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Seamless Transition with Contrec’s LoadPro®: Replacing the Obsolete Contrec/Honeywell 1010 Load Controller in Airport Fuel Farm

 

This case study explores the straightforward task of replacing a Single or Dual Arm 1010 Load Controller. Contrec’s new innovative LoadPro® solution ensures a smooth transition for AV fuels, acting as a direct stand-alone replacement for the 1010 controller.

This solution was used in Brisbane QLD for Archerfield Airport’s fuel farm, which is operated by AV Fuels and supported/serviced by electrical contractor Total Energy Services Australia.  Archerfield Airport is Brisbane’s second airport still with substantial volume of small to medium aircraft activity.  The controllers are required to load the AV Fuel trucks in a safe and controlled manner, with a simple and clear operator interface and accurately recorded volumes.  

 

For this instance of replacing an old 2-Arm 1010 with 2 single arm LoadPro® units, Contrec Systems supplied a changeover overview, a remapping wiring diagram and the offer to pre-program the LoadPro® with compatible settings before shipping. However, with the old 1010 display already failing so much, commissioning had to be carried out on site in full via the front panel. With the work Total Energy Services provided, the install, mounting and rewiring was even easier than what we had hoped for.

Two pieces of inexpensive ‘angle iron’ mounted directly across the top of the original 1010 pedestal created a very effective seat for the LoadPro’s, and an adequate number of easily accessible gland entries allowed any shared wiring to be linked between the LoadPro® Controllers.

 

While there are plans in the pipeline for a 2-Arm Contrec LoadPro®, the single arm LoadPro with its 18-key Ex510 Ex D or IP66 Field enclosures with a large display provides a practical solution for at least the next two years. 

 

So, was it more economical to use two Single Arm Contrec LoadPro’s instead of another multi-arm load controller?

 

With the 1010 being obsolete and the client preferring not to do a major rebuild or rework to the overall loading system, the cost of the two LC01.312NS LoadPro’s with a straightforward change over, was by far an economical advantage once all changeover options and costs were considered. Add to that a quick lead time of 4-6 weeks and availability of experienced field support… the new Contrec LoadPro® is very real solution.

 

The application was for a DCV-controlled load with specific full and slow flowrate targets. With just a few initial parameters set for these targets, the LoadPro’s unique control algorithm smoothly tracked the flowrate target (700 L/min in this case) and concluded with only a 0.9L overrun, making the use of the overrun compensation function unnecessary. Overall, a really neat outcome with a very pleased client.

 

Dave Shinners, Operations supervisor at AvFuel Services said “On behalf of AvFuel Services we would like to thank Paul and Gavin for the outcome achieved for this project. Paul is a wealth of knowledge and paired up with our electrical contractor Total Energy the process was seamless. The new Controllers not only work well but are extremely easy to use which makes for an easy transition with multiple staff when it comes to training on operation. AvFuel Services takes pride in being the first in the industry to have the process of going from the 1010 system to the new LoadPro® controllers and we hope other facilities out there now have a solution to their Load Controller issues”

For more information on Contrec’s LoadPro® series, please email us on [email protected] or visit our contact us page for your nearest Contrec sales office.

StocExpo Review

StocExpo, Europe’s largest international tank storage and future fuels event returned to Rotterdam in March. The event which attracts hundreds of thought leaders from across the world to discuss the future of the bulk storage industry provided the perfect opportunity to unveil Contrec’s new one arm preset load controller to the tank storage and distribution market. 

Accredited with full Exd and IECEx certification for hazardous areas LoadPro® provides a safe and accurate solution for fuel and chemical loading in smaller chemical distribution hubs and fuel depots. 

stocexpo

As the world’s energy requirements change to more sustainable sources, the technology and control solutions must adapt to meet these demands. The ability to safely and accurately measure these varied products in the petrochemical industries, is becoming more critical. Alternative fuels are driving the industry forward, Contrec’s Sales Director Craig Naylor talks about how Contrec’s systems can adapt easily to these changing requirements.

“As the fuels and chemical industries adapt to sustainable production methods, cleaner more efficient processes and increased flexibility for storage and transportation, the role of loading and unloading products safely, accurately and with instant visibility has never been more important. Contrec have been manufacturing electronic preset controllers since the 1980’s when automation of legacy mechanical systems began gathering pace.  In those 40 years we’ve learned and adapted our solutions to meet the constant shifting in technology and customer demands.  The modern day preset controller doesn’t just need to count the flow, it needs to operate reliably in sites that rarely close or maybe unmanned, to be able to integrate with every aspect of the loading/unloading process including authorising competent users and monitoring safety systems, to then produce transport documents and transmit that data to remote supervisory software for report generation or invoicing.

LoadPro® covers all these requirements in a simple to operate, compact system.  Our in-built RFID reader will authorise operators ensuring theft/misuse is minimised by only allowing approved users to load/unload products.  For extra security, a second authorisation can be used or assigned to vehicles to help maintain audit trails.

New installation or upgrading an old mechanical system? No Problem.  LoadPro® is as happy working with existing Positive Displacement or Turbine flowmeters as it is with new technologies such as Coriolis and Ultrasonic flowmeters. 

What about control?  The traditional method in petroleum applications of Digital Valve Control (DCV) is catered for, however we also handle simple On/Off valves and for some chemical applications 4-20mA modulating valves are catered for.

Can I compensate for temperature/pressure/density?  The answer is yes, we have the API/ASTM tables for oil products built in, and for those with specialist fluids then a custom table can be entered into the device to correct against.

What safety features are included? Earth, Overfill and Vapour Return alarms are covered by our permissive inputs which can be configured to pause or abort the load if triggered.  Emergency Stop circuits will instantly terminate the load.  All alarms are reported as ‘exceptions’ on the loading dockets so that these incidents are highlighted to supervisors.

What else does can LoadPro do? Gantry isolation/pump control output.  Deadman operation which ensures the operator remains near the loading point during operation. LoadPro® keeps a log of all transactions (up to 1500) so in the event of communications going down, no loads are lost, the loading can continue and historical transactions can be printed/downloaded to the supervisory system once comms are re-established.

The push towards alternative renewable fuels such as HVO (Hydrotreated Vegetable Oil), SAF (Sustainable Aviation Fuel), along with Bio-Diesel and Gasohol/Ethanol throws up the requirements to blend, add to this marking fuels to help prevent fraud or adding performance and efficiency improving chemicals requires additives, Contrec have a range of solutions to handle these tasks simply and accurately.      

For Volumetric or Mass Frequency Flowmeters, the LoadPro™ Load Controller has a range of application packs tailored to the various requirements found in single arm loading systems. It is a simple to use numeric controller with the capabilities for Dual Stage Relay, Digital Valve Control or Analogue Valve/VSD drive for the reliable and accurate delivery of preset quantities of liquid products. The frequency flow input, from volumetric or mass flowmeters, can accept aquadrature signal for ISO 6551 level B pulse security along with pressure, temperature and/or density inputs can be used to provide volume correction to recognised national standards.

Easily integrated with Datamod™ Contrec’s simple to use reporting software or most commercial TAS systems.

For more information on LoadPro please Click on the link

New terminal automation products at StocExpo 2022

It was a long time coming but finally Contrec were able to unveil their new terminal automation products, LoadPro Load Controller and Trac-50 Truck register to the tank storage market. StocExpo returned once again to Rotterdam last month and with Covid restrictions being lifted thousands of industry professionals, including representatives from the likes of Shell and Vopak, as well as key terminals and storage players from over 100 countries worldwide flocked to the Ahoy exhibition centre in Rotterdam.

terminal automation

Contrec’s new terminal automation solutions include LoadPro™ a single arm load controller. Ideally suited to smaller fuel depots and chemical plants, LoadPro™ provides a safe and accurate solution for loading fuels, chemicals and any fluids into tankers. Easily integrated with Datamod™ Contrec’s own simple to use reporting software or with most commercial TAS systems, the full alpha numeric keyboard has  capabilities of Dual Stage, Digital Valve, and Analogue Valve Control for the reliable and accurate delivery of preset quantities.

For off-truck metering, Contrec’s new advanced Truck Register, Trac-50 ensures every drop is accounted for when delivering your valuable assets. Our instruments are approved to international metrology standards when used as part of an approved metering system and can be supplied as cab/field mounting (safe area) or trailer mounted where hazardous area approvals are required. Our new Trac–50 is an intelligent off-loading controller for the safe and accurate discharge of chemicals, fuels and other liquids from trucks, railcars, barges and portable metering trolleys. Superseding the popular Trac-40, the new model comes with a host of new features and communication options, to make off-loading of these expensive commodities safe, secure and fully traceable.

In addition to this Contrec offer a range of solutions for blending/additive control – the 515-BR and 515-CB applications offer secure blending flow control designed to measure the volume flow in a main and process line using frequency flow inputs to determine the net volume flow. The operator can easily view and change the batch values of totals as well as the ratio of flow rates. The flow rate, deadband and control responsiveness can be adjusted to reduce wear on valves and plant. For additive dosing Contrec’s 515-TA01/02 Dual Channel On-Truck Additive Batch Controllers are designed to allow an operator (driver) to pre-dose the appropriate amount of either of two additives into tanker compartments in accordance with the Load schedule. Operating either from the control room or in the hazardous area at the point of loading, our flow controllers ensure you get the correct blend in every compartment, on every truck, every time. For more information on our terminal automation solutions for additive and blending control click here. 

 

Craig Naylor, Contrec’s Sales Director said“Contrec have a long history of producing high quality dependable loading and unloading controllers, and we were delighted to reconnect with the petroleum and chemical storage, terminal and distribution industries by releasing our LoadPro™ and Trac-50 instruments at StocExpo in Rotterdam recently.  The exhibition was a great way to announce our return into these markets and show our latest product ranges.  In a constantly changing industry it was fantastic to meet so many new people on the stand with exciting applications as the world looks to develop it’s renewal strategies and carbon neutrality. It also gave us a great opportunity to catch up with so many familiar faces, and we came away from the show delighted with the reception our new instruments received and excited about the future with Contrec continuing to be an important player in the loading automation business for many years to come”

For more information on Contrec’s terminal automation solutions, call us on +44 1422 829944 or email [email protected]

 

 

 

Brexit

 

As we are all aware, the United Kingdom’s transition period for leaving the European Economic Union (EU) ended on the 31st December 2020.  Thankfully, at the last minute an agreement was reached to ensure trade with our EU partners can continue with minimal disruption to the export and import of goods from the UK. 

 

THE TRANSITION – How will Contrec adapt to Brexit? 

 

Contrec Ltd. have over 20 years’ experience in shipping our products all across the world including European non-EU countries, so our dedicated staff are knowledgeable on the documentation requirements for goods where ‘Free Trade’ agreements are not in place.  Our administration and accounts staff are fully trained to handle documentation for cross border shipments and we have been utilising a Euro bank account for over 10 years to reduce the impact of currency fluctuations and banking delays with our partners.  Our warehouse staff understands the logistical requirements and customs procedures for ensuring our products reach you in the shortest possible time. They will also ensure correct labelling of consignments, backed up with accurate documents to make it easy for you to receive deliveries from Contrec.

Contrec uses several different transport methods and specialist freight companies’ dependent upon customer preference for transit time/cost etc.  We have spent the last few months increasing our stock holding, so we are not at the mercy of potential delays from our own supply chain around the world because of Brexit.  Our reputation for being able to supply most of our products to Europe within days will not be adversely affected due to Brexit.

REFERENCE INFORMATION

Please find below reference information relating to our products, we would appreciate it if you could ensure this information is passed to the necessary departments within your organisation:

EORI/VAT Number:                                      GB 124 159 139 / 000

Customs Tariff Commodity Code:             85371091

Euro Bank Account Details:                        Sort Code:- 203584

A/C No:- 653874 66

Swift Code:- BUKBGB22

IBAN: GB54BUKB20358465387466           

A NEW YEAR

On behalf of all our staff, I would like to thank you for your support and continued business through the unexpected and challenging times we have all faced in 2020.  Like all our partners around Europe, we look forward to a much brighter 2021 where we can all travel freely again both for holidays and business. As the world recovers from this pandemic, there are great opportunities for Contrec to support you with new products and exciting releases as the year unfolds,  we will be keeping you up to date with these as they happen.

I would like to wish you, your families, and colleagues a safe, peaceful and prosperous New Year.

Coronavirus Update 07-09-20

Contrec have implemented many changes during these uncertain times to protect our colleagues, suppliers and visitors to our offices. Throughout the Covid-19 epidemic, we have maintained a manufacturing presence and distribution for the many essential manufacturers out there who were increasing production or shifting their operations in order to produce increased quantities of sanitizer, hand wash and other products essential in helping the fight against Coronavirus. Contrec instruments play a crucial role in chemical, pharmaceutical production in accurately monitoring and blending liquids.
Thank you to all our customers and suppliers through these difficult times, and we look forward to being of mutual service throughout 2020 and beyond.

DataMod & Contrec, both IoT ready, welcome to the new 1.3.000 software release.

Contrec’s DataMod software package continues to evolve, and like most of Contrec’s development over the years new features have initially been developed for specific customer projects before being added to a general release. The benefit of this is that you know the features have real and genuine purpose and you can have confidence that not only are they expertly engineered, but that they have already been properly field tested before being released to the wider market.

In this DataMod release 1.3.000, we offer a host of new features, such as:

• Continued Improved User Interface as we take on feedback and DataMod gets wider uses
• Email Alerts for Auto and Live data collection applications
• Delivery Numbers can now used to specify the range of data collection for Load & Batch applications
• Stored Configuration Records for easy load and re-use to allow data collections from multiple 515 field instruments to be made much faster   and simpler, including with clear feedback when changes are made
• Easy Creation and Management of Configuration Records that hold all the settings to suit each individual field instrument or type of report      required.
• Stored Locations Remembered for CSV files and report templates making file handling faster.
• Further IoT Support and Readiness with refined TCP/IP interface being easier to configure and store separate IP addresses, falling in line       with the release of the new 515 Ethernet option card.

Read below our DataMod Case Study which highlights the benefits of the new software release and shows DataMod and Contrec are both IoT ready.

In this case the real field application involves two 515-LC01 Loading stations on a site where there is no access to any communication networks, their head office is over 3000 km away and needs to get weekly reports of all delivery transactions. Each loading station does approximately 80 deliveries a week to up to 50 different customers. On a Monday each week DataMod which is installed at the head office is used to collect the previous week’s delivery records. DataMod has access to both 515 field instruments as a result of Contrec moving comfortably into the new world of IoT.

These communications are via a combination of a secure and encrypted Virtual Private Network (VPN) on a Contrec managed internet cloud server, through to the cellular network to a 4G field gateway module with its own dedicated IP address. The particular gateway used has an RS485 port to which both 515 instruments are connected with their own Modbus RTU address. A VPN client and certificate (issued by Contrec) is installed on the computer where DataMod software is also installed. DataMod with its built in Modbus TCP/IP protocol has a stored configuration record for each field instrument with all the communication and address settings and custom text etc, specific to each instrument.
(In this project Contrec Systems supplied the IoT solution as a package, including the VPN server and client software and certificates, plus the configured 4G gateway with data subscription and IP addresses.)

When the DataMod operator is ready, they simply start the VPN connection, open DataMod and click to load the stored configuration for the required instrument. Once they establish connection this will show the most recent delivery number and then specify the delivery range required for the week’s report, before clicking again to start collecting.
When collection is complete the operator generates a PDF report with their own custom template and saves the data as a CSV file to integrate into their own inventory and reporting system.

From over 3000 kms away, the customer has a very economical and simple way to get the instrument delivery data and is able to see exactly what loads and volumes occurred and which client they were allocated to.

To see for yourself how easily DataMod can work with the wide range of Contrec 515 applications to help you keep control of your operations, click here to get your 15-Day Fully Functional Free Trial

New Ethernet Port for the 515 Series

Ethernet Port

Contrec are delighted to announce that the 515 series Flow Instruments can now be ordered with an optional Ethernet port.

Ideal where there is an existing LAN (Local Area Network) or WAN (Wide Area Network) in place, it now simplifies the communication network and avoids the need for an external 3rd party Serial to Ethernet converter. The 515 can now connect into the network with its dedicated IP address making access to flow and batch data quick and simple without the large installed costs associated with running individual cabling from production areas back to the control room. Having an Ethernet port offers a stable, consistent signal compared to Wi-Fi installations, and is also a more secure and controlled environment for transmission of important data.
The Contrec 515 Ethernet port provides an ideal access route to our own DataMod software tool, making visibility of measurement and control information, data analysis and management decision making even quicker. 

For more information on our Ethernet options – Email [email protected] or call us on +44 1422 829944.

14/02/18 – Contrec 515 series – 7 New Applications Added

We have recently released 7 new applications for the Contrec 515 Series of Flow Computers and Batch Controllers, giving the you more flexibility for your flow applications.  

Contrec 515 Series

 

The 515 Series flow controllers are easy-to-use, easy to understand and offers exceptional flexibility over many applications. This controller is the most advanced model in the Contrec 500 Series range. It has more inputs and outputs of higher accuracy, giving it a greater capability and configurability to suit a wide range of applications. There are multiple frequency and analogue inputs which make the controller suitable for applications that require external sensors for temperature, pressure, density, level devices and many other applications.
The Contrec 515 series is capable of operating in a wide range of temperature ranges and its plug and play option card makes enhancements easy to undertake without reprogramming. The behavior of the instrument is determined by the function software which is selected from an increasing list of applications in the 500 series program manager.

New applications for the Contrec 515 Series include:

515-BS03 Secure Batch Controller for Mass frequency flowmeters
515-BT01 Temperature Compensated Batch Controller for Volumetric frequency flowmeters
515-AC01 Additive Controller for Volumetric frequency flowmeters
515-CS02 Steam/Condensate Flow Computer – Analog flowmeter in Steam line
515-CS12 Steam/Condensate Flow Computer – Analog flowmeter in Condensate
515-MP01 Master Proving – Volume Frequency Flow, Temperature & Pressure inputs
515-MP02 Master Proving – Mass Frequency Flow, Temperature & Pressure inputs

All the information on these new applications can be found by clicking on the links above, or downloading our 500 Series program manager.

 

03/07/17 – Contrec have raising money down to a tee!

Rob and Craig recently swung in to action and took part in the annual charity golf day in aid of the NSPCC (National Society for the Prevention of Cruelty to Children).  The day is held annually at the local West End Golf Club and is attended by many local businesses who support this worthwhile charity and help raise money for such a good cause.  The day was a great success despite the Yorkshire weather being slightly unkind, and over £17,000 was raised on the day, which is a fantastic effort.  As for the golf, well, despite both Rob and Craig being fair weather golfers, we managed to finish in the top ten out of over forty teams !!

13/07/17 – Contrec release new condensate and steam flow computer

Contrec have released the new CS02 application for the 515 flow computer. The 515-CS02 application accurately accounts for returning condensate energy when calculating the net energy in a closed ‘steam to condensate’ system.
The volumetric, mass and energy content of the steam and condensate lines are calculated by using an analog volume flowmeter installed in the steam line which works in conjunction with a temperature and/or pressure inputs.

For more information please click here