A Tactical Fuel Solution Using Real-world Technology
Varec’s combination of systems, communications, instrumentation and application expertise have allowed a clear understanding of fuels accounting in the tactical theatre. Through extensive research, development, test and evaluation we are able to present a solution for complete asset visibility and control that enables effective decision support at all levels of command. The local level solution consists of a mobile laptop and handheld computers operating TacFuels® software, data collection units, flow meters and fuel gauges. A combination of these ruggedized devices is deployed based on the configuration of the tactical fuel point. Information from each local site can then be shared across networks using secure communications to base- or enterprise-level users.
Accurate Measurement
Many instrument technologies, such as radar, sonar, ultra-sonic and laser were evaluated, but Varec found that a combination of pressure and temperature technologies are currently the best suited technology for the application. The fuel gauge provides a reliable and precise digital measurement, thus removing the inconsistencies associated with manual measurement procedures. The pressure of the fuel in the CST can be directly related to the amount of fuel. Ambient temperature is an influencing factor on measured volume, especially in extreme locations, such as the deserts of Iraq or Afghanistan where there is a large day time to night time fluctuation. The Varec system utilizes temperature data to correct volumes to recommended American Petroleum Institute (API) standards for petroleum measurement. This standardization of volume measurements throughout the entire day and from location to location provides a true measurement of physical inventory.
The Fuel Gauge can be easily installed or removed by military personnel in a few minutes with no specialized tools.
Installation, Support and Maintenance
The fuel gauge’s pressure and temperature sensor is incorporated into a specially designed vent pipe with minimal support or maintenance requirements. It is a direct replacement for an existing collapsible storage tank vent pipe in new or existing CST installations. Venting characteristics are not compromised and the sensor can be easily installed or removed by military personnel in a few minutes with no specialized tools. All power and communications cables are connected via military style “quick” connect/disconnects that are familiar to military personnel.
Example of a standard fuel gauge installation on a full and partially full CST.
Hazardous Areas
Due to the nature of petroleum products stored in CSTs the fuel farm is classified as a hazardous area. The fuel gauge instrument is approved as explosion proof, suitable for use in Class 1 Division 1 areas and compatible with all petroleum fuel products.
Measurement Requests
To minimize power requirements, the fuel gauge is normally in a suspended mode of operation that requires no power. When a measurement request is received by the Data Unit from a mobile or handheld computer, it activates the gauge to perform a measurement cycle. Inventory measurement cycle times and manpower allocations are dramatically reduced by providing an immediate measurement of product when requested.
Data Collection
The Data Unit provides three key functions for the tactical fuel system. It provides power to the fuel gauges and acts as a communications interface from the fuel gauges to the system software installed on the mobile computers. Most importantly and key to the overall system, it dynamically creates an accurate gauge chart (“strapping table”) for each CST in a TacFuels Measurement System – an automatic “Tank Strapping” process.
Power and Communications
Up to four fuel gauges can be connected in series (daisy chained) from a single power and communications port of a Data Unit. The Data Unit has configurations to support tactical fuel points with multiple fuel gauges. It is also approved for use in hazardous areas and can be installed at the fuel point on a standard military style ground rod. To provide support for larger tactical fuel points, multiple Data Units can be used. It receives power from a local generator or an integrated battery pack. Under battery operation, the Data Unit automatically shuts down when not in use. When polled by a TacFuels system computing device, it activates and collects inventory measurements. It is able to store data under battery power for up to 6 months.
Example of 4, 6 and 8 CST tactical kit installations
System components, such as a mobile computer or handheld device, can be connected to the Data Unit continuously or connected periodically via military style “quick” connect/disconnects. A hardwired communications solution was selected for all components due to wireless security and visibility to the enemy in a tactical environment.
All TacFuels systems components are capable of communicating via commercial wireless/radio systems, such as Bluetooth. However, the system was developed to use hardwired communications due to the sensitive nature of fueling data and the strategic ways wireless communications infrastructures can be utilized by an enemy force.
Automatic “Tank Strapping”
The Data Unit is designed to dynamically create an accurate gauge chart (“strapping table”) for each CST. It is recommended that tank strapping is performed during installation of the TacFuels measurement system, again after a CST has settled and then periodically to improve fuel inventory management accuracy.
Tank strapping a CST involves creating a gauge chart of entries correlating volume measurements from the flow meter to pressure measurements inside the CST at the metered product temperature. The 8240 TDU performs a continuous data collection cycle until a strap table has been constructed. This table, which can include up to 1,000 data entry points, is then stored in the non-volatile memory of the Data Unit.
The tank strapping process compensates for the variances in tank construction and installation conditions, such as tank expansion, tank bulge and height measurements above manufacturer specifications. It allows increased accuracy and reliability of physical inventory measurements that can then be used throughout the system. During live testing when comparisons were made against manual measurements, ledger variances of physical to book inventories were reduced from 3.5% to 0.38% or 1,249 to 204 gallons on 53,695 gallons of total inventory.
Mobile Computing
Varec’s mobile and handheld computers run dedicated tactical fueling software that assists decision making at an accelerated pace. Laptop computers are utilized in the control area to manage, reconcile and report inventories, while handheld computers are used at the fuel point to request measurements and collect transactional data. Mobile computing reduces the errors associated with manual data recording, calculations and ‘paper form’ based process.
All recorded data is uploaded to the mobile computer, which automatically populates the transaction records in TacFuels software.
Recording Transaction Data
The handheld computer running TacFuels software provides a ruggedized local operator interface to collect, store and view fuel inventory and transactional movement data (receipts and issues). For example, during a disbursement to a fuel truck, vehicle, unit, fuel product and amount can be input manually into the handheld rather than recording this data on a paper form. An epoxy coated full alpha-numeric keypad and touch screen makes data entry a breeze.
Uploading Data
All recorded data is uploaded to the mobile computer, which automatically populates the transaction records in TacFuels software. Data upload can be accomplished in batches using a memory card transfer or automatically when the handheld is returned to a docking cradle. When connected to the Data Unit, the handheld is able to request measurements and display inventory overviews to the user on a color touch screen that is suitable for clear viewing both indoors and outdoors.
Real-time Fuels Inventory Management and Accounting
The mobile computer operating TacFuels software provides local military personnel real-time inventory and accounting tools to assist, manage, account and report on their current fuel stocks and transactional fuel movements (receipts and issues) on a daily basis.
An example overview display of a 120,000 gallon tactical fuel point in TacFuels software on a mobile computer
Inventory at-a-Glance
Tacfuels provides graphical views of the local tactical fuel point and individual details of each CST. The operator can quickly gain an idea of the total fuel stocks and their distribution throughout the CSTs.
TacFuels provides two types of tank groups: static and dynamic. A static group is composed of CSTs that have been explicitly identified as part of the group. For example, CSTs 1 through 6 located in the “120,000 gallon fuel point” are combined into a group. Dynamic tank groups are groups of CSTs that have common characteristics. You are able to define the requirements for the group based on variables. TacFuels then identifies the CSTs with the required characteristics and includes them in the group. For example, the CSTs that show a status of “filling” would show all CSTs that are receiving product. Operators can easily toggle between graphical and table formats, depending on their individual preference.
A tank overview display in TacFuels software. To perform the same function today, operators may need to review many paper forms, extract data and manually perform calculations, all of which takes time that may not be available to support a decision during a critical tactical situation.
Tank Status
Each individual CST display provides a clear indication of the contents and status of an individual tank. Measured values are obtained automatically from your fuel gauge via the Data Unit or handheld device and are used to provide calculated values.
From the Tank display you can monitor the transfer of products through your CST and any product movement is shown on the CST image as a flow icon.
Alarm Management
TacFuels provides the mobile computer operator pre-configured alarm settings for each CST; all they need to do is enable them during installation. TacFuels constantly monitors the system to check for conditions that may require immediate attention, such as overfill or a decreasing level on a static CST. If an alarm is triggered, TacFuels provides the tools to help effectively manage the situation in real-time. It supports multiple alarm groups and alarm priorities, each with its own color and audible attributes. For example, these include high and low level, temperature or CST specific alarms for illegal movement or reverse flow.
When an alarm situation occurs, the operator is notified regardless of which display is active. To assist with quickly resolving the issue, an alarm summary display allows you to quickly acknowledge the alarm and find out why the alarm occurred. TacFuels also creates a historic file of all alarms and events. You can use the Log File Browser to access this history, add comments for individual alarms or print logs for any selected day.
Reporting
Reports provide a way of recording and reviewing the daily activities across the local installation in a clear and concise manner. Two types of reports are available: real-time and historical. Real-time reports display live data while Historical reports are created from archived information within TacFuels.
Reports can be printed as required or scheduled to print at defined times, such as at the change of an operator shift. Simply activate or print the report to a local printer or Adobe Acrobat (PDF) file for electronic distribution.
Trending
Trends are provided to show a graphical view of collected data over a particular time period. An operator can create a CST Trend to track data from a single CST, such as temperature, pressure, level, flow, volume, etc., or a generic trend could be created to show any data collected in the TacFuels system, such as CST levels for four different CSTs simultaneously. Trends show a graphical view of collected data over a particular time period. For example, they can be used to view the effects of ambient temperature on a CST; this could then assist with a decision as to when is the best time of day is to receive product.
Daily Reconciliation
TacFuels provides an inventory accounting ledger that assists site operators to accurately track, reconcile and report fuel inventories usage down to the vehicle level.
Operators are able to work in real-time with updated data as product is received or disbursed. This minimizes any downtime by automating end-of-day or monthly bulk petroleum summary records, which can be generated by location, unit or product. All captured physical inventories from CST storage are automatically included in variance calculations for close-out records. Operators can also lock down accounting periods once reconciliation begins so that operational personnel cannot modify the data during reconciliation. TacFuels allows the local operator to automatically deliver reports to command or fleet headquarters for processing via e-mail in standard formats, such as Microsoft Excel, Microsoft Word, CSV and PDF.
The TacFuels system enables timely and accurate record keeping and provides actual daily ‘local’ fuels inventory reconciliation with audit and documentation trails.
Product Allocations
TacFuels allows the control of product allocations down to the unit or vehicle level. Allocations can be defined per day, week, month or year and also configured to automatically reset at the end of the allocation period. This allows for complete command level control of product distribution and usage so that fuel inventories can be reserved for critical operations. For example, Company B may be allocated a maximum of 10,000 gallons to use over the next 10 days while performing required maneuvers. It also assists with over allocations and helps identify fraudulent or unauthorized disbursements.
Security and Anti-Fraud
TacFuels software utilizes standard Microsoft Windows user and group access rights throughout the system. This allows the tactical fuel point operators to manage data securely while providing authorized users access to only the data that is relevant to their operations. The system includes detailed audit logging of records and configuration changes, including what was changed, who made the change and when.
Enterprise Integration
When multiple sites are combined into a command level TacFuels enterprise system, enterprise users are able to access reports and graphics overviews configured at each individual site or run queries across all site data to create custom reports based on their unique requirements. The local mobile computer connects to the enterprise via secured satellite or cellular communications when required. At command level, custom, real-time reporting of fuel assets assists with supply chain management, invoicing and logistical decision making across the entire tactical arena.
