ATPC / VTTI Terminal Automation

DeltaV Control System Integration Production

Engagement Overview

Production-grade DeltaV integration platform operating at the ATPC / VTTI petroleum terminal. The system bridges Emerson DeltaV control hardware with terminal back-office data, orchestrating safe, real-time truck loading, badge authentication, recipe synchronization, and tank inventory visibility.

Terminal Automation - End-to-end workflow from badge scan to valve control across 8 loading bays
DeltaV Gateway - OPC DA bridge connecting field devices with SQL Server back-end systems
Order and Recipe Sync - Automated synchronization of products, tanks, blends, and loading limits
Operational Safety - Embedded interlocks, watchdog recovery, and audit trails for every transaction
Offline Resilience - Graceful degradation with cached authorizations when central systems are unavailable
15+ Years in Production - Continuous 24/7 operation within the VTTI terminal environment

Terminal Operations Portfolio

Loading and Access Control

Integrated workflows that authorize drivers, validate orders, and execute secure loading sequences inside DeltaV.

Truck Loading Workflow

Event-driven orchestration of CSN scan, badge resolution, order lookup, setpoint calculation, and pump/valve control.

Badge and Access Management

CSN-to-ID conversion, customer-level authorization, and offline badge issuance to keep loading bays available.

Tank and Recipe Synchronization

Automatic sync of tank assignments, blend percentages, and product recipes from back-office databases into DeltaV.

Technical Solutions Delivered

Industrial Integration

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OPC DA Connectivity - Robust client implementation for reading and writing DeltaV tags in real time
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Workflow Engine - Deterministic steps governing badge validation, order checks, and loading bay sequencing
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Offline Continuity - Local caching and queued badge creation to prevent downtime during back-end outages
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Watchdog and Self-Healing - Automatic detection and recovery of blocked workflows to protect throughput
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Tank Monitoring - Live inventory visibility with connection status checks and reconciliation to orders
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Security and Audit - Full traceability for every scan, authorization, and control action

Technology and Architecture

Technical Stack

Industrial Protocols

OPC DA DeltaV Real-Time Event-Driven

Application Platform

C#/.NET Windows Service Workflow Engine SQL Server

Operations

24/7 Uptime Redundant Networks Watchdog Telemetry Audit Trail

Architecture Principles

Reliability First - Defensive coding, self-healing workflows, and health monitoring
Safety Gates - Multi-step validation before enabling valves, pumps, and loading arms
Observability - Detailed logging for every industrial tag interaction and workflow transition
Configurability - Tank, recipe, and bay configurations managed centrally and synced to DeltaV
Data Integrity - Transactional database operations with reconciliation to terminal orders

Terminal Deployment Scope

Site Operations

Proven in production at the ATPC / VTTI terminal, supporting high-throughput loading operations with strict safety and compliance controls.

8 Loading Bays - Simultaneous, independent loading cycles with shared workflow engine
Multi-Product Support - Recipes, blend percentages, and tank routing managed per order
Back-Office Integration - Linked server connections for orders, customers, and tank data
Industrial Hardened - Designed for harsh terminal environments and network constraints

Operational Excellence

Continuous Availability - 24/7 runtime with automated recovery of blocked workflows
Safety and Compliance - Enforced interlocks, auditability, and traceable authorization chains
Performance - Low-latency tag reads/writes to keep bay cycle times within target SLA
Longevity - More than a decade of uninterrupted production service for VTTI

Expertise Demonstrated

Technical Leadership Areas

Industrial Protocol Mastery - Deep experience with DeltaV and OPC DA in live terminal environments
Real-Time Systems - Deterministic, low-latency workflows coordinating multiple field devices
Workflow Automation - Stepwise orchestration of badge, order, and loading actions with rollback paths
High-Reliability Operations - Watchdog-driven self-healing and offline continuity planning
Data and Integration - Secure SQL Server connectivity via linked servers and stored procedures
Lifecycle Ownership - Long-term support, enhancements, and operational stewardship

            Business Value Delivered
            * Throughput - Faster loading cycles with automated validation and control
* Safety - Enforced interlocks and traceability for every loading action
* Accuracy - Reliable recipe, tank, and order synchronization to prevent misloads
* Uptime - Self-healing workflows and offline modes to avoid bay downtime
* Cost Efficiency - Extends life of existing DeltaV and terminal infrastructure
* Compliance - Complete audit trail for industrial and customer reporting

        

Project Status

The ATPC / VTTI terminal automation platform is a production-deployed system with a proven multi-year record of stability. It continues to run 24/7 in a mission-critical petroleum terminal environment with ongoing improvements and support.

* Active production deployment across 8 loading bays
* Continuous uptime with automated watchdog recovery
* Tank, recipe, and order synchronization in daily use
* Ongoing optimization and operational support