Abstract for the lesson

Crude Oil Pipeline SCADA system review

Dr. György Bezerédi

MMG AM Nova Ltd., Hungary

Content

COMPANY HISTORY............................................................................................................2
BALTIC PIPELINE SYSTEM (BPS) HISTORY .......................................................................2
CRUDE OIL PIPELINE AUTOMATION..................................................................................4
TELEMETRY SYSTEMS .......................................................................................................4
PUMP STATION AUTOMATION ...........................................................................................4
TANK FARM AUTOMATION AND MANAGEMENT ...............................................................5
INTRODUCTION TO TELEMETRY .......................................................................................6
COMMUNICATION TECHNOLOGIES...........................................................................6
COMMUNICATION TECHNIQUES ...............................................................................7
DATA GATHERING TECHNIQUES...............................................................................9
TELEMETRY AND CONTROL ......................................................................................9
PROTOCOLS ...............................................................................................................9
BPS SCADA SOLUTIONS...................................................................................................10
BPS DMON SCADA....................................................................................................10
BPS Pipeline Application Software ..............................................................................11
BPS Block valve stations (BVS)...................................................................................12
BPS Pump Station control system...............................................................................12
BPS Tank farm control system ....................................................................................14
CONCLUSION ....................................................................................................................14
COMPANY HISTORY

The MMG, formerly known as the Company for Mechanical Measuring Instruments, was established in
the year 1900.
The Company received its MMG AM name
(Automatika Mûvek = Automation Corporation)
later in the 1970s, when Hungary as a COMECON
country seized the opportunity to supply crude oil
industry automation equipment for the socialist
countries.
Since then MMG AM has played a unique role in
the design and implementation of oil and gas
industrial automation systems in Eastern Europe
and throughout Russia. In recent years, the
company became the leading supplier of process
control equipment for facilities such as tank farm
management projects, pipeline telemetry projects
and pumping station automation projects.
This is indicated by the fact that systems have been installed at nearly 500 locations in the Eurasian
region during the last three decades.

BALTIC PIPELINE SYSTEM (BPS) HISTORY

By experts „Russia loses up to 1.5 billion dollars annually transporting through foreign ports of Baltic
states (Butinge, Ventspils). The transport of Russian fuel gives 25% of Latvian and Estonian state
income. The questions of realizing the Baltic Pipeline System is also important from economical security
point of view for Russia.”

Baltic crude oil terminals

The realization and start up for BPS was planned to be in December of 2001. The owner of BPS
became „Transneft” joint stock company. The BPS is oriented for the transport of Russian crude oil from
the so called Timano-Petchorsk, West-Siberian and Ural-Povolzhsk regions.
The Baltic Pipeline System (BPS) envisages a phase-by-phase development with the oil exports
reaching up to 30 million tons a year. In December 2001, 1st phase BPS was commissioned for
exporting 12 million tons of oil a year with no reducement for the BPS intermediate Kirishi refinery.
457km pipeline from Yaroslavl to Kirishi was expanded and reconstructed. A new Kirishi-Primorsk
pipeline was built with a new on-shore terminal in the Finn gulf at Primorsk.
 BPS-I pipeline route to Primorsk

On November 2, 2001, the Russian Federation Government issued Regulation No.1467-r on projecting
and construction of 2nd phase BPS (BPS-II). The goal of BPS-II was a further growth of capacity of the
Baltic Pipeline System up to 18 million tons a year. With the construction of 264km new pipeline of 720
mm diameter with 3 new/reconstructed pump stations and 95000 cubic meters of tank capacity.
Commissioning of BPS-II was planned for December 2003.

BPS-II expansion plans

BPS has a crucial significance for Russia. Now there is a peak of oil prices and the Russian budget,
dependent on it, receive additional revenues. President of Russia actively stands for these issues and
all works on increase of export capacity of the country are under President’s supervision

Due to limited construction schedule of Transneft and the huge amount of references in pump
station, tank farm and telemetry automation for crude pipelines, MMG AM Nova Ltd was selected
as automation supplier for the BPS!
CRUDE OIL PIPELINE AUTOMATION
Even the highest quality motors, pumps, and piping accessories, incorporated into a well constructed
pipeline network, cannot absolutely guarantee safe and economical operation of a product pipeline
without well designed control systems.
Based on many telemetry, pump station and tank farm references, additionally undertaking the short
time from the design to the commissioning, MMG AM Nova Ltd was granted the majority of the station
automation projects as well as the telemetry for the BPS.

TELEMETRY SYSTEMS
Telemetry systems have become an important part of communication and control strategies throughout
industry. Increasingly, telemetry and SCADA systems are making use of more complex technologies
and techniques to provide cost effective methods for remotely monitoring and controlling assets.
Systems delivered by MMG AM NOVA can assure large flexibility for communication technology and
protocols, controlling possibility, expandability etc.
As reconstruction, new Block Valve Station (BVS) RTUs were supplied for the whole BPS pipeline by
MMG. Using existing and newly installed (for the Kirishi-Primorsk section) communication equipment the
BVS RTUs measure the pipeline pressure, cathodic potential values for operational and leak detection
purposes.

Typical BVS RTU with 5 gate valve control

PUMP STATION AUTOMATION

A pump station automation provides the means of machine (electrical motor & pump aggregate) control,
auxiliary system (lubrication, ventillation, drainage etc) control, station protection (flooding, gas, fire etc.)
control functions. These functions mainly require PLC control, as all the equipment should be provided a
„state machine”, where the transitions among the possible states are controlled by technological signals
and operator’s interaction.
 Typical pump for crude oil pipelines

A Crude Oil Booster or main Pump Station's (NPS) control is a responsible task. In this technological
process failures are not permitted. Similarly, there is no possibility for prevous testing of newly
developed algorithms under operating conditions. Therefore pump station control system is the key
element from reliability point of view.
The experience acquired by MMG engineers on earlier Transneft stations proved to be vital importance
in the commissioning of BPS.

TANK FARM AUTOMATION AND MANAGEMENT

Tank farms in BPS are used for providing the continuous pumping to the on-shore terminal in Primorsk.
The short time service for tankers is very important, therefore a 500 000 cubic meter terminal tank farm
at the end of BPS, and other intermediate buffer tanks were automated in the project.

High capacity Transneft tanks

The tank farm automation is used only for operational, not for custody transfer purposes. Very important
part in tank farm automation was the gate valve and tank overfill protection control for the tanks. The
main purpose of tank farm automation was to monitor the route of crude oil batches along the BPS
pipeline even at Transneft higest level offices to check the fulfillment of crude transportation contracts.
INTRODUCTION TO TELEMETRY
Telemetry is the mechanism by which information is interchanged with remotely separated locations for
the purpose of monitoring and/or control. Telemetry ranges in complexity from systems with a couple of
I/O to complicated controlling systems of pipelines embracing more thousand technological units.
Telemetry systems delivered by MMG AM NOVA belong to those of larger complexity, where data
processing features from a few thousand to more hundred thousand signals.
The key components in many telemetry systems are the RTU (Remote Terminal Unit), communication
protocol, physical communication network, SCADA system (Supervisory Control and Data Acquisition).
The key components are as follows:

• RTU
The RTU is the remote device responsible for acquiring the “real” information, typically from
field devices. It queries the data from the field devices and typically formats data according to
requirements of communication protocol, puts datas forward to communication network. The
RTU may acquire their information through electrical signals connected to the RTU or from
other intelligent devices via a serial data connection. RTUs may also perform local control
functions. The RTU functions are often fulfilled by a Programmable Logical Units (PLC).
According to this the mostly applied RTU device in the systems by MMG AM NOVA is a PLC
made by Modicon.

• The communication protocol

The communication protocol is the language used in the transmitting and receiving of data
messages on the physical network. A protocol can describe who sent the message, who it is
going to, the meaning of the data in the message, verification information to ensure the
complete message arrives and that it is error free. Both the transmitter and receiver of the data
message must use the same protocol in order that both understands the data message.

• The communication network

It provides the physical means for the transfer of information (message data) from an RTU to a
SCADA system, from an RTU to another RTU, and in some architectures between multiple
SCADA systems. Choice of communication network is critical to the operation of a telemetry
system and can be a costly aspect of a telemetry system.

• The SCADA system

The SCADA system is comprised of one or more computers, providing an interface to the
physical communication network (and hence to the RTUs), and an operator interface to the
data obtained from RTUs. This data may be rebuilt, stored for later retrieval, analysed and
transferred to other computer systems. A SCADA system often provides a control interface for
sending data to RTUs. This can happen by operator commands and automatic sequences
based on RTU data can release commands too. Commands can be received from other
computer systems (eg. leak detection at oil pipeline for automatic shut down pipeline
gatevalves.)

COMMUNICATION TECHNOLOGIES

As with most technology, available communication technologies are evolving. The technologies used in
telemetry are often different than in other communication disciplines such as computer networks,
although there is some overlapping with other computer systems. Hardware needs to be flexible enough
to the eventual common use of various communication techniques. (cable connection, radio channels,
optical cables, phone lines etc). So much the more as in case of systems with increased safety a
reserve channel is a need which possibly requires an other kind of medium.
In the practice of MMG AM NOVA the following tools have been applied:
• Radio
While initial equipment and installation costs can be higher than in other technologies, the on-going
running costs of a radio system are very economical independently from the number of RTUs
applied. Expansion does not represent any problem either. Also conventional radios based on UHF
or VHF can also be used, furthermore data-radios enabling special multiport structure, or
conjugated. Dial-up and GSM phones can be used too furthermore the RTUs by MMG AM NOVA
are capable to establish any kind of accordant radio connections too.

• Landline
Landline communications were once the dominant communication medium used in telemetry.While
radio telemetry has significantly gained in popularity and reliability, landline systems continue to be
used in various renewed forms. The leased lines are mostly used. Their recurrent costs can be very
 expensive. Various options are available: two-wire, four-wire, analogue and digital data services.
Care should be taken in assessing landline options e.g. a point-to-point line with conventional
modems is not suitable for multidrop telemetry applications.
Furthermore some digital data services are Master/Slave and not suitable for more complex
communication arrangements. Often subject to failure due to lightning. Expansion is not always
possible cheaply. Standard dialup modem technology is generally inappropriate in telemetry
systems because of long connection times. In systems with shorter communication distances
building RS485/RS422 lines is also possible. Lines can be organised in master/slave or peer-peer
configurations with half and full duplex arrangements.

• Miscellaneous
Optic fibre technique gains more and more ground in the future and even nowadays. Very high data
rates are achievable, even Ethernet networks can be established. Ethernet networks enable
connecting fast and high performance devices, comprises the use of more advanced
communication technologies.
The devices the RTU devices developed by MMG AM NOVA are already suitable applying such
techniques. These can be networked via bridges to wide area networks but can be. This is a
standards based communication media where compatibility is assured. At protocol level the TCP/IP
(eg. Modbus/IP) is most widely spread, enables communication between different vendor brands
both of the physical and link level.

COMMUNICATION TECHNIQUES

There are as many communication techniques as there are different communication media
technologies, each optimised or using clever ways of improving bandwidth, or decreasing cost per
connection. Regardless of the communication techniques used, it is a fundamental requirement for
different devices on a common communication channel to be uniquely identified. This usually takes the
form of a device address unique to that device and not used by any other device on the same channel.
Using communication medium already in use for some years, most telemetry communication networks
will support fairly low bandwidth data only. Larger amount of data can only be transferred via most up-to-
date channels. (eg. Ethernet)

• Master/Slave Communication
This is the simplest but also least flexible of the telemetry communication techniques, despite of this
the mostly used one. It assumes centralised communication control, usually performed by a SCADA
system. The centralised controller is responsible for requesting all data and interpreting responses
from remote devices. The most common Master-Slave systems permit only one remote device to
communicate at a time, and only after a master station has requested the data. This method
provides very low bandwith effectivity. The Master-Slave data gathering activities commonly use
sequencing based on a polling arrangement. While allowing priorities to be assigned to gather data
more quickly from some sites, or sending data to sites, Master -slave communications usually
results in inefficient use of communication bandwidth. Expansion of an installed master-slave
system directly impacts on update rates or requires installation of additional communication
channels. Some communication medium technologies can only be used with this type of
communication technique.

• Peer-to-Peer Communication
Peer-to-peer communication varies from the Master-Slave technique by allowing all devices on a
communication network to initiate communication with other devices. There is not a centralised
communication controller, instead each remote node on the network must perform its own
communication control. Examples of this in the computer networking field are Ethernet or Token
Ring networks. While no centralised communication controller is required, it is very common to have
a SCADA system receiving a majority of the network data. Data update rates from remote devices
are much improved over the Master-Slave case for similar sized networks and communication
efficiency is much higher. Importantly: telemetry, peer-topeer architectures provide the possibility for
remotes to exchange data independently from a SCADA system or central controller. This provides
enhanced reliability particularly for distributed control systems. Expansion of peer-to-peer networks
by the connection of additional nodes can have minimal impact on communication performance.
Note that not all communication medium technologies support peer-to-peer communication
architectures.

• Enhancing reliability in communications

Some telemetry systems require very high communications reliability. This is achieved to varying
extents by duplication of critical equipments (e.g. hot standby radio repeater systems). Dual
communication channel systems are sometimes arranged in a primary link and backup link
arrangements. Depending on the use of Master-Slave or Peer-to-Peer techniques, control of
switching from primary to backup links may be handled at SCADA system or RTU level. It is not
uncommon to use different communication medium to primary-backup links.
The use of Peer-to-Peer techniques opens the way for networking of telemetry systems. In its
simplest form, communication between two nodes on a single network relies on a pair of device
addresses: the source and the destination.
More complex communications are possible when more networks are connected, even through a
differring communication media where routers, gateways, bridges are needed. Issues of unique
device addressing across networks then need to be carefully examined. Combinations of linked
local area telemetry networks can become part of a wide area telemetry network and provide
scenarios where multiple master stations can be connected on a wide area network, where RTUs
can exchange information for control purposes even though they are not on the same
communication channel.It should not be understated that the facilities which result from Peer-to-
Peer communications and telemetry networking are providing major operational and asset
management advantages to industry. The most network telemetry networks uses TCP/IP protocols
that have the advantage of operating with equipment from various vendors and provide an overlap
with computer network technology. This can be advantageous for it is not necessary to build an
entirely independent system at SCADA system level but networks and PCs already in use can also
be applied.

BPS communication line redundancy

 DATA GATHERING TECHNIQUES
• Polling Techniques
The most common data gathering technique is polling. In its simplest form, a single master
station sequentially requests data from each of the remote stations. While simple, able to
operate on virtually all physical communication media. Polling often results in wasted
communication bandwidth, it is slow, with the system expansion data reqest period can be
significantly longer.
• Polled Report By Exception Techniques
It's a little bit more complex while maintaining most of the characteristics of polling, the master
spends most of its time requesting event changes from the remotes. If no changes have
occurred, then there will be no event data to return to the master. This is a much more efficient
data gathering technique for remotes which have large amounts of data which varies
infrequently.
Owing to the possibilities provided by communication channels this technique is mostly used by
MMG AM NOVA. The applied communication protocol supports this solution, SCADA as well
as RTU understand the notions 'events' and static 'data'. Events are often timetagged at the
time of their occurance. This can significantly improve the interpretation of data and events
received at a SCADA system. In case of standard polling the time of occurance of an event is
inaccurate by as much as the polling cycle time.
• Unsolicited Report By Exception Techniques
Unsolicited reporting is becoming an important technique in telemetry architectures. The key
difference in this architecture is the ability for a remote station to initiate a communication
without first being requested to do so as in the polling architectures described above. Telemetry
systems operating in this manner make very efficient use of available bandwidth, as the
majority of data on the physical communication channel is sent by the remote only when it
determines it is required. Continuous data request process remains only at the extent that
background polls verify a central station's data is up to date and checks the health of remote
devices.
• Quiescent Techniques
Similar to unsolicited report by exception, the most bandwidth efficient technique is quiescent
operation. All communication is unsolicited report by exception and the receiver always
acknowledges reception of transmitted messages. The only disadvantages in using this type of
network is that a central site does not regularly check on the state of devices and it may take an
extended period to reliably detect the failure of a remote device.

TELEMETRY AND CONTROL

As MMG AM NOVA accomplishes the tasks concerning RTUs mainly with PLC devices, the possibility of
remote controlling is obvious. Local controls often performed with PLCs (eg. on site PLC automation)
then connected to telemetry RTUs or adjoin them into telemetry systems directly. The difference
between PLCs and RTUs will soon disappear namely not for the reason PLCs are more and more
similar to RTUs but the possibilities of RTUs are increased by the fact that they become more and more
capable to control tasks, that is they function also like PLCs. Very interesting and promising topic is the
appearance of IEC 1131 protocols, for it makes unification of controlling regardless of RTU vs PLC.

PROTOCOLS

The communication protocol concept of layers as described in ISO's communication models are
applicable to telemetry protocols.
Most telemetry protocols use between 2 and 5 layers of the OSI 7 layer model. Typically the following
services shall be rendered in order to avoid loosing from usability:

Knowing protocols is important beacuse of the large number of the tools available on the market,
however some vendors do not release their proprietary protocols. This is indispensable in the interest of
interoperation. It is common for proprietary protocols to be accompanied by a public domain protocol on
the same device to allow telemetry systems to interface to other devices.
The most common example of this is MODBUS, however it is basically not a telemetry protocol. Also
MMG AM NOVA applies Modbus and Modbus /TCP protocols because of the RTU hardwares applied.
With special bridges it is suitable to interface with any other kind of protocols IEC870, R9364 etc) .
Standardization of communication protocols is valuable for interoperation, technical supports, building
communication lines, evaluating network developments. The recently accepted fieldbus standard has an
impact also on telemetry systems.
BPS SCADA SOLUTIONS

The central Regional Dispatchers’ Control Rooms are situated in two cities: Yaroslavl and St.
Petersburg. Both control rooms use PCs for I/O server and workstation purposes. The system was
planned to have cold reserve. In case of I/O server failure a reserve PC can be started up. All the
workstations have the same functionality, therefore they have „hot” reserves. At the same time for higher
level interfacing there are OPC,SQL or WEB based connectivity provided.
For the connection of BVS dual Ethernet/Modbus bridges are used in multipoint structure, while to all of
the pump stations peer-to-peer high speed communication is provided. The switchover to the reserve
(lower speed) communication line is automatic in the SCADA.
The used communication protocol is Modbus TCP, which can also be used for remote programming
from the engineer’s workstation.

BPS DMON SCADA

The SCADA software package used for BPS-I was “ Dmon”, developed by ScadaSys Ltd, running under
“QNX“or Windows operating systems.

Dmon is a modular, real-time, distributed client-server SCADA

system. It can be multiplatform even within one project (QNX
I/O server and W2k HMI workstations). Beside Dmon’s
standard SCADA functions (trending, logging, timing etc.) its
main advantages can be summarized as follows:
• The modules are configurable be text files, there is no
need in big project to manipulate tables by clicking
the mouse thousand time when assembling the
database and technological scemes.
• The operation of Dmon monitoring system under
QNX opsys is so fast that it cannot be compared with
other HMI systems on Windows platform (Win9x,
Win2000, NT). Images and data refresh periods
under normal circumstances are below 1 sec.
• The Dmon monitoring system is applicable to supervise large technological objects (containing
more main and auxiliary pumps tank farms and measuring stations) or to form telemetry
centres where connections shall be maintained with numerous PLCs and other data acquisition
devices. Such systems provide fair response time even when handling 150-200000 tags and/or
technological signals.
• In the Dmon SCADA System there are already solutions elaborated for telemetry and pump
stations control. This substantially decreases developing time of the projects' application part.
The rule “time is money“ is really considered in our practice. The communication with PLCs
occurs through Modbus Plus or Modbus TCP/IP Ethernet network based on changes. The
counterpart of this programme in the monitoring system, in the PLCs ensures the flow of the
information units with time stamps in the order of their appearance. This is an important feature
for such a system where sequential algorithm is applied.
• Besides Windows 2000 system Dmon can be run on UNIX-like platforms (eg. Digital Alpha,
QNX RTP), however the QNX (real time) version running on IBM compatible is the most
approved one among them. No virus problems on UNIX platform!
• Possibility of displaying the archives in re-play function at will
• There is special event handling module (not alarm) exist in Dmon, required by the user

In addition to Dmon the other SCADA System used by MMG AM NOVA is the iFix monitoring software
package by Intellution (by Transneft decision).
 Overview scheme in BPS SCADA

The telemetry object are the BVS, pump stations, tank farms and measuring stations. The
mnemoschemes for these objects can be activated from a menu driven windows, grouped into pipeline
sections.
Also there is a special „tree-like” alarm/warning/signalling module in Dmon, which is very useful in big
size SCADAs, when minimal amount of mouse clicks should be used to find a technological object with
changes (alarms, warnings).

BPS Pipeline Application Software

Most of the telemetry systems as also BPS uses special pipeline application software (PAS). Beside
operational control other important software can be realized for optimal control and leak detection. The
leak detection software for BPS was planned to be realized by a Transnett company (with MMG
provided interface). The other PAS functions include:
• Pig tracking
• Pump optimization
• Pump characteristics identifications
• Effective diameter calculation
• Pressure profile calculation and monitoring
• Pipeline stationarity calculations
• Pipeline route maps included
 BPS Block valve stations (BVS)

On the block valve stations there are only some analogue measurements (pressure, cathodic potencial,
temperature) as well as pig, gate valve state and control discrete signals (for up to 8 gatevalves), the
Compact PLC of Modicon is a good choice.
As the BVSs are on far places, the reliability in hars
environment suggested to use the highest MTBF PLC
family. This PLC has the lowest operating temperature
specification. It is placed into a thermo-isolated control
cabinet together with Uninterruptable Power Supply.
The BVS has a dual communication line to the
telemetry centre. One with a leased line 1200 baud
modem and one with 9600 baud radio modem.

The PLC is programmed by „Concept” of Schneider

Electric in IEC 1131, and uses the polled report by
exception data gathering method. The changes are
monitored with time stamp with a special FBD within
the program.

Using Modbus communication a relatively short query

cycle can be provided. For the connected leak
detection system require a 10 sec update time for all
BVS data, therefore in case of many simultaneous
technological changes the query cycle should not be
exceed this 10 sec time even at 1200 baud speed.

The Modbus protocol, as native to the Modicon PLCs

provides remotely programming capability for testing,
debugging and downloading purposes/

BPS Pump Station control system

As mentioned pump station control is a very responsible task. Owing to the development of various
system design institutes of Russia, Ukraine, MMG AM Nova has gained access to a large sum of
algorithm modules for controlling different technological units. We always prepare and harmonize the
control algorithms and programme specifications with our clients. These specifications are applied at the
FAT Test, START-Ups and project commissioning. The algorithm directories among others include the
basic blocks embracing both AVR (Automatic Reserve Switch On Regulators) and APV (Automatic
Repeated Switch On) functions which enable technological system input data analysis.
With the basic blocks in the algorithm directory the control over two, three and sometimes even four
pumps, ventilators etc. equipped distribution systems is also possible. The basic operation principle for
the connection between PLC programmes and the monitoring systems is that all commands received
from the dispatcher systems shall be confirmed by the PLC system. Therefore not only the received
command is logged in the event register by the dispatcher system, but also those received from the PLC
programmes thus data loss can be avoided.
Another important function of the PLC is to determine the source of incoming commands, therefore it
differentiates and differently confirms commands received from the CDP (Central Dispatcher Station)
and MDP (Master Dispatcher Point or Local Operators).
At the level of the PLC programmes the source of each commands shall be identified, because from
different levels receiving commands is allowed only in specific operation modes, on the other hand the
different sequential commands can be given out from various control levels.The third source of
commands in the algorithms is being the automated programme control (e.g. activating a main pump
aggregate's starter programme no.1 means opening the gate valves in that group.)
The set-up and start-up of a new pump station’s automation system often requires the partial operation
of the pump station. During the start-up adjoining the aggregates and various auxiliary systems to the
automation can be performed step by step, however in such cases not the total quantity of technological
signal are generally standing at our disposal yet.
Algorithms check the validity of each signals being important for supervising equipments, completing
sequential tasks. During system start-up and operation, our software programmes provide the distinctive
features of masking and emulating station and aggregate protection. Errors from the different
technological distribution systems are not allowed to disrupt the start of aggregates and station units.
Temporary cheking of various monitoring and protection systems can also be performed without any
malfunctions or disturbances in the station. The masking and the imitation of task are carried out with an
absolute responsibility, therefore it requires a deep knowledge and experience on the application of I/O
signals.By switching appropriate signals and protections into “test“ operation mode the protection
becomes checkable, thus tested protection signal will not result in stopping the station. Of course
masking and imitation tasks are of high responsibility, therefore they require password of high priority. In
sequential programmes causes and consequences shall always be determined thus changing event
order is not allowed. In a slow monitoring system, when only cyclical polling is performed during
significant changes in the state of the technology (e.g. aggregate start-ups) there are seconds needed
for polling all the necessary datas.
During this period signal time values are interlaced in the monitoring therefore not the real event order
will be indicated in the event registry.In such cases it is very difficult to detect the causes and
consequences i.e. the real reason for a station breakdown.
In the system developed by MMG AM NOVA’s there is a specific module running on the PLC which is
monitoring data changes and creates event messages with time stamps and puts them into an event
buffer in chronological order. Event messages can also be formed from changes in specific discrete
signals or analogue values in the PLC besides from changes in memory ranges containing variables
and parameters. A counterpart of this program runs in the monitoring system. This programme reads
native event messages from the controller event registry through the available communication channel.
In our monitoring system the real technological event order is stored in the event log furthermore the
event log includes real occurrence times and also their arrival times at the monitoring system.

Dual pump station scheme on BPS

 BPS Tank farm control system

For tank farm measurement MMG can use its own measurement devices (servo and radar gauges,
temperature transmitters) and alos other vendors’ devices, such as Enraf’s or the standardtly used
Saab-Rousemont measurement system. All the mentioned system have Modbus interfaces, so the
interfacing to the Modicon based control system proved to be very easy.

The operation tank control means level and temperature measurement for the tank with volume and
mass calculation. The special application software for volume and mass calculation was made in the
API module of Dmon on the base of Transneft algorithm.
The measured tank parameters are interfaced to the station PLC system for tank overfill or high
charging/discharging speed control. Independent level signallers are also used for such protections.
The tank farm control system key task is the remote control of tank gate valves. Most of the BPS tanks
farms are using intellectual gate valve actuators (Auma, Limitorque as well as Russian made). Some
gatve valve interlocking functions are also realized in the station PLCs.
Crude oil tank farms are special kind from level gauging point of view. The high contamination feature of
the crude in still pipe measurement should be prognosed during the design phase. Also critical can be
the floating roof tank instablity.

Tank farm tank and gate valve control schemes

CONCLUSION
In accordance with the Russian Federation Government issued Regulation Transneft is continuing to
increase pipeline capacity. In 2005 the BPS throughput will be expanded up to 50 million tonns annually,
with a further option to increase up to 62 million tonns.
MMG AM Nova Ltd. makes efforts to be a reliable partner for Transneft’s future automation plans. The
acquired experiences during the BPS realization can benefit for MMG AM Nova Ltd. in getting further
pipeline projects.