Tank Offload Control System
UK built control system with integrated safety, installed and commissioned in-house by our own engineers.
STEP ONE
What Was the Brief?
We were commissioned to design, manufacture, and install a bespoke Tank Offload Control System to support a new above ground fuel storage facility in the UK.
The system was required to manage the safe transfer of fuel from delivery tankers to onsite storage tanks, providing automated control, visual feedback, and robust protection against overfill and leakage events.
Operating within a classified hazardous area, the project demanded a high level of engineering compliance, functional safety, and installation precision, all delivered by Meson’s inhouse team from design through to site commissioning.
Meson provided a complete end-to-end service covering:
Electrical design and documentation including schematics, I/O allocation, and control philosophy development.
Control panel manufacture within our Leeds production facility, built to BS EN 61439 and Blue Book standards.
On-site installation and containment works including SWA cabling, junction box wiring, and interconnection to local control devices.
Integration with existing site systems such as overfill protection, bund alarm panels, leak detection, and emergency stop networks.
Testing, commissioning, and certification to NICEIC Hazardous Areas standard.
Ongoing maintenance support and periodic inspection to ensure system reliability over time.
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STEP TWO
What Does the System Do?
The control system was designed around a Siemens S7-1200 PLC architecture, offering flexibility, scalability, and reliability for future site expansions.
The side fascia incorporated a rugged Siemens keypad providing clear, illuminated feedback and tactile control for field engineers.
Key design features included:
Eight illuminated pushbuttons providing individual control and indication for key site functions — such as Pump Start/Stop, Transfer Running, Overfill Alarm, Bund Alarm, Emergency Stop, and Fault Reset.
Integrated key switch override allowing safe reinstatement of operations following an emergency stop or alarm condition.
Panel-mounted beacon and sounder for clear external indication during tanker offload.
Siemens SITOP 24VDC power supply with overload protection and UPS-ready interface for continuous operation.
Overfill interlock logic — automatically isolating pump outputs when high-level conditions are detected from ATEX tuning forks or level sensors.
Terminal segregation between field I/O, safety circuits, and control wiring to ensure clear traceability and simplified future maintenance.
All internal wiring was installed to BS EN 60204-1, with trunking segregation, and engraved traffolyte labelling to support long-term maintainability.
Installation & Integration
Once the system was factory-tested, Meson’s site engineers completed the full installation and integration works, including:
Glanding and termination of all pump, level, and alarm circuits using stainless steel cable glands and flexible conduit where required.
ATEX-compliant cable routing through steel containment and barrier glands to maintain zone protection integrity.
Installation of local isolation devices and interface wiring to bund alarms, leak detection, and emergency stop posts located around the offload area.
Final connection and testing of earthing and bonding systems in line with BS 7671:2018 and BS EN 60079-14.
Verification of TT earthing arrangement and resistance measurements prior to energisation.
The system underwent a structured commissioning process, including simulation testing of high-level alarms, pump interlocks, and emergency stop recovery to confirm functional safety under all operating scenarios.
Integration
Safety & Reliability
Monitoring & Control
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STEP THREE
What Was the Result?
The completed installation provides a safe, intuitive, and fully automated tanker offload system, giving operators complete visibility of transfer operations and immediate feedback in the event of an alarm or shutdown condition.
Built with standardised Siemens hardware and modular I/O architecture, the system can be replicated or adapted for future facilities across the UK, offering a proven, field-tested control solution for critical fuel handling environments.
Ongoing Maintenance & Support
Following completion, Meson continue to provide scheduled inspection, testing, and maintenance for the installation.
Our service team conduct periodic verification of safety circuits, confirm correct function of sensors and indicators, and carry out preventive panel maintenance including cleaning, torque checks, and firmware updates.
This ensures long term reliability and continued compliance with the latest APEA and BS 7671 requirements.
Speak to our team today.
0113 286 4300
enquiries@mesonelectrical.com
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