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Petrochemical Industry
One-Card Batch Loading & Unloading System

One-Card Batch Loading & Unloading System

System Overview

Built around loading-rack batch controllers, this system addresses the process-control and digitalisation requirements of refineries, product depots, LNG/LPG terminals and liquid chemical storage. A single card integrates electronics, networking, explosion protection and RFID, automating process monitoring, bill-of-lading handling, access control, weighbridge operations and batch loading. Parameter setup, data acquisition, safety interlocks, automatic control and report printing all happen inside one loop, so information moves quickly and accurately at every stage, the uncertainty of manual data entry disappears, and production runs efficiently under safe, controlled conditions.

System Composition

The system comprises computers and software, a communication server, an optional weighbridge, batch controllers, electric or pneumatic control valves, static and overfill alarms, volumetric or mass flow meters, and explosion-proof large-screen displays.
Loading instructions can be issued from the computer to the field batch controller for online loading, or entered directly at the controller for standalone automatic loading. The controller acquires loading quantity, flow, temperature, overfill and static alarms and valve feedback, then drives valves and pumps to deliver a measured batch.
Weighbridge readings are collected and reconciled against controller data to complete product delivery.
Architecture and Functions

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.
Equipment Configuration and Performance

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

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.
System Benefits

System Benefits

01
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.
02
Faster logistics and tank storage
5–15 seconds per vehicle — ten times the weighing throughput.
03
Process design that keeps every step safe
Online training and safety assessment; intelligent guidance and safety checks; equipment interlocks and protection.
04
Fewer staff,
more output
80% fewer weighing staff, with lower labour and management costs.
05
Mobile app
Delivery booking, online assessment, delivery-note review and safety inspection.
06
Interfaces across systems
Integrates with ERP (SAP, Kingdee, Yonyou), LIMS and DCS.
Case Studies

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.
  • 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.
  • 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.
  • 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.