Communication solutions to MySQL data bases
General description:
At truck loading facilities it's required to have an information exchange between the customers Terminal Automation Software and the truck loading stations in the field. The loading stations need to have access to the open loading orders and the customers software system needs to get the loading information for the generation of delivery papers and for the invoicing. The customers want this procedure without paperwork by the operator, in order to avoid failures.
Operation at the batch controllers:
As access control for the loading of the truck the operator needs to enter the order number at the batch controller. Then the PCC 400 checks in the MySQL data base if the entered order is available and if the product can be loaded at the selected loading station.
If the operator gets the access for the loading, then the Batching Master indicates the customer name, the product name and the pre-sent value for the truck loading. The operator is able to confirm the pre-set value or to reduce it. A higher pre-set value can't be entered.
After this interaction the operator is able to start the batching process. 
When the loading is finished, the PCC 400 creates the CT loading protocol and it sends a data set with the complete loading information to the MySQL data base of the customer. This information will be used for the creation of the delivery papers and for the invoicing procedure.
Link to the product page of the PCC 400
Batch controllers for belt scales or other flow meters for solids, granules and powders
Different batch controllers and pre-set counters from IBS BatchControl can be used for the loading of solids, granules and powders via belt scales or other flow metering systems. Different data communications e.g. to SCADA systems, data bases or terminal automation systems are available.
Applications:
- Filling machines for big bags
- Loading of trucks at silos
- Filling of railway wagons
- Loading of ships
Connection diagram of a loading system with belt scale and BC 20:
Types of batch and loading controllers:
Batching Master 110i/210i
- As intrinsically safe device for the using in ATEX zone 1 available.
- It is a heavy duty device with integrated emergency stop for an easy and safe operation in the field.
- Indication of the following information: pre-set value, batched quantity, actual flow rate, process status and failure messages
- Part of different MI 005 approvals for custody transfer
- Software communication to supervisory systems by two Modbus interfaces.
- Different systems for the creation of loading reports and for the communication to MySQL data bases and to terminal automation software packages are available.
Batch controller BC20-AC / BC20-DC
- Non-Ex batch controller for not custody transfer proofed applications.
- Easy to handle device due to a 2-line backlighted display and a numeric keyboard.
- The BC 20 is a low priced device but is provides a lot of special functions e.g. for truck loading which are normally available only at high end batch and loading controllers.
- If the filling process is controlled by on/off signals, it's possible to activate an automatic overfill / underfill compensation function in order to optimize the batch accuracy.
- Different data communication solutions are available e.g. for the storage of loading reports and for the communication to data bases and software solutions for order management.
Precise batch results with the 4-20 mA valve output
The batch controllers is able to control the speed of the belt or an actuator for the product flow by a 4-20 mA output signal. Because of a soft-start ramp and a 5-step shut down ramp also small quantities can be batched with highest accuracy.
PID flow rate controller
The PID flow controller makes it possible to control the flow rate during the batch process.
Flow rate monitoring
If the flow rate during the batch falls below a programmed value, then the batch controller stops the batch process after a programmed time. This function prevents the uncontrolled filling during a failure in the measuring system.
Data communication by Modbus
Via the RS 485 Modbus interface it's possible to read out the actual batch information of the loading process. It's also possible to send the pre-set value, the flow rate set point or a batch start and stop signal to the batch controllers.
The information for a loading protocol is stored in a special address range.
Storage of loading reports by the PCC 400
Both batch controllers BC 20 and Batching Master 110i/210i can be connected to the communication PC, type PCC 400. The PCC 400 creates loading protocols and communication solutions to MySQL data bases or to customer's software packages for order management (TAS Software) can be realized.
Complete batch and loading systems
IBS BatchControl devices are suitable for creating complete solutions for your metering application. We supply Batching Masters and Exi separation modules.
We are happy to provide you with the right contact person for the procurement of flow meters.
Our co-operation with all leading manufacturers of measurement and control technology enables us to provide the best possible solutions.
Typical truck loading system:
Custody transfer loading systems for railway wagons
The batch controller type Batching Master 110i/210i is a part of different European approvals for custody transfer conform MI005 / OIML R117. The CT proofed communication controller PCC 400 controls the input of the UIC number of the wagon via the display of the batch controller. This UIC No. will also be shown in the loading protocol and it is part of the stored loading information.
Filling systems for container, IBC and barrels
With a dosing system consisting of a flow meter, a Batching Master 110i/210i and a batching Valve it is possible to build a filling station for container, IBC and barrels. Via special functionalities of the communication controller PCC 400 it's possible to print labels with the product name, quantity of product and additional information about the product after the filling procedure.
Dosing systems for liquids in the production
In production areas it's required to have exact dosing systems for liquid products into batch reactors or mixing tanks. For the dosing of alcohols or if the plant produces medicine it's necessary to store the batch results or to print dosing protocols. With the PCC 400, IBS is able to deliver solutions where the operator is able to enter additional information like a batch number before the start of the dosing.
Calibration rig for custody transfer proofed water flow meters
The company Biesenthal is a leading manufacturer of custody transfer proofed flow meters for water.
At the new calibration rig the Batching Master is used to control the required calibration steps. Electromagnetic flow meters deliver the flow signals and the Batching Master controls the flow rate by regulating a connected control valve.
The operator is able to enter the batch quantity and the required flow rate for each calibration step. This is an easy to use system which performs all requirements for the calibration procedure.
Simple dosing systems with the BC20:
With the BC 20 it's possible to realize simple batching and dosing systems for safe area applications. It's possible to use simple mechanical flow meters and at low flow rate systems simple valves without air supply can be used. Optional a 4-20 mA valve output signal with PID flow control function is available, as well as an optional RS 485 Modbus interface.
Batching system for liquefied gas
Liquefied gas like LPG, Propane or Butane demonstrates out gassing effects as soon as the pressure falls below the vaporization pressure of the gas. These vapour locks would cause fail-measurements in the flow meter.
The override controller function of the Batching Master keeps the pressure during the batch.
The 25-step linearization function of the Batching Master delivers the right pressure set point depending on the actual temperature signal.
A parallel PID flow controller function is also available.
Batch system for ultrapure water
Used in the pharmaceutical and cosmetic industries.
The continuous water flow in a circulatory system prevents the formation of germs.
The Batching Master close the circle valve before the batch start. Different time functions take care, that only the batched quantity during the batch will be counted.
Batch controller / dosing counter BC 20
The batch controller type BC 20 is designed for automation of simple batch and dosing applications in the safe area. The back lighted LCD has a character high of 5,6 mm.
Due to the numeric keyboard and the 2-line display the BC 20 is simple to use and the operator has a perfect overview about the dosing process.
The BC 20 is a low priced device but is provides a lot of special functions e.g. for truck loading which are normally available only at high end batch and loading controllers.
If the filling process is controlled by on/off valves, it's possible to activate an automatic overfill / underfill compensation function in order to optimize the batch accuracy.
Link to the presentation of the BC 20
The following information is indicated:
Pre-set value- Batched quantity
- Status of the dosing process
- Actual flow rate
- Error messages
Inputs and outputs:
- 1 x pulse input, active
- 3 x 4-20 mA input, passive
- 3 x digital input, active
- 2 x relay output, passive
- 2 x transistor output, passive
- 1 x 4-20 mA, valve output, active
- 1 x RS485 Modbus interface
Precise batch results with the 4-20 mA valve output
The BC 20 is able to control the batching valve with a 4-20 mA output signal. Because of a soft-start ramp and a 5-step shut down ramp also small quantities can be batched with highest accuracy.
No pressure "hammers" in high flow rate systems
This problem is eliminated because of the soft start-ramp and the shut-down ramp of the batching valve.
PID flow rate controller
The PID flow controller makes it possible to control the flow rate during the batch process.
Flow rate monitoring
If the flow rate during the batch falls below a programmed value, then the BC 20 stops the batch process after a programmed time. This function prevents the uncontrolled filling during a failure in the measuring system.
Connection diagram of a simple dosing system with a BC20:
Modbus data communication (optional)
Via the RS 485 Modbus interface a customers' DCS system is able to read the actual information about the batching process. By writing function it is possible to send the preset value to the BC 20 or to start and stop the batch. In a special Modbus address range, the information for the printing of batch protocols is provided
Exi Batch controller Batching Master 110i/210i
The intrinsically safe batch controller Batching Master 110i/210i is designed for the automation of truck loading and dosing applications where precise results are required. The communication to the DCS can be done via digital signals or by a Modbus interface.
The Batching Master 110i/210i can be installed in the field, locally at the filling station. It indicates the important information for a safe using by the operator.
In the case of an emergency, the batch can be interrupted immediately. Failure messages are shown in clear text.
(Link to the Presentation of the Batching Master 110i/210i)
Typical applications:
Truck filling systems for liquid products:
The Batching Master controller can be installed locally at the filling station. In the case of an emergency the batch can be interrupted safe and quickly.
Due to different failure monitoring function it is possible to realize safe and accurate batching systems. Release signals can be connected via digital inputs.
Two Modbus interfaces allow the connection to a CT approofed communication and data storage system PCC 400 and also a communication to the customer's DCS system.
Custody transfer loading systems for railway wagons
The batch controller type Batching Master 110i/210i is a part of different European approvals for custody transfer conform MI005 / OIML R117. The communication controller PCC 400 creates the loading protocol after the filling process. The operator need to enter the individual UIC number of the railway wagon at the batch controller and the PCC 400 checks in a MySQL data base if this UIC number is available for the loading. The UIC No. will also be shown in the loading protocol.
Filling systems for containers, IBC's and barrels
With a dosing system consisting of a flow meter, a Batching Master 110i/210i and a batching valve it is possible to build a simple filling station for containers, IBC's and barrels. Via special functionalities of the communication controller PCC 400 it's possible to print labels with the product name, the quantity of product and additional information about the product after the filling procedure.
Dosing systems for liquids in the production
In production areas it's required to have exact dosing systems for liquid products into batch reactors or mixing tanks. For the dosing of alcohols or if the plant produces medicine it's necessary to store the batch results or to print dosing protocols. With the communication controller PCC 400, we are able to deliver solutions for the input of additional information like a batch number before the start of the dosing process.
Some important features of the Batching Master 110i/210i:
Precise batch results with the 4-20 mA valve output
The Batching Master is able to control the batching valve with a 4-20 mA output signal. Because of a soft-start ramp and a 5-step shut down ramp, also small quantities can be batched with highest accuracy.
No pressure "hammers" in high flow rate systems
This problem is eliminated because of the soft start ramp and the shut down ramp of the batching valve.
PID flow rate controller
The PID flow controller makes it possible to control the flow rate during the batch process.
Pressure control of liquefied gas
Liquefied gas like LPG, Propane or Butane demonstrates out gassing effects as soon as the pressure falls below the vaporization pressure of the gas. These vapor locks would cause fail-measurements in the flow meter.
The PID override controller function of the Batching Master is able to keep the pressure during the batch by the 4-20 mA valve output signal.
The 25-step linearization function of the Batching Master delivers the right pressure set point depending on the actual temperature of the product.
Flow rate monitoring
If the flow rate during the batch falls below a programmed value, then the Batching Master stops the batch process after a programmed time. This function prevents the uncontrolled filling during a failure in the measuring system.
Product way selection via the function keys F1-F3
With this function 3 products can be batched with one metering system. The product way can be selected with the function keys before the start. The question text and the text for the product way can be entered in a programming menu.
Batch system for ultrapure water
Ultrapure water is used in the pharmaceutical and cosmetic production as basic product.
The continuous water flow in a circulatory system prevents the formation of germs in the water.
The Batching Master closes the circulation valve before the batch start. Different time functions take care, that only the real batched quantity during the batch will be counted.
Device types:
Batching Master 110i (ATEX)
Exi batch controller with an IP 65 field housing for the using in the hazardous area, ATEX zone 1
Batching Master 110
Preset counter with an IP 65 field housing for the using in the safe area, for the installation direct at the filling station.
Batching Master 210i (ATEX)
Exi loading controller with a panel mount housing for the using in the hazardous area, ATEX zone 1
Batching Master 210
Dosing counter with a panel mount housing for the using in local control panels in the safe area.
Flow computer for continuous flow metering systems
The 1-channel flow computer Pipeline Master 210i is used at continuous flow metering systems.
Input signals are flow rate, temperature, density and pressure. Calculations between mass, volume and volume at 15 °C are available.
Six counter blocks are available:
One non-resettable main counter and five resttable counters can work as batch counters.
Batches can be started and stopped by the keyboard of the device, by a digital input or by the Modbus interface. The counter values of the batch will be printed and stored in the PCC 400.
Indicated values:
The Pipeline Master can display the following values:
- Actual mass flow rate
- Actual volume flow rate
- Actual standard volume flow
- Actual temperature
- Actual pressure
- Actual density
- Actual calculated base density
- values of the counter blocks A - F
Values in the counter blocks A-F:
- Forward counters in mass, volume and standard volume
- Forward failure counters in mass, volume and standard volume
- Reverse counters in mass, volume and standard volume
- Reverse failure counters in mass, volume and standard volume
- Average temperature
- Average density
- Average pressure
Photo: Pipeline Master 210 for the using at continuous metering systems in a refinery.
Printout of the counter values and batch protocols:
Up to 16 flow computers, type Pipeline Master can be connected to one custody transfer communication controller PCC 400. The PCC 400 creates protocols with the counter values. These protocols can be printed and also stored on the PCC 400.
API flow conversion function:
The flow conversion functions are used for the calculation between volume, mass and volume at standard temperature. The calculation can be done via temperature, density and pressure. The formula is conform API 2540 for crude oil, refined products and special products in metric units. A second linear formula is also available.
Inputs and outputs:
- 1 x double pulse input, active
- 3 x analog input 4-20 mA, passive
- 5 x digital input, active
- 5 x digital output, passive
- 2 x Modbus interface
Storage system for loading reports - PCC 400
The PCC 400 can communicate with up to 8 Batching Master, BC20 or Pipeline Master. The loading protocols or counted values are stored in an internal database. The printout of the report can be done automatically after each batch process or after a manual selection in the PCC 400 menu.
There is an additional database inside the PCC 400 available which stores the complete batch information parallel to the storing of the loading reports.
The batch report can show the following information:
- Fixed text block before the printout
- Station name
- Consecutive batch number
- Date/time batch start
- Date/time batch end
- Preset value
- Batched quantity in mass
- Bached quantity in volume
- Batched quantity in standard volume
- Last failure message during the batch
- Fix text at the end of the printout
In addition a non-CT proofed PDF-file of the loading report will be stored at a drive of the PCC 400 which is available by Ethernet.
Different MID approvals for custody transfer are available.
The PCC 400 works without connected mouse, keyboard and monitor.
Indication of the custody transfer loading protocols:
At the left side of the software there is a list with all loading protocols. By a klick on the protocol in the list, the selected protocol will be indicated at the right side of the software. The selected protocol can be printed via a connected printer.
List with the loading information in the internal data base:
This table shows the complete information of the loading processes. It is possible to filter the information by the station name and the date and then the selected information can be exported into a CSV file.
Configuration of the loading protocols:
The loading protocol of each loading station can be programmed separately. Fixed text blocks for the beginning and for the end of the protocol can be programmed. It is possible to select which values have to be printed and headline can be translated or modified.
