TAS & Control Room Operations

TAS & Control Room

Operations

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 TAS & Control Room Operations
The Terminal Control System is integrated in to the
following systems
 Reliance Application Server (SAP server)
 Real Time synchronization done with TAS Central
Server.
 Automatic Tank Gauging System
 ESD System
 Bhopal & REWARI with – GE Rxi (window
platform)
 Kanpur, Haldia & Chennai - GE Fanuc 90-70Series,
GMR (DOS)
 Actuator Master Station (Pak Scan).
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 TAS & Control Room Operations

The philosophy of distribution of I/A Series DCS

equipment are broadly classified in to following
categories.

1.Information Management
2.Operations HMI and Maintenance (Man Machine
Interface)
3.Control ( Cause & Effect through DCS & PLC for
any emergency)
4.Auto Pump demand for dispatch pumps.
5.Input / Output (Pump start/stop etc..)

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TAS & Control Room Operations
Terminal Control System is covered in two
parts.
1. DCS Interface.
2. TAS Interface.

DCS Interface :-
 I/A Series Integrators (Modicon and Device
Integrators) are used to interface DCS with various
third party Systems.
 ESD, MOV and ATG systems interface to DCS using
Modbus protocol for Kanpur, Chennai & Haldia.
 For Bhopal & Rewari Integration achieved through
FBM231.
 The BCU systems are interfaced to DCS system
using SLIP (Serial Link Interface) protocol.
 All the Integrator used are fault tolerant i.e 4

Redundant.
 TAS & Control Room Operations

TAS Interface
Access Control Device is connected with LRCs
through terminal servers. IOSERVER application
is running in both LRCs i.e. active & backup to
avoid any interruption in case of Master
changeover. ACS is part of TAS interface. It is
interfaced with Load office computer to meet
the following functionality.
1. To control the entry at the Barrier Gate
2. To control the exit at the Barrier Gate
3. To automate the Truck Registration.

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 D:\PDF folder\Cycle in TAS TT in-TT Out.pdf

IPS
 TAS & Control Room Operations
The main functions of the TAS software (iTAS) are:
 Minimum interruption to terminal operation in
the event of communication failure between the
TAS and subsystems.
 Tank Truck Customer order Linking (TOL – Truck
Order Linking)
 Accurate and uninterrupted product loading to
trucks
 Truck / Rail / Ship / Receipt Automation

 Product Receipt / Dispatch

 Stock Inventory by TIS (Tank Inventory System)

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 TAS & Control Room Operations
 Traffic management by controlling access to the
truck loading area and validating trucks at
strategic points.
 Perform plant control functions such as pump
control,
measurements, and interlocks and interface to plant
ESD.
 Easy to use and interactive Graphical User Interface
or HMI.
 Pump/MOV/ESD & Process Control

 Transaction/Inventory Reporting & report generation.

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 TAS & Control Room Operations
The main objectives of an integrated Terminal
Automation System are :-

1. Increased Efficiency :-
 Faster Loading
 Increase in Overall loading volumes.
 Reduction in labor cost

2. Surveillance: The Fight against fraud is

facilitated by automation, which ensures:
 Access Control of Trucks as well as human being.
 Availability of various reports.
 Control of loading / unloading by Real time
Graphical User Interface layer. 9
 TAS & Control Room Operations
3. Quantity Control:
 Real Time Measurement of the quantity
allowing leaks and fraud to be minimized.
 Control of amounts actually delivered against
predetermined loads.
 Quick and precise billing.

4. Safety & Security:

 Automation Makes the Terminal safer as it
eliminates dangerous actions like earth
connection control, loading arm control,
emergency shut down system, interlocks,
overspill control.
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 TAS & Control Room Operations
Instruments / Equipment -TAS
 Batch Control Unit: It is the Brain of TAS.
Controls loading Oprn.
 Flow Meter : Turbine flow Meter
 DSSV: Digital Set Stop Valve To control the
product delivery to TT.
 RIT : Remote Interacting Terminal for TT crew to
load the truck.
 ACD : Access Control Device , Registration,
Entry & Exit
 Card Reader : Reads the Touch key and
authorizes the TT. 11
 TAS & Control Room Operations
• Contrec1010RH –electronics:
• The nerve center of loading
operation
– CPU card (D)
– Relay Card or the output
card (B)
– Flow card or the input
card (C)
– Power supply card (A)
– Display card (E)
• Configuration 12
 TAS & Control Room Operations

Earthing Relay
Petroleum Transporting vehicles
should be properly tied to ground
before and during the loading
operation.
An intelligent system
Continuously and automatically
monitors the grounding connection
during the entire loading operation
It is designed to immediately shut
down the loading operation if the
ground tie-in is broken.
Clamp and Cable Unit 13

Designed to drain static charges

TAS & Control Room Operations
TANK INVENTORY SYSTEM
Ullage
LAHHH, interlock (no alarming in TIS)
LAHH, Movement shutdown
Maximum working level
LAH

Measured Level
Tank Capacity
Maximum Working Volume

Operator setpoint
Pumpable Volume

Total Observed Volume

LAL
Minimum working level
Min. working volume LALL, Movement shutdown
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TAS & Control Room Operations

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TAS & Control Room Operations

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 TAS & Control Room Operations
Control Room In Charge plays an important role in doing the
Terminal Operations in most efficient and effective manner. Also
the CRI plays a very key role on ensuring Quantity and Quality
during receipt, storage and delivery operations through their
commitment to “Quality Management System, strict adherence to
“Standard Operating Procedures” and compliance to “Work
Instruction Document”.

Here are few activities / Roles & Responsibilities to be carried out

by CRI:

1.Ensure that the present product stock as per TIS is matching

with the previous day’s day end closing stock.
2.Co-ordinate with maintenance in charge and ensure that TCS,
MOVs, BCU’s, entire instrumentation is always in working
condition including calibration of TSV’s/PG’s for uninterrupted
operations.

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 TAS & Control Room Operations
3. Cross check ATG reading with manual dip
reading and take corrective action wherever
necessary. Reconcile the tank delivery through
meters verses ATG and propose corrective
action in the setting of meters/ATG.
4. Updating density @ 15 deg C as per the batch
formation certificate in TIS from time to time.
5. Allocate tanks to different products as advised
by TM/TFI in TAS.
6. Opening of Tank Movement in TAS as per the
plans and closing of Tank Movement at the end
of shift/operation.
7. Checking of BCU / MOV status, Checking the
bay allocation activities, performing
Deactivation / Activation of bay and handing
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over it for maintenance job.

 TAS & Control Room Operations
10.Monitor the material temperature captured by
RTD vs the actual material temperature
physically recorded by GI, and 15 deg C density
captured by online densitometer vs the density
recorded in SAP system by GI/LOI on regular
basis. Also monitor preset vs actual delivered
quantities of each BCU in TAS system on
continuous basis for accurate deliveries.
11.To ensure that all the MOVs including ESD
system and pumps can be operated centrally
from Control Room by obtaining confirmation
from field on proper/actual functionality of
MOVs along with manual valve line up before
commencing operations. Also to facilitate
operation in Auto Mode to ensure that all
remote operated valves are kept under Auto 19

Mode. To ensure that all the interlocks are in

 TAS & Control Room Operations
14. Co-ordinate with tank farm operator / TFI /LOI/GI and ensure
that all receipt and dispatch operations are carried out as per
laid down procedures including lining up of tanks in
auto/manual mode.
15. Checking operability of MOV’s / Pumps on Local & Auto mode;
checking of Interlock / ESD logics; Stroke checking of Different
Control Valves; Operability of PA System, VHFs / Base Station,
Siren System (Auto & Manual )once in a month &maintain
records.
16. Ensure right documentation of all events during receipt
operations as per Standard Operating Procedures and IQCM.
17. Always ensure good house keeping standards in the control
room and daily monitoring checks of UPS and PAC system.
18. To keep track of various alarms and co-ordinate to ensure
disposal of alarms as per Standard Operating Practice by
taking prompt action and to ensure reduction of alarms on
month to month basis.

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 TAS & Control Room Operations
19. To coordinate with field/MI/TFI for isolation and release of
equipment for PM/CM schedule.
20. Taking timely back ups at stipulated intervals and store data.
21. Co-ordinate with MI/TFI/SO and ensure that FAP, OSD, LHSC, MCP are
functioning smoothly and maintaining records.
22. Maintain records of all instruments along with tag numbers for
tracking the operability & maintenance with the help of MI.
23. Co-ordination with MI and ensure that air compressor is always in
operable condition and sufficient air pressure available for FCVs etc.
24. Keep abreast of Fire-order and Onsite emergency plan and ensure
entire area fully framed on the same and perform roles as defined
in the documents.
25. Check Regularly all TAS reports and maintain in auditable manner.
26. Maintaining Work Permit Register to keep track of all the
Maintenance related activities and coordinating different
functionalities.

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TAS & Control Room Operations

REPORTS

1. Configurable End of Shift, End of Day, End of

Month reports.
2. Terminal throughput reports
3. Inventory and product reconciliation reports
4. Product transfer reports.
5. Filling Advice Note and Bill of Lading
6. Alarm and event summary/audit trail.

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 TAS Upgrade
Present system : Terminal Automation System (supplied by M/s
Invensys India now Schneider Electrical ) handles dispatch of products
through Road.
The components are:
1. DCS system (I/A V6.1.2, CP60, INT30 Gateway for serial
communication, AW51D and AW51G( Kanpur ) and WP51 for monitoring
and managing the real time data during the loading operation.
2. TAS application software for enabling & controlling the data flow for
Road and for interfacing with SAP Business Server.
3. VERITAS clustering for hot redundancy of TAS application software
AW(Application Workstation Processor).
4. User interface in Oracle forms for managing the database.
5. Third party interfaces ( ACD) for managing the integrity of data flow.
6. SAP-TAS application interface through Gateway for to interface with
to interface with the SAP Business Server.

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 TAS Upgrade
New Scheme: The TAS components have reached the end of their life
cycle and maintenance support is lacking due to obsolescence.
It's also unable to cater to any flexibility/modification due to
overloaded systems.
Following are included in the new TAS system
1. Windows based DCS system on high speed Mesh network.
2. Windows based TAS applications software for Road loading.
3. User interface on windows latest platform.
4. Fault Tolerant (FT) Server for Applications & Database server.
5. RDBMS upgrade to latest available version.
6. Third party applications interface through Terminal Server.
7. Plug-in SAP-TAS interface through TIBCO interface.
 Centre of Maintenance & Engineering Excellence have done value
engineering and final scheme was given. Which include Full upgrade
at Bhopal and Rewari and Partial Upgrade at Kanpur, Chennai and
Haldia.

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TAS Upgrade

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TAS Upgrade

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 RELIANCE IT CENTRE, / MUMBAI.
LEGEND
BHOPAL
REDUDANT PRIMARY DATABASE
DATABASE SERVER CHENNAI

HALDIA SECONDARY DATABASE

KANPUR
SAP-TAS DATABASE
REWARI

Witness Server Database Server Witness Server Database Server Witness Server Database Server

Witness Server Database Server Witness Server Database Server

MCT BHOPAL MCT HALDIA MCT REWARI

MCT CHENNAI MCT KANPURI

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 TAS Upgrade
Business Risk Solution
High Potential downtime of Redundant database
Businessdatabase
Availability Risks and Solution
service system components
-REDUDANT DATABASE SERVER
considered for business Risks
Disaster In case that database Redundant data.
Solution. service is down with Redundant database
Recovery
potential data loss, system
get database service components .
back online with
minimum impact
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TAS Upgrade

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 TAS Upgrade
Easy to operate
Reliable & redundant
Local data base available, which will eliminate the data base
locking/nonfunctional of data base
In absence of network we can continue loading –feasible local
data base
Better control on plant operation
Reduce possibility of aborting the compartment/skipping
compartment
Increase reliability of TAS system and easy
maintenance/flexibility/modification
Enhance control features in the field
Over all control passes to Panel operator
Reduce data uploading /down loading time, as there is no buffer
concept

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 TAS & Control Room Operations
DIFF IN OLD AND NEW TAS , DCS SYSTEM
OLD TAS NEW TAS
Bayallocation was happening for all TOL TT's. It First Come First Out (FIFO).
was difficult to say system will allocate FAN for 1st
1 TT or Last TT.
2 Engineering was with JMNGR team Local, we can configure Arm product,
no. of arms, Tank Product etc.. Locally
3 Oracle Database locking & non functional issue
This issue has been ruled out.
For activating any new touck key, JMNGR team
4 involvement Can configure locally
Redundant database server, Local &
5 Single Database server @ JMNGR RCP
6 Timing mismatch in TAS Report, also was not current day report can be generated.
giving ample information as per requirement. It was Timing relaxed .
having fixed timing for a day/movement from 06:00
AM to nextday 06:00 AM and intermittent report
generation was not possible.

7 During network failure, operation was not possible Can continue the loading process from
local server
8 Time stump issue for loading sequence Captures time stump 31
9 Unable to retrieve BCU totalizer in Report Totalizer is getting captured in almost
 TAS & Control Room Operations
  OLD DCS NEW DCS
1Pump demand: last pump to stop timing was very Now it is arm based, saving energy and increasing
high pump efficiency
2Only two AW's Seperate Engineering server for any
modification/configuration - no need to disturb
LRC's
Same AW's were handling all application like TIS &
3 DCS Separate TIS Server
4ACD program was based on serial communication, Now attached with LRC1 & 2 on TCP/IP, so less/no
PC com port, Database communication, oracle and maint required
was limited to XP platform
5RS 232 -485 converter was used for FBM's handle RS 485, Converter not required
communication for PLC, ATG,ACD,BCU
6Limited Trend tags were assigned and one screen Almost all tag has been configured. Numerous tags
can show single tag at a time. can be viewed in single page.
7Redundancy was limited Hardware flexibility
8Working on boot host LRC 01 Separate work station provided for CRI's
9Difficult to operate as it was command based Unix Easy to operate as it is window based.
& solaris system
10Bay comm Failure, abort, part fill issue due to This issue resolved by updating similar EPROM in
different EPROM ver installled in gantry. all bays.
11Same modicon gatways used for both PLC & Separate FBM provided for PLC & PAKSCAN
PAKSCAN system
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 TAS & Control Room Operations
Alarm OLD ALARM system New Alarm System
1 alarms Server Apart from all old alarms new alarms
configured under critical alarm

2Mailing was not possible Mailing is happening

SMS was not possible for
3 critical alarm Working fine
audio for critical alarm was
4 not available Available (under progress)
5Limited storage Incresed storage capacity
     
Safety
System OLD Control New Control
Window base PLC, Easy to operate,
latest Hardware - Windows platform
DOS base PLC - Now this is and can be continued for approx 15
1 absolute, No spares Yrs 33

     
ACD

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Bay Activation Screen

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Bay Diagnostics

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Equipment History Sheet

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FAN

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RAIL RECEIPT

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SYSTEM OVERVIEW

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Tank – P&I -Alarms

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TAS- SUMMARY

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TRUCK LOADING GANTRY

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FAN LOADED

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TAS & Control Room Operations

Thank You

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