2T6 Gb; IECEx: Ex db IIB+ H2T6 Gb
Protection level: IP66
Power supply voltage: DC24V
Ambient temperature: -40～60℃
Device working status display
Automatically read card swipe data
Cardholder account and file management

Software Functions

Basis document management: information of storage-tanks, oil products, tank trucks, transport licenses, driver licenses and etc.;
Monitoring function: real-time status display of platform, pumps/valves, electrostatic/oil spill protectors, all alarm signal and various parameters set such as safe flow rate, pulse equivalent, advanced-close volume, temperature and pressure limit and etc.;
Service operation: information key-in and card issuing, remote unlocking, order cancellation, emergency delivery and etc.;
Alarm management: any equipment failure or abnormal condition, system occurs an alarm and reminds the operator to handle, and automatically records the alarm signal;
Data management: acquire and process real-time data of access, weighbridges, batch controllers in system, and store all loading/unloading records more than 3 years;
Query function: according to different combination conditions to query loading records and generate reports;
Operation protection function: by authority setting and password protection, each operator can only operate within authority to prevent unauthorized operating;
Interface function: with a standard communication bus (MODBUS.RTU), system can connect with other systems such as DCS.