AOS' Joe Shotwell and Novaspect's Hasit Patel, Greg Juchniewicz, and MC Chow present at 2011 Emerson Exchange in Nashville, TN USA. Their abstract:

1. State-of-the-Art
Automation at Asphalt
Loading/Blending
Terminal
AOS Chicago Terminal
Workshop# 4-2973

2. Presenters
 Joe Shotwell
 Hasit Patel
 Greg Juchniewicz
 MC Chow

3. Introduction
 Design & Implementation of state-of-the-art
Automation for Asphalt Storage, Blending & Loading
terminal
 Selection process of equipment & integration
 Business Results
 Path Forward

4. AOS Chicago
 Asphalt Operating Services of Chicago, AOSC, LLC,
is a liquids terminal service company that provides
safe and efficient storage, handling and shipment of
bulk liquid products for customers in the petroleum
industry.
AOSC Mission:
 To provide storage, production and terminal services
to the petroleum industry in an efficient and effective
manner that provides the greatest value to the
customer, utilizing internal and external knowledge,
skills, and resources

5. ECF, Inc
 ECF, Inc. provides the liquid terminal and industrial
manufacturing industries with a source of qualified
and experienced construction professionals.
ECF is committed to building long term customer
relationships based on quality products installed in a
safe working environment with customer service
second to none
 ECF provided Project Management, Design and
Construction Management services for this project.

6. AOS Chicago Terminal Project
 Brown field terminal
built to provide Asphalt
Storage, Blending &
Loading
 2nd terminal owned &
operated by AOS
 Construction started in
Nov-2010, 1st barge
received Jun-2011

7. AOS Chicago Terminal
 5 product storage tanks
 Barge unloading Jetty
 6 Rail Car loading spots
 Hot Oil Heater
 4 Truck loading spots with
Weigh scales
 6 Ratio blenders with Coriolis
flow meters and VFD’s
 18 MOV’s for product lineups
 Odor Control system for loading spots

8. Instrumentation & Automation Goals
 Integrated system which provides
– Flexibility in operations & expansions
– Compliance to regulatory needs
– Meet business needs of AOS
– Single point of responsibility
– Easy to operate & maintain
– Integrate with AOS & its client’s business transaction systems
 Meet Aggressive Delivery and Commercial needs
 System provider to be:
– Local
– Posses Domain expertise in Terminals
 #1 requirement – KEEP the System simple

9. Automation Supplier Selection process
 Novaspect had experience working with ECF on their
previous projects with BP Whiting
 Early engagement in the project
 Novaspect scope extended to Main Automation
Contractor
 Leverage learning's from Automation challenges from
AOS’s Bartlett, IL terminal

10. Process Automation System Selection
 300+ I/O system with distributed I/O at
– Tank farm/Blenders (DeltaV Controller and I/O),
– Rail Terminal (CHARMS Cabinet) &
– Truck Terminal (CHARMS Cabinet)
 DeltaV Operator stations at Rail, Truck Terminal &
Control Room/Admin Office
 DeltaV Reporter for Transaction reports
 ICONICS BridgeWorx transaction server for data
transfer and reporting

11. DeltaV System Architecture
AOSC-OPR01 Rail Kiosk AOSC-OPR02 Truck Kiosk Admin Office
RCU1 RCU2
RCU3 RCU4 To AOSC-Office LAN
DeltaV Operator DeltaV Operator
Station @ Truck AOSC-OPR03
Station @ Rail
Weigh Weigh Weigh Weigh
Scale Scale Scale Scale
CP-701 (DeltaV Cabinet) Controllers Controllers Controllers Controllers Fiber media
CP-601 (DeltaV Cabinet) convertor
AOSCCIOC01 Profibus DeltaV Operator
AOSCCIOC01 Fiber
CIOC for Truck Station @ Admin
CIOC for Rail Extender
DeltaV Area Control Network (Redundant)
MCC-301 Building
Server/UPS Cabinet TMS cabinet Terminal Manager
…. AOSC-OPR04
AOSCBRIDGE Patch Fiber Cord
AOSCPRP00 AOSCAPP01 DeltaV Operator
Transaction AOSC-TMS
DeltaV PROPLUS DeltaV App Station Station @ Terminal
Engine Server TMS Server(s)
AMS Server Plus Continuous Historian Manager Office
Qty=2
CP-301 (DeltaV Cabinet)
AOSCWIOC01 AOSCCTR01 Profibus
WIOC for Modbus Serial to TMS Server
DV Controller Fiber
Chicago Terminal For Chicago Extender
Terminal
DeltaV Architecture @
AOS Terminal
Wireless Antenna
EEP cabinets
2835 E 106th St,
Wireless Antenna
Model 781 VFD’s VFD’s Chicago, IL 60617
Model 781
On Roof of RIE On Roof of RIE

12. DeltaV Cabinet in RIE & CHARMS cabinet
Field Mounted CHARMS Cabinet with Fiber
DeltaV Cabinet with Mass-Termination

13. Instrumentation Selection
 Blending skids comprising of
– Micro Motion Coriolis flow meters for Mass, Volume, Density
& Temperature measurements
– Control Technique Variable Frequency Drives for Flow
Control.
– MOV’s for valve line-ups and Odor Control System
 Tank Level & Temperature measurement with Saab-
Rosemount Radar gauges with multi-spot
temperature
 Tank Hi-Hi Level measurement with Wireless TT’s
 Mettler-Toledo Weigh scales with Profibus Interface

14. Blender Skids with Micro Motion flowmeters
• Pulse Input (for
Multiple Custody Transfer)
interfaces • HART/ Analog
• Density
Multi- • Volume/Mass flow
variables • Totalizer
• Casing
(HART) Temperature

15. Level Measurement
• Radar gauge for Level
measurement
• Multi-spot RTD for
Multiple temperature averaging RDU
Instruments • Wireless TT for High-
High level detection
• Tank Level
• Volume with tank
Multi- strapping
variables • Average Tank
Temperature
(HART) • Temperature rate of
change for High-High

16. High High Level Measurement

17. Controls Implementation
 Use of Class based Control Modules
 Use of Human Centered Design (HCD) graphics and
objects
 Use of Equipment Modules (EM’s) and Sequential
Function Charts (SFC’s) for loading sequences
 SQL server for transaction management

18. Business Transaction Interface
BDS BP
Rail Car SAP
Orders & Financial &
Invoicing R
Invoicing
ai
lC
ar
Tr
an
sa
Rail Car ct
io
Strapping ns
Tables
Inventory &
Transaction Rail Trx Invoicing
Manager
middleware
s
ent
Ev
Process TMS – Truck
Automation Loaded Weights, Tank Levels Loading
System System

19. Flexible Loading Sequences
implemented in DeltaV Control System

20. Easy of use – Operator Interface Graphics

21. Easy of use – Operator Interface Graphics

22. Easy of use – Operator Interface Graphics

23. 3rd Party Interfaces to Business Systems
 Real time tank levels and
truck loading status
information to Terminal
Accounting System using
Serial Modbus interface
 Rail car strapping and Rail
Transactions interfaced to
BDS Railtrack @ YardMaster
system for accounting and
load tracking
 Truck/Rail transactions
interfaced to Client’s
Accounting system (SAP)

24. Business Transaction System Interface

25. Business Results Achieved
 Quick Startup
 Compliance
 Safety
 System Performance
 Ease in Operations & Maintenance

26. Business Results Achieved – Quick Startup
Terminal Operations started on schedule
1) Intelligent devices enabled quick checkout and
commissioning
2) Flexible Architecture allowed for changes during course of
construction and startup
3) Ease of use allowed for operations acquaintance
4) Distributed I/O with use of CHARMS allowed for reduced
wiring and troubleshooting

27. Smart Devices & Digital Communications
 HART interface to Micro Motion meters for:
– Mass/Volume flow rate & totals
– Temperature
– Density
 Profibus interface to VFD’s
– Motor Electrical parameters
– Diagnostics & Reset
 Profibus interface to Weigh Scales
– Scale diagnostic parameters & Zero values
 wiHART interface to Tank HIGH level interface

28. Business Results Achieved - Compliance
 Micro Motion meters for Blend Certification
– Pulses used for primary measurement & Control (Mass for
Trucks, Volume for Rail Cars)
– HART Totalizers used for verification of batch totals
 Wireless HART Temperature transmitters
– Provides separate technology (then Radar for Level) and
separate communication path for HI-HI Level on tanks
– Field verification and testing setup provided to perform
periodic verification of High level detection

29. Verification & Test setup for High Level

30. Business Results Achieved - Safety
 Interlocks configured to prevent inadvertent
operations with simple operator communications
through Graphics
 Checks and balances for Rail & Truck compartment
capacities and product compatibilities
 Tank Overfill Alarm verification
 Tank Low Level for minimizing hot oil coils exposure
to atmosphere

31. Business Results Achieved - Performance
 Terminal Throughput
– 32 Rail cars/day
– 125 trucks/day
 Blend and Shipment accuracy
– Rail cars loaded at +/- 6 gallons for 23,000 gals rail car
– Trucks loaded at +/-20 lbs for 50,000 lbs truck capacity

32. Business Results Achieved –
Ease in Maintenance
 Configuration & Troubleshooting of all Instrument &
Controls managed by single tool (AMS)
– Micro Motion Coriolis meters (HART)
– Saab-Rosemount Radar Level/Temperature (HART)
– Control Technique Variable Frequency Drives (Profibus DP)
– Temperature Transmitters (wiHART)
 AMS Alert Monitor for all “smart” instrumentation
 AMS audit trail for revision management

33. VFD configuration & troubleshooting w/ AMS
• Perform initial set-up for new drives
• Change parameters on existing devices
• Track runtime data
• Configuration changes are automatically
documented in the Audit Trail

34. VFD configuration & troubleshooting w/ AMS

35. VFD fault history & runtime with AMS

36. VFD status view through AMS

37. Automation System accessibility –
55” LCD Monitor in Admin Office

38. Automation System accessibility on
iPAD through cellular network

39. Path Forward
 Expand the system to:
– Monitoring process variables wirelessly for
• Hot oil system
• Unloading pressure at barges
• ….
– Mobile Worker for
• Wireless Video Cameras for Surveillance
• Operations and Maintenance stations
• ….
– Transaction reports for
• Material Balance reconciliation
• …
– …

40. Summary
 State-of-the-art Automation system allows
– Integrated operations & maintenance
– Compliance
– Flexibility
– Room for expansion
– Reduced cost of ownership
– Simplicity in use and support

41. Where To Get More Information
 http://www.aoschicago.net/
 http://www.aosterminals.com/
 http://www.ecfinc.net/
 Contact
– Joe Shotwell - joe.shotwell@aosterminals.com
– Al Meitl – AJMeitl@ecfinc.net
– Hasit Patel – hpatel@novaspect.com
– Greg Juchniewicz – Gjuchniewicz@novaspect.com
– MC Chow – MCChow@novaspect.com