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REPSOL Puertollano Refinery

Petroleum Products Loading Automation

MONTREL has developed for REPSOL Refinery Fuel Truck Loading Platform at Puertollano, a modern Automation System based entirely in SIEMENS Process Control System.

The design is developed as the needed complement to the Administrative Management System of the Plant, being this a System that meets all the actual requirements of loading Tank Trucks, such as the possibility of mixing different products and additives.


A Solution has been implemented for the complete automation of the loading process, all within the Simatic PCS7 environment.
Its main features are:
  • Driver identification by HID proximity cards.
  • Control over the maximum loading amount in each compartment of the tank truck, as required by ADR (European Agreement concerning the International Carriage of Dangerous Goods by Road).
  • Control via TCP/IP communication of the performance of loading microcomputers.
  • Determination of the amounts of additive to be injected in the different tank truck compartments.
  • Fuel discharge from railways.
  • Report generation concerning the performance of the Loading Plant.
  • Tax treatment of additives.
  • Automatic stopping and starting mechanism of main product and additive pumps.
  • Control of safety interlocks of the loading process.
  • Incorporation of signals from the various Engine Control Centers of the Refinery, via Profibus optic fiber.
  • Load control of supplied products in volume and mass.
  • Analog signals trend records.

Given the characteristics of the products handled as well as the environment in which it is performed, the facility is subject to ATEX regulations.


We have taken a great care in the design to have a high degree of availability, for which the chosen configuration has been the following:

  • Redundant Operator Workstations.
  • Redundant Database Servers.
  • SIMATIC S7 417 H driver, with dual CPUs, dual power supplies and dual Ethernet communication cards.
  • Double Profibus fieldbus.
Faced with the loss of any of the above items, the twin element automatically takes control, generating a warning in the System.

The system also has an Engineering Station for the tasks of performance monitoring, remote maintenance and control modifications.

Open System

For seamless integration of the System in working environment, it has been equipped with a high capacity for information exchange:

  • Information exchange with the Loading Plant Management System for the receipt of loading authorizations and sending the results. TCP/IP link in XML format.

  • Incorporating System signals of third parties, for its graphical representation via Profibus protocol, adapting the redundant bus singularly for this function.

  • Information exchange with other Systems for representation and control in OPC.