CIMCON iRTU

OIL & GAS

APPLICATION NOTE

CIMCON PROTECTS PIPELINES

FROM CORROSION AT ONE OF
THE LARGEST PETROCHEMICAL
COMPLEX OF ASIA
Result: Predictable maintenance schedule and better pipe health management through
GPS guided true off potential measurement.

Introduction

The Project

The Customer: GAIL (INDIA) Limited is Indias flagship

Natural Gas company, integrating all aspects of Natural
Gas value chain.

In This SCADA System covers monitoring of around 80 TR

Units with 854 reference cells on CIMCON make Remote
Terminals. These TR units and RTUs comprise the
petrochemical Plant CP monitoring system.

GAIL's business portfolio includes:

5,800 km of Natural Gas high pressure trunk

pipeline with a capacity to carry 130 MMSCMD of
natural gas across the country,

7 LPG Gas Processing Units to produce 1.2

MMTPA of LPG and other liquid hydrocarbons,
north India's only gas based integrated
Petrochemical complex at Pata, India with a
capacity of producing 3,10,000 TPA of Polymers,

1922 km of LPG Transmission pipeline network

with a capacity to transport 3.8 MMTPA of LPG

30 oil and gas Exploration blocks and 3 Coal Bed

Methane Blocks

A SCADA network on a telephonic communication based

backbone was envisaged as a solution. A schematic
diagram of the system is attached herewith.

The Work
Design, execution and customization of the SCADA
system for cathodic protection of plant and hooking up of
the system with the Central CP monitoring system at GAIL
Petrochemical Complex located near PATA in Uttar
Pradesh, India.

The challenge

The Consultant: EILs (Engineers India Limited) field of

interest includes Petroleum Refineries, Pipeline, Oil & Gas
processing, petrochemicals, Oil & Gas Platforms etc.

The cathodic protection system with 854 reference cells

monitored more than 600 parameters and the data
collected from RTUs were distributed all over the plant.

EIL has 4300 assignments including 320 major projects,

successfully completed and operating smoothly. EIL has
45 petroleum refinery projects in different stages of
execution.

The proposed system was supposed to synchronize all the

TRUs through GPS technology. The interruption cycle of
all the 80 TRUs in the 5 Sq. KM plant area could be
programmed remotely. All the TRs built in GPS &
MODEMs could be used to acquire & control TRU data
and Off-Potential. The system had to undergo rigorous
testing
for
certification
from
EIL.

The turn over of the company in 2005 06 was $178

million and the profit was $ 32 million approximately.

This paper is produced for internal use at CIMCON.

www.cimconautomation.com

OIL & GAS

APPLICATION NOTE

The Solution

CIMCON offered CPSCANET software and telephone

communication (PSTN) enabled Remote Terminal Units to
ensure seamless data integration for monitoring.
CIMCON having its own development based in India,
Ahmedabad customized the CPSCANET software to suit
GAILs requirement. The software had mimics to represent
the transformer rectifier unit readings.

The Remote Terminal unit (RTU) should call back

central Monitoring computer station to report if at
least one of the monitored signals is outside set
limits. It shall be the report abnormal output
current, voltage, if those are the input signals
being monitored.

The RTU should dial three alternate numbers in

case a number is busy.

RTU should generate visual alarm and e-mail as

and when the parameters go outside
programmable limits,

Reference cell integrity check for all 814 cells,

Include GPS hardware for time synchronization,

Historical data availability and multiple spreadsheet based

reports improved the data analysis process.
The RTU can be specified by the following attributes:

The RTU should be able to record input voltage

and current in real time.

The data memory should be 64 KB

It It should have auto reporting features to make
periodically calling back the Central Control
Room Computer to report operating parameters
as per user defined call back schedule
programmable from one call back every of 2
Hours to 24 Hours.

This paper is produced for internal use at CIMCON.

www.cimconautomation.com

In HDPE plant, RTU for TRs is be capable of

handling 96AI, 56DI & 32 DO.
Modification of scheduling information,
Log & store data with time stamping, and retain it
even in case of power failure,

OIL & GAS

The SCANET software can be specified like as described
below:

Windows XP operating system,

APPLICATION NOTE

Benefits
The benefits of installation of the system can be listed as
follows:

Scalable to respond growing network need,

Communication capability includes manual calls
to Remote Monitoring System, Standard
Scheduled Monitoring calls, Calls from RTUs in
report-by- exception mode,
Real time database accommodates 500
measurands, 500 status indications, 5000
computed values,

High Availability

Alarm log generation based on defined limits

All PSP and TR Unit current & voltage data for

different 854 cells are available at MCS.

Data integrity improved and custom information

searching becomes easy due to use of SQL
server,

Results in Predictable maintenance schedule.

Corrosion of pipe can be monitored for best

results,

Exceptional events recorded in the system gives

an indication of maintenance requirement of the
system.

Remote monitoring of off-potential through GPS

based system.

As the SCADA software talks to existing as well

as the new RTUs, GAIL has more options in case
of augmentation / upgradation of plant pipeline
network.

Easy data maintenance

Access control
Performs logical operations,
Allows remote programming of control logic ,
Customized detailed data acquisition screen,
Customized report generation based on customer
requirements,

This paper is produced for internal use at CIMCON.

www.cimconautomation.com

Less maintenance cost due to better

maintenance planning and less unscheduled
shutdowns,

OIL & GAS

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APPLICATION NOTE

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Global Support Center

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2007 CIMCON Software, Inc. All rights reserved.