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Case Studies

Tank Farm Automation: Bridging Operations and Enterprise Systems

The Client

The client was a specialty chemicals manufacturer, who manages dozens of storage and transfer tanks across their production facility. Accurate inventory tracking is essential for regulatory compliance, supply chain planning, and financial reporting. Manual processes and disconnected systems were creating inefficiencies and introducing risk into their operations.

The Challenge

The client was using a standalone Microsoft Access database for inventory tracking, resulting in data silos between operations and enterprise systems. The client wanted to test an automated system for recording, monitoring, tracking and storing the chemical inventory in several tanks. If successful, the client wanted to scale the solution to a total of 55 tanks at a single facility.

Why Salem Automation

The client selected Salem Automation based on a recommendation from a field device vendor, who recognized that Salem had both the OT expertise for the control layer and the IT capabilities needed for enterprise integration. Salem’s detailed phased approach to the project combined with competitive pricing, gave the client confidence in both the technical solution and business case.

The Solution

Salem Automation integrated field devices with control devices that exchanged important data with supervisory level components.  Several Input/Output (I/O) cabinets included five control cabinets, six distribution panels, and 49 junction boxes. Additionally, a custom-designed control system included:

An HMI panel for the operator to input and monitor data,

  • An Allen Bradley ControlLogix PLC
  • 13 Yaskawa drives (between 10 and 20 HP)
  • High-voltage transformers
  • IFM remote I/O Ethernet panels
  • An Ignition SCADA package

Ignition SCADA imports legacy Access data and pipelines this data to MariaDB and ERP systems.

The Results

As material is delivered to and stored within the storage tanks, the operator can track and monitor important data through the new HMI. This data includes tank location, material weights, and product usage. The HMI interfaces with the Ignition SCADA program, which writes and saves this data to the MariaDB and is shared to the client’s ERP systems. The integrated system eliminates manual data entry and provides a centralized source for inventory management that enables accurate planning and compliance reporting.

Outcomes

The solution showed how to maintain the reliability of operational technology, while leveraging the flexibility of information technology. The result demonstrated:

  • Risk mitigation via pilot validation before enterprise-scale investment.
  • Elimination of data silos between field operations, standalone databases, and business systems.
  • Real-time operational data is accessible to enterprise applications and ERP systems.
  • Reduced operational risk through automated tracking and validation.
  • Foundation for advanced analytics and optimization initiatives built on integrated operational and business data

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