Liquid Heating & Pumping Control System for Export to South America

Electrical & Control System Integration for a Temperature and level Critical Bitumen/Oil storage tank Installation

PSL Controls recently delivered the electrical and control system package for a bitumen storage, heating and pumping installation manufactured in the UK for export to Suriname.

The tank structure and pipework design were developed and supplied by TEC Container Solutions, with PSL Controls responsible for the complete electrical installation, trace heating integration, control panel design, and system interlocking.

This collaborative approach ensured a fully integrated, safety-led solution for a temperature-critical pre-treatment application.

The Application: High-Temperature Liquid Product Storage & Transfer

Product must be maintained between 90–100°C to remain pumpable and process-ready. Stable temperature control and safe level monitoring are essential to protect both equipment and operators.

PSL’s scope included:

• Temperature control and heater management

• Full pumping and agitator interlocking

• Level monitoring integration

• Trace heating installation on all associated pipework

• Control panel manufacture and wiring

• Export-ready electrical design for 480V 3-phase supply

• Factory Acceptance Testing (FAT)

Multi-Layer Temperature Control & Safety Interlocking

To ensure reliability in a demanding high-temperature environment, the system incorporates four independent layers of temperature monitoring:

1. Primary tank temperature control governing system operation

2. Individual thermostatic control of heating elements

3. Independent over-temperature safety monitoring

4. Low-temperature interlock preventing pumps and agitators from operating below safe process temperature

This layered control philosophy protects the system while maintaining consistent operating conditions.

Level Monitoring & Equipment Protection

The control system integrates VEGA instrumentation to provide both operational visibility and safety protection:

• High-level switch to inhibit overfilling

• Low-level switch to protect heater tubes from becoming exposed while heating and prevent pump dry-running

• Continuous level measurement for live tank monitoring

All instrumentation signals are fully integrated into the control logic and remote monitoring outputs.

PLC Control & Remote Monitoring

System interlocking is managed using a Millenium 3 smart relay PLC along with Siemens Safety relay, providing reliable control of:

• Fill, discharge and recirculation pump modes

• Temperature-based operational sequencing

• Safety shutdown conditions

• Pump & Agitator interlocking

• Local and remote alarms for system

  
  

Remote monitoring outputs were provided via analogue signals and volt-free contacts, allowing integration into the client’s supervisory system.

Electrical Integration for 480V 3-Phase Supply

The destination facility operates on a 480V 3-phase supply with no neutral available. To accommodate this, PSL designed and installed:

• 110V transformer for control circuits which feed the 24V control circuit.

• Dedicated transformer for trace heating

• Separate transformer for compressor and internal lighting

  
  

This ensured stable and compliant operation within the export electrical specification.

Delivered Within a Two-Week Programme

Despite tight space constraints within the pumping house and a two-week installation and build window, the project was:

• Installed

• Fully wired

• Trace heated and cladded

• Factory Acceptance Tested

All completed on schedule ahead of export.

Collaborative Industrial Control Solutions

This project highlights the importance of strong collaboration between mechanical system designers and control system integrators. By working closely with our client, we delivered a fully integrated electrical and control package tailored to a demanding oil handling application.

Require Electrical & Control Integration for an Industrial Heating Project?

If you're developing a storage, heating, or pumping installation and require a specialist partner for the electrical design, trace heating integration, and control system development, PSL Controls can support your project from specification through to commissioning.

Get in touch to discuss your requirements.