IBP1137_19

INCREASING RELIABILITY IN ENERGY

SYSTEMS FOR NATURAL GAS COMPRESSION
STATIONS
Paulo L. B. Teixeira , Tarcildo F. Costa 2, Tarciso F.
1

Costa3, Levy T da S. Filho4

Copyright 2019, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Pipeline Conference and Exhibition 2019, held
between 03 and 05 of September, in Rio de Janeiro. This Technical Paper was selected for presentation by the
Technical Committee of the event according to the information contained in the final paper submitted by the
author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is
presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute’ opinion, or that of its
Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Pipeline
Conference and Exhibition 2019.

Abstract

Any power system is subject to failures that often cannot be predicted. These failures can
compromise facility’s operation and consequently affect the transmission system.
The energy system installed in TBG's Compressor Stations uses a combination of electric
generators with local public electrical grid or, in some cases, only electric generators. The
hardware responsible for control and local supervision is powered by a redundant system that
uses an uninterruptible power system with a battery charger.
In order to increase operational reliability, TBG has studied a number of possible power supply
options for the control system. This paper describes the different options analyzed, from
technical and economical points of view, in order to assess advantages and disadvantages of
each solution, leading to the option that was implemented in all TBG’s Compressor Stations.
Initially the paper briefly describes the Bolivia Brazil gas pipeline and two of its main facilities,
the Control and Supervision Center and the Compressor Stations. This description is important
to provide the reader with a better understanding of the architectures that have been analyzed.
Then, the work describes each architecture analyzed, indicating its pros and cons until it reaches
the architecture that was deployed in 14 Compressor Stations.

1. Introduction

The Bolivia Brazil Gas Pipeline (GASBOL) is a pipeline extending from the gas
producing fields of Rio Grande, Bolivia, to Canoas, Brazil. It transports gas to five states in
Brazil, with a total extension of 3 160 km (1,970 mi) and a rated operating pressure of 100
kgf/cm2g (1,420 psig). GASBOL is owned and operated by Transportadora Brasileira Gasoduto
Bolivia- Brasil S.A., TBG, a company whose shareholders are Petrobras Logística de Gas S.A.,
GTB-TBG Holdings S.A.R.L., YPFB Transporte do Brasil Holding Ltda. and BBPP Holdings
Ltda. TBG’s Gas Pipeline has 15 Compressor Stations, 47 City Gates, 4 Measurement and
Transfer Stations, 2 Pressure Reduction Stations and 1 Control and Supervision Center located
at TBG's headquarters in Rio de Janeiro.
______________________________
1
Eletronic Engineer, Consultant - TBG
2
Eletronic Technician, Consultant - TBG
3
Eletronic Technician, Consultant – TBG
4
Eletric Engineer - TBG
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2. Nomenclature

CSC: Control and Supervision Center

ELOS: Local Operation Station
SCADA: Supervisory Control and Data Acquisition
ECOMP: Compressor Station
UPS: Uninterruptible Power Supply
VSAT: Very Small Aperture Terminal
QTM: Manual Panel Transfer
PLC: Programmable Logic Controller

3. Control and Supervision Center

TBG concentrates the Bolivia Brasil Gas Pipeline (Brazilian side) control and operation
in Rio de Janeiro, where the Control and Supervision Center (CSC) is located. Through the
CSC, it is possible to obtain satellite information on the operational conditions for a perfect gas
pipeline control. Using a Supervisory Control and Data Acquisition system (SCADA), it is
possible for gas controllers to interact with all TBG stations.

4. Compressor Stations

In the gas natural transport process through pipelines, the compressor stations perform
a very important role, compressing the gas to raise its pressure, since the gas is carried by
differential pressure. Its unavailability may cause from the reduction of the transport capacity
or even the gas supply full interruption, triggering a series of consequences with significant
losses, considering the several customers that can be affected.
Compressor Stations have a redundant local control system called ELOS, Local
Operation Station, performed by two computers. The ELOS main function is to allow CSC to
remotely receive all the process data and transmit to the process the remote commands executed
by the Control and Supervision Center (CSC), in addition to, in case of a communication failure,
to operate the Compressor Station locally.
The Compressor Stations have 2 to 4 sets (depending on the Station) of turbo
compressors, consisting of a gas turbine and a centrifugal compressor or a moto-compressor.
In addition, the Stations are composed of the following systems:
 Natural gas main system;
 Fuel gas system;
 Air compressor system;
 Power generation system.
To enable the system monitoring and control, Compressor Stations utilize a redundant
Programmable Logic Controller (PLC) and a distributed architecture for field data acquisition.
Figure 1 below shows the Compressor Station automation architecture.

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Figure 1 – Compressor Station automation architecture

5. Power Systems

Due to TBG's characteristic of operating the Gas Pipeline remotely, a reliable power
system is critical. TBG has Compressor Stations that use only gas power generation systems
and Stations that use both the local public electrical grid and gas power generation.
In the event of a total failure of the power system, it is critical that the Programmable
Logic Controller (PLC) remain operational for a period of time until the entire Compressor
Station goes to a safe condition without causing interruption in the natural gas supply.
This work will not debate whether local public electrical grid is better than those based
on gas power generators or vice versa. The work will discuss the most reliable architecture to
guarantee the electrical supply of the main systems of the Station, especially the system
responsible by the control and supervision, so as to make a safe stop in the case of a blackout,
that is, in case of a failure in the Station main power systems.
Let's define that the power supply from the local utility and the gas power generators are the
Compressor Station main source of power and the Uninterrupted Power System (UPS) the
secondary source of power.
The turbo compressor control panels have their own uninterrupted power system, and
are not part of this work scope.

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6. Basic Project

In the electrical designs original conception at TBG Compressor Stations, the secondary
power system was based on the use of a single Uninterrupted Power System (UPS) that power
the Station main and secondary panels. Figure 2 below shows a Compressor Station typical
electrical system architecture with a UPS.

Figure 2 – Compressor Station Electrical System with one UPS architecture

In 2009 TBG installed another UPS to increase the reliability of the power system. The
two UPSs operated in a hot stand by architecture, with a main UPS and a backup UPS. The
spare UPS was plugged at the static transfer switch of the main UPS. A problem with the main
UPS or the use of the entire battery load, caused the transfer of the main UPS to the backup
UPS. Each UPS had its own battery cabinet with an autonomy of approximately 8 hours each.
The problem with this architecture is that the backup UPS, was dependent on the static transfer
switch of the main UPS. In addition, as both UPS’s operating all the time energized, a problem
in the main power supply could affect both UPS’s. Figure 3 below shows the electrical system
architecture with two UPS’s. In this configuration, as the UPSs were from different
manufacturers, there were synchronization problems and noise generation in the supplied power
supply.

Figure 3 – Electrical system with 2 UPSs and the static transfer switch architecture

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In 2010 TBG modified the UPS architecture by installing a manual transfer panel
(QTM) at the UPS output. The main UPS powered the loads and the backup UPS remains off.
If it was necessary, the backup UPS was connected and powered the loads through the manual
transfer panel (QTM). Because the UPS was off, a problem in the main power supply would
only affect the main UPS. In addition, TBG eliminated one of the battery cabinets. As UPSs
share the same battery cabinet, which was connected to the UPS in operation through a DC
distribution panel. This architecture presented two problems, turning on the backup UPS
required greater care and it was necessary to periodically test the backup UPS operation in order
to avoid a hidden fault. Figure 4 shows the electrical system architecture with two UPSs and
the manual transfer panel.

Figure 4 – Electrical system architecture with 2 UPS and the manual transfer panel

TBG was not satisfied with this situation and organized a task force to find out a solution
to increase reliability and allow the UPS’s to operate in hot stand-by mode. The solution came
about through the Critical Loads Project.

7. Critical Loads Project

In 2012 TBG created the working group that should propose a solution for the backup
power system for the Compressor Station critical loads. The Compressor Station critical loads
are:
 Utility Programmable Logic Controller (PLC) main panel
 Electrical remote panel (Utility PLC expansion)
 Compressed air remote panel (Utility PLC expansion)
 Local Operation Station computers (ELOS)
 Compressor Station communication rack (switches, routers and vsat)
The main PLC panel, the electrical remote panel, and the air-compressed remote panel
have been classified as level 1, i.e. as the highest priority loads. These loads should remain

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energized for as long as possible. The PLC is the equipment responsible for the acquisition of
process variables, control, operational and safety interlocks such as the ECOMP by-pass valve
and shall ensure a safe shutdown of the Station in the event of a failure in the main power
supply.
The Local Operation Station computers (ELOS) were classified as level 2, that is, as
medium priority loads. ELOS has two main functions, allowing the CSC to remotely receive
all the process data and transmit to the process the remote commands executed by the Control
and Supervision Center (CSC), in addition to, in case of a communication failure, to operate
the Compressor Station locally. Once a main power failure is detected, the CSC controllers can
remotely monitor all equipment’s shutdown safely, opening the by pass valve after the pipe
upstream and downstream pressure equalization without interruption the gas transmission.
The communication rack was classified as level 3, i.e. low priority loads. In the communication
rack are installed the Compressor Station switches, routers and VSAT.
The working group analyzed a number of possible technical alternatives in order to
ensure the highest reliability possible for the system. At first the group had adopted the premise
of maintaining the architecture using the two UPSs, but over time, new ideas were being
analyzed, until deciding on the architecture that was deployed at TBG Compressor Stations as
described below.

8. Technical alternatives analyzed

8.1. Voltage Inverter

Figure 5 shows the proposed architecture using a voltage inverter (250VDC /

127VAC) connected directly to the battery cabinet.

Figure 5 – Voltage Inverter architecture

In this architecture, all loads (level 1, 2 and 3) would be powered directly by an inverter
connected directly to the battery cabinet of the UPS or direct output from the UPS.
As an advantage, installing the inverter (250VDC / 127VAC) on the battery cabinet
provides power redundancy to the UPS system, reducing plant recovery time. This proposal
also had another advantage: the low cost for implementation.
As a disadvantage, we can mention that the inverter failure rate is similar to the UPS
system failure rate, which to the desired standard was considered high. The switching between
the UPS system and the inverter could only be done manually, which would not prevent the
disconnection of loads in case of failure. Electrical noise on 127VAC caused by the inverter
(250VDC / 127VAC) can generate noise in the power supply.

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8.2. Redundant power supply

Figure 6 shows the proposed simplified architecture using two redundant power supplies
(250VDC / 24VDC).

Figure 6 – Redundant Power supplies architecture

In this architecture the two redundant power supplies would be used to power the level
1 loads. The level 2 and 3 loads would be powered by the UPS.
As an advantage, the installation of two power supplies (250VDC / 24VDC) ensures an
acceptable level of reliability for the PLC supply, reducing catastrophic effects for operation,
in the event of a UPS system failure. This proposal also has as an advantage the low cost for
implementation.
The disadvantage of this architecture is that the local operating system (ELOS) and
communication rack would still suffer the impacts in the event of a UPS system failure, leaving
the Control and Supervision Center (CSC) without communication. In addition, the transfer
between UPSs continues to be done manually.

8.3. Redundant power supply with a battery

Figure 7 shows the simplified architecture proposed using two power supplies
(250VDC / 24VDC) and one battery at the output to the PLC.

Figure 7 – Redundant power supply with a battery architecture

In this architecture the two redundant power supplies with a battery would be used to
power the level 1 loads, the level 2 and 3 loads would be powered from the UPS.

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This architecture is very similar to the previous architecture, the difference is in the battery that
was introduced in the 24 VDC power supply to the CLP, in order to guarantee a extention to
the control. It has the same advantages and disadvantages as the previous architecture.

8.4. – Redundant power supply and inverter

Figure 8 shows the architecture proposed using two redundant power supplies (250VDC
/ 24VDC) and one inverter (250VDC / 127VAC).

Figure 8 – Redundant power supplies with inverter architecture

In this architecture, the two redundant power supplies would be used for supply level 1
loads, and a voltage inverter would be used to supply the other level 2 and 3 loads. In addition,
an auxiliary input would be available at 24 VDC to ensure a extension to CLP operation in case
of battery bank depletion at 250 VDC.
As an advantage, the installation of 2 power supplies (250VDC / 24VDC) ensures an
acceptable level of reliability for the PLC supply, reducing the catastrophic effects of operation
in case of failure of the UPS system. The voltage inverter guarantees power to the local
operating system (ELOS) and communication rack in the event of a UPS system failure.
As a disadvantage, we can mention the electrical noise in the power supply at 127 VAC,
caused by the inverter (250VDC / 127VAC). A fault in the UPS system would leave the
Compressor Station without communication with the Control and Supervision Center (CSC).
In addition, the transfer between UPS continues to be done manually.

8.5. Voltage converter and inverter

Figure 9 shows the proposed architecture using a voltage converter (250VDC / 24VDC)
and an inverter (127VDC / 24VDC). It is important to note that this architecture proposes a
change in the characteristics of the equipment used for the Local Operating Station and for the
equipment responsible for the Station communication, which would be powered at 24 VDC. In
this way one ELOS would be powered by 24 VDC and the other by 127 VAC. Likewise, the
communication system would have one switch powered at 24 VDC and one at 127 VAC.

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Figure 9 – Voltage converter with inverter architecture

As an advantage, using equipment energized by different voltages greatly increases

the reliability of the system. This proposal also has an advantage, the implementation low
cost.
The disadvantage is that the transfer between UPSs continues to be done manually.

8.6. Two UPSs and battery charger

Figure 10 shows the proposed architecture using the UPS and a battery charger.

Figure 10 – Two UPS and battery charger architecture

In this architecture a battery charger with a 24VDC to 24 VDC converter was included.
Part of the loads will be powered by the 24 VDC system and the other part by the 127 VAC
system from the UPS. In addition, it was proposed to unify the UPS battery cabinet, since they
will never operate in hot stand-by configuration, sharing the load.
As an advantage, this architecture presents a high reliability because the system now
has two different independent sources, no longer depending on the batteries of the UPS.
The disadvantage is that the transfer between the UPS continues to be done manually
and it will be necessary to purchase the battery charger that has a high cost.

8.7. UPS and battery charger

This architecture is very similar to the previous architecture, the difference is the
elimination of one of the UPS that simplified the system.

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Figure 11 – UPS and battery charger architecture

This architecture has the same advantages and disadvantages of the previous
architecture, but with the elimination of one of the UPS maintenance cost has been reduced and
now we have triple redundancy and two battery cabinets with different voltage to power the
loads.
This architecture was chosen to be installed in the TBG compression Stations, because
it has a high reliability, independence between the UPS system and the battery charger,
redundant power supply for the PLC, to the Local Operating Stations and to the communication
system.

9. Conclusion

The project of critical loads was executed in 2016 in the Compression Stations of TBG.
The adopted architecture proved to be extremely reliable, making the power system more
flexible, allowing maintenance of the UPS and battery charger systems individually, always
ensuring at least one active back up system.

10. Acknowledgements

Our thanks go to Renata Sarmento by the encouragement and support in the execution of this
work.

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