Accurate control and monitoring of bulk material movement in tanks and hoppers. Scalable solutions with multiple sensor technologies, graphical touchscreen interface, and integrated safety features for overfill and overpressure protection.
Bulk Tank Control System – HMI Main Screen
Bulk Tank Control System – HMI Calibration Screen
Bulk Tank Control System – HMI PLC Diagnostics Screen
Bulk Tank Control System – HMI Analogue Input Screen
Bulk Tank Control System – HMI Digital Input Screen
Bulk Tank Control System – HMI Setup Screen
Bulk Tank Control System – HMI Main Screen
System Overview
RCP bulk tank handling systems provide comprehensive weight monitoring and level measurement for bulk material storage and transfer operations. These systems accommodate any number of tanks and hoppers, integrating sensor data, valve control, and process automation through an intuitive graphical interface.
Weight measurement is achieved using hydraulic load cells for straightforward applications or high-precision electronic load cells where greater accuracy is required. For level-based monitoring, guided wave radar sensors provide reliable bulk level sensing across a wide range of material types and tank configurations. This flexibility in sensor selection allows the system to be configured for the specific measurement requirements and accuracy needed for each application.
Control Interface
The colour touchscreen interface displays a clear graphical representation of each monitored tank, hopper, and associated valve. This visual mimic approach provides operators with immediate understanding of system status across the entire bulk handling process. The touchscreen interface allows direct control of valves, material transfer sequences, and process parameters without requiring navigation through multiple menu screens.
User functions are designed for simplicity, enabling operators to control and monitor complex multi-tank processes through straightforward interactions. Process requirements such as batch transfers, sequential filling operations, and material blending can be configured and executed through the control interface.
Safety Features
Built-in automated safety features protect against overfilling and excessive pressurisation of bulk tanks and hoppers. The system continuously monitors tank levels and pressures, automatically interrupting filling operations when predetermined limits are approached. These safety interlocks help prevent serious incidents, product spillage, and equipment damage that can result from overfilled or over-pressurised vessels.
Technical Specifications
System Architecture
- PLC-based control platform with multi-tank monitoring and control capability; typically configured for up to 6 tanks or hoppers per system, expandable to accommodate additional tanks or silos as required
- Supported communication protocols include Modbus, Profibus, Profinet, Modbus TCP/IP, Ethernet over Fibre, CANbus, RS-485, and RS-232; additional protocols available on request
- Power supply: 110–230 V AC, 50/60 Hz auto-switching; control system operates on 24 V DC
- Control system enclosure rated IP66 for safe area installation as standard; ATEX Zone 1 and Zone 2 variants available
- Instrumentation is ATEX Zone 1 compliant as standard
- HMI units available in safe area, ATEX Zone 1, and ATEX Zone 2 configurations
Weight Measurement - Load Cell Systems
- Hydraulic load cell options for straightforward applications; electronic load cell options for high-precision measurement
- Capacity range typically 0–200 tonnes; systems can be engineered for larger loads on request
- Load cell quantity per tank is determined by support configuration: single cell for 3-legged tanks; 1 or 2 cell layout for 4-legged tanks
- Mounting type is shear beam as standard; alternative configurations available on a case-by-case basis
- Signal conditioning via 4–20 mA analogue output as standard
Level Measurement - Guided Wave Radar
- Guided wave radar sensors for bulk level sensing with volume determination calculated from level measurement
- Measurement range: 0–20 m standard, expandable to 0–100 m
- Accuracy: ±0.2 mm standard; ±0.1 mm enhanced specification available
- Compatible with all bulk solids and liquids including powders, granules, pellets, and slurries; specific sensor selection determined during the design stage according to the bulk material properties
Control Interface
- Colour capacitive touchscreen HMI, 15″ or larger, with graphical representation of tanks, hoppers, and valves
- Display resolution 1920 × 1080
- Operating temperature range –20 °C to +50 °C
Valve Control & Automation
- Automated valve control for material transfer supporting pneumatic, hydraulic, and electric actuation
- Control modes: automatic and semi-automatic as standard; manual override available on request
- Sequential filling operations, batch transfer control, and material blending capability
Safety & Interlock Systems
- Overfill prevention with automatic shutoff; configurable alarm setpoints for Low-Low, Low, High, and High-High levels
- Overpressure protection interlocks; pressure monitoring range determined by mechanical system requirements
- Soft E-Stop as standard; full E-Stop to machine guarding standards available on request
- Emergency stop integration capability
- System can be designed and manufactured to SIL 1 or SIL 2 where functional safety requirements apply
Alarm & Data Management
- Alarm notification via HMI text alarms and external audio/visual sounder and beacon
- Configurable alarm priority hierarchy (highest to lowest): hardware failure alarms, operational alarms (including E-Stop), setpoint alarms, user-defined alarms, and logged events
- Data logging is optional; default retention is 6 months FIFO covering all available parameters, alarms, and events; retention period extendable to 2+ years
- Report export formats: alarm and event logs in PDF; trend data (raw parameter values) in CSV
- Integration with plant SCADA and historian systems supported on a case-by-case basis
Standards Compliance
- IEC 60079 applied for Ex-rated equipment; IEC 61010, IEC 61131, and other standards available on request
- Control system enclosure rated IP66 for safe area installation as standard; ATEX Zone 1 and Zone 2 variants available
- Instrumentation is ATEX Zone 1 compliant as standard
- HMI units available in safe area, ATEX Zone 1, and ATEX Zone 2 configurations
Optional Features
Advanced Process Control
- Multi-recipe management for different materials and processes
- User access control with audit logging available
Remote Monitoring
- Optional remote viewing via internet browser; all logged parameters, alarms, and events accessible through secure cloud hosting on AWS infrastructure
Redundancy Options
- Redundant sensors for critical measurements available on request
- Controller redundancy available on request
Applications
RCP bulk tank handling and weight monitoring systems are used in industrial processes requiring accurate measurement and control of bulk materials including powders, granules, pellets, and liquids in storage tanks, silos, hoppers, and process vessels.
