Central fuel supply system (new business line)

The design, manufacture, software and installation of the control technology of the fuel service system installed at the JLR Whitley factory was made by 3i Ltd.

The fuel supply can be functionally separated

  • refueling of vehicles
  • servicing the engine test cells with fuel

Fueling of vehicles

  • The fuel can be different types of gasoline and diesel.
  • The vehicles can be serviced from 6 different fuel tanks and 20 barrels.
  • The driver selects the fuel type at one of the field STAHL ET-208 terminals. Once selected, the system will allow the fuel for the appropriate tank to be serviced.
  • Drivers are identified by an RFID card.
  • The system also includes handling of tanker unloading and rescue channel emptying.

Service of test cells with fuel

  • The task of the system is to supply the test cells with different fuels.
  • There are two test lines, one with 12 and the other with 8 test cells.
  • The source of fuel into the test cells
    • from the central tank farm, which includes 7 tanks – from which the vehicles are also serviced.
    • from barrels.
  • It holds 2×12 barrels per barrel serving system
    • one of the 12 barrels from which the cells are served is active,
    • the other 12 barrels are in “hot standby” state.
  • The barrel is stored and connected to the system in a separate room, but this is also part of the system.
  • Fuels reach the cells on pipes.
  • The actuators of the ball valves required to supply the cells with fuel are controlled by FESTO VSVA pneumatic valve islands.

Security system

  • Classification of test cells, barrel handling rooms and tank farm is Zone 1.
  • The level of security to be achieved is PLd.
  • The pneumatic valve islands are depressurized with Festo MS6-SV safety relief valves.
  • The tank farm and the 2 test cell systems are monitored by 3 Siemens S7-1518 F Siemens safety PLCs.
  • The safety PLCs are connected to the central Safety Profinet backbone, where the test cells communicate via a PN / PN coupler.

The user interface

  • Stahl terminals are also installed in the tank farm and test cell lines for field display, while Siemens TP1500 touch screens are available for the operation of the instrument cabinets.
  • WinCC Runtime Advanced was developed on the field to create the user interface, while WinCC 7.5 was developed on the SCADA platform for central data evaluation and storage.
  • An MS SQLserver 2016 database is available to store the data.

Some information about the size of the system

Hardware features piece(s)
Number of cables 2500
IO channel number 2462
Two-state signals, interventions
Pneumatic valves 554
Filling nozzle with position sensor 39
Limit switch 553
Leakage sensor 9
Level switch 54
Analog instruments
Pressure difference transmitter 44
Volume flow meter 43
Level transmitter 8
Pressure transmitter 167
Temperature transmitter 27
Other devices
Pump 61
Gas sensor 4
User interface piece(s)
Measured parameters 257
Number of screens almost 100
Trend screens 257
Figure 1: Tank farm
Figure 2: Cell serving pneumatic valve island
Figure 3: Serving from barrel station
Figure 4: Valve matrix to serve cell and refueling stations from barrels
Figure 5: Valve matrix control pneumatic panel