PIPELINE SCADA (SUPERVISORY CONTROL & DATA ACQUISITION) AND APPS (APPLICATION SOFTWARE) SYSTEM

Engineering activities
SCADA & APPS System

Review of basic Process documents (Process Design Basis, P&IDs) as applicable for SCADA Conceptual design SCADA Design Basis Firming up of system configuration and specifications of SCADA & APPS Furnishing room sizes, layout, etc for control room, to Arch. Dept. Preparation of Material Requisition (MR) for systems Technical bid evaluation of bids Preparation of Purchase Requisition of system Review of vendors critical detailed engineering documents Participation in factory acceptance tests Site assistance as required Preparation of man-hour estimates, MR schedules, progress reports
2

OBJECTIVES
TO MONITOR & CONTROL THE PIPELINE FACILITIES VIZ. PUMP/ COMPRESSOR STATIONS, DESPATCH & RECEIVING TERMINALS, PIGGING/ SV/ CP STATIONS ETC. IN A TIMELY MANNER FROM A CENTRALIZED LOCATION wrt: Monitoring of Flow, Pressure, Temperature, Density, Electrical parameters etc. Pumps/ compressors status Status of all station & Intermediate valves Readiness to dispatch products and receipt of products Pumps/ compressors start/ stop, valves open/close commands Set point downloading to controllers CENTRALIZED ALARM & EVENT MANAGEMENT AND OPERATION & MANAGEMENT REPORTS FOR ALL THE DISTRIBUTED PIPELINE FACILITIES. PROVIDE REMOTE-EYE TO THE PIPELINE OPERATION
3

OBJECTIVES (Contd..)
Centralized checking of status of various pipeline facilities wrt

Readiness to despatch products Pumping status Readiness for receipt & distribution of products Status of valves

to ensure that the requested control action will not result in unsafe pipeline operation i.e. the above confirming tasks can be defined in SCADA system to ensure that operator cannot operate the pumps & valves in a manner that could jeopardize the safe operation of the pipeline To ensure proper pipeline shutdown by closing various pipeline facilities in orderly manner as per pre-defined sequence

OBJECTIVES (Contd.)
TO FACILITATE RUNNING OF APPLICATION SOFTWARE PACKAGES FOR RELIABLE & EFFICIENT OPERATION OF THE PIPELINES VIZ.

LIQUID PIPELINES LEAK DETECTION & LOCATION PIPELINE EFFICIENCY INVENTORY ANALYSIS BATCH TRACKING PUMP OPTIMISATION
GAS PIPELINES LEAK DETECTION & LOCATION PIPELINE EFFICIENCY INVENTORY ANALYSIS PREDICTIVE ANALYSIS CONTINGENCY ANALYSIS PLANNING FUNCTION COMPRESSOR FUEL OPTIMIZATION
5

SCADA SYSTEM FUNCTIONALITIES

MONITORING CONTROL ALARM & EVENT DETECTION MAN-MACHINE INTERFACE TRENDING REPORT GENERATION DATA ARCHIVING COMM. HANDLING & ERROR RECOVERY DATABASE CONFIGURATION & ENGINEERING FUNCTIONS SYSTEM MAINTENANCE & SECURITY INTEGRATION WITH APPLICATION SOFTWARE

SCADA SYSTEM HARDWARE COMPONENTS

SCADA System is designed with the distributed architecture in following key areas:

Computer Workstations
Separate server & MMI machines with client server concept implemented at hardware & software level

Remote Workstations Communication Controller Units Remote Telemetry Units WAN Routers

Master Station

SCADA & APPS Man Machine Interface

To Second Master Station

SCADA Computer WAN System Routers

APPS Computer System

Projection System

Telecom Network High Speed Channel Remote Workstations

Dual Local Area network Communication Controller Units Data channels as part of Telecom Network
To Second Master Station

RTU 1
IS for DT/ Pump Station/ Compressor station

RTU 2
IS for SV/ CP/ RP station

RTU 3

RTU n

FC

IS for IP station

FC

IS for Receipt Terminal 8 FC:Flow Computer

IS:Instrumentation System

10

11

12

13

14

15

Engineering activities
SCADA & APPS System

Review of basic Process documents (Process Design Basis, P&IDs) as applicable for SCADA Conceptual design SCADA Design Basis Firming up of system configuration and specifications of SCADA & APPS Furnishing room sizes, layout, etc for control room, to Arch. Dept. Preparation of Material Requisition (MR) for systems Technical bid evaluation of bids Preparation of Purchase Requisition of system Review of vendors critical detailed engineering documents Participation in factory acceptance tests Site assistance as required Preparation of man-hour estimates, MR schedules, progress reports
16

Inputs Required from Other Departments

Leak Detection Target Figures from POSD

Electrical I/O List from Electrical Dept.

Pipeline Inputs for Leak detection indicating elevation, burial status & Pipe OD, ID from Pipeline engineering Dept. Process Process data for APPS P&IDs Process design basis Pipeline Operation & Control Philosophy Batch size and sequence

17

Inputs Given to Other Departments

Electrical Loads to Electrical Dept.

Heat Loads to Package equipment dept.

Control room Size requirement to Architectural Dept.

18

19

REMOTE WORKSTATIONS

Remote workstation is normally envisaged at manned stations (other than Master Station location): Pump/ Compressor stations Terminals

to provide complete SCADA & APPS capability (graphics & reports) so that the operators at these locations are fully informed of:

All the monitoring variables in the pipeline Status of various pipeline equipments Alarms for the complete pipeline facilities

20

REMOTE TELEMETRY UNIT (RTU)

Microprocessor based intelligent unit supporting CPU, RAM, Real time clock, EPROM. The basic unit of RTU consists of power supply module, master processor module and no. of I/O modules, communication modules, serial interface module etc. Remote Telemetry Unit Interfaces with the field instruments and pipeline equipments through intelligent input/ output subsystem and converts the information into the digital frame structure for interfacing with Telecom channels through communication modules
(Contd)

21

REMOTE TELEMETRY UNIT (RTU)

(Contd.)

The RTU provides the engineering functions of

High/ low limit checking Time tagging Engineering unit conversion, filtering etc. Self diagnostics Check before execute, time out Remote configuration and downloading Interfacing with flow computers Digital input card Digital output card Analog input card Analog output card

The various I/O cards provided are:

22

APPLICATION SOFTWARE
LEAK DETECTION MODULES

Steady state/ Transient state modeling

Transient Modeling enveloping volume balance

Shutdown state modeling

Shut in leak detection

BATCH TRACKING MODULE SUPPLEMENTARY MODULES

Pipeline Efficiency Inventory Analysis

23

VOLUME BALANCE
BASED ON What goes in must come out! EMPLOYS ACCURATE FLOW MEASUREMENTS AT BOTH ENDS Flow In is RECONCILED WITH Flow Out CONSIDERING PIPELINE INVENTORY TO CALCULATE FLOW IMBALANCE V (Leak) = V (Inlet) - V (Outlet) - V (Change in Inventory) LEAK DETECTION IF FLOW IMBALANCE EXCEEDS PREDEFINED LIMIT

24

VOLUME BALANCE (Contd..)

FEATURES RETROSPECTIVE BETTER SUITED FOR PIPELINES WITH LOW PRESSURE GRADIENT SENSITIVITY FOR LEAK DETECTION IS HIGHER FOR LONG TERM VOLUME BALANCE LIMITATIONS NO INFORMATION ABOUT LEAK LOCATION LONG LEAK DETECTION TIME DEPENDENT ON PIPELINE INSTRUMENTATION ACCURACIES AND DRIFTS (SEE REMARKS) DOES NOT PROVIDE DYNAMIC INVENTORY CALCULATIONS (SEE
REMARKS) REMARKS : TRANSIENT MODELLING ENVELOPING VOLUME BALANCE WOULD CIRCUMVENT THESE LIMITATIONS

25

TRANSIENT MODELLING
EMPLOYS MATHEMATICAL MODEL OF THE PIPELINE (EQ. OF MASS, MOMENTUM, ENERGY, STATE) PIPELINE MODEL REQUIRES FLOW, PRESSURE, TEMPERATURE, DENSITY ( PROPERTY ) INPUTS PREDICTED VALUES ARE COMPARED WITH FIELD VALUES AND ALARM IS GENERATED IF WEIGHTED DEVIATION EXCEEDS PREDEFINED IMBALANCE LIMITS LEAK LOCATION IS DONE BY FINDING THE BEST LOCATION WHERE THE SIMULATED PIPELINE STATE MATCHES WITH CURRENT STATE

26

TRANSIENT MODELLING (Contd..)

FEATURES

DETECT, LOCATE AND SIZE THE LEAK UNDER STEADY STATE AND EVEN UNDER TRANSIENT CONDITIONS GRADUALLY OCCURING LEAKS CAN BE DETECTED INSTRUMENT DRIFT ANALYSIS, DYNAMIC LINE PACK CALCULATIONS ARE PROVIDED

Note : Transient Modeling enveloping volume balance could additionally provide higher sensitivity for leak detection and would be better suited for pipelines with low pressure gradient

27

BATCH TRACKING MODULE

MONITORS THE TRANSPORTATION OF DIFFERENT BATCHES THROUGH THE PIELINE Dispatch a batch to the pipeline (density variation and together with batch schedule) Determine the batch volume (based on actual flow measurement and by batch interface detection alarm) Monitors the extent of mixing as a function of time along the length of the pipeline Update the position of batch fronts (based on velocity profile generated by the Transient model) Monitors whether the actual batch transportation is taking place in accordance with the batch schedule
(Contd)
28

BATCH TRACKING MODULE

Batch graphic on APPS operator MMI provides overview of different batches in the pipeline and expected arrival time Following alarms are configured on APPS operator MMI Batch is approaching destination Batch has reached destination Batch size exceeds the schedule batch size New batch launched not being identified on the schedule or not in proposed sequence identified by schedule Discrepancy between actual time of batch arrival and expected time of arrival

29

SUPPLEMENTRY MODULES (Contd)

Inventory Analysis

Generates current pipeline inventory information (accounting for the variations in line pack on the basis of pressure, temp. & density profiles) Comparison of inventory and packing rates against minimum & maximum allowable limits to generate alarms for limit violations, thereby facilitating the dispatcher in responding to changes in supply & demand

30

PIPELINE EFFICIENCY
PURPOSE
To detect whether pipeline friction losses in any section have exceeded defined limits

FUNCTION

Calculate actual friction factor based upon flow, pressure measurements at end points of pipeline section and product density profile as generated by product module Pipeline efficiency factor is compared to a predefined limit violation of limit results in an alarm This module gives requirements for carrying out pipeline pigging operation

31

EIL Activities for SCADA and Apps Systems

Conceptual design SCADA design basis Firming up of system configuration and specifications Evaluation and selection of vendors Providing inputs to system design and implementation as a part of functional design specifications [FDS] review for both SCADA and Apps systems Providing engineering inputs, database definition, SCADA I/O list, displays and reports Review of vendors detailed engineering drawings and documents for system implementation and testing Factory and site acceptance and testing of SCADA and Apps

32

EILs Experience Record of SCADA Jobs

Project Name
HBJ Pipeline MGCC Pipeline Maqta-Alain Pipeline PIL Pipeline Nahar-KatyaBarauni P/L Bombay-Pune Pipeline

Client
GAIL IPCL ADNOC (AbuDhabi ) PIL OIL India HPCL

Product
Natural Gas C2/ C3, C3, Lean Gas Natural gas

Length (km)
1700 160 150

Vendor
SSI/ Texas Instruments USA L&N Australia Serck Controls, UK Siemens ABB Norway ECIL/ Texas Instruments USA
33

Ethylene Crude Oil Multi-product

80 1160 165

EILs Experience Record of SCADA Jobs(Contd)

Project Name Client Product Length (km) Vendor

Sajjah-Layyah P/L
MMPL

SEWA (Sharjah)
BPCL

Natural Gas
Multi-Product

80
250

Sparton Controls Canada

Foxboro, Australia Foxboro, Australia Dectra, Malaysia

VVPL JLPL

HPCL GAIL

Multi-Product LPG

350 1200

Maqta-JebelAli P/L
CCKPL

ADNOC

Natural Gas

115

Serck Controls, UK
Neles Automation, Canada Foxboro, Italy
34

Petronet-CCK

Multi-product

290

Hazira-Dahej P/L

IPCL

Rich/ Lean Gas

100

TELECOMMUNICATION SYSTEM FOR CROSS COUNTRY PIPELINES, OFFSHORE PLATFORMS, ETC.

35

FACILITIES PROVIDED
VOICE COMMUNICATION

Subscriber Dialing Facilities Direct dialing facilities between the various attended stations and between each unattended station to the nearest attended station. Conference Facilities To enable selective/all-call connection amongst the attended and unattended stations. Engineering Order Wire (EOW) One or two EOW circuits provided to facilitate maintenance of the system at all attended and all unattended stations. Facsimile communication Facsimile Communication is provided amongst all attended stations.
36

 DATA COMMUNICATION
Dedicated low speed data channels (19.2 Kbps) are configured at all TELECOM stations to enable remote operation, monitoring and shutdown of the pipeline through SCADA System. High Speed (2 Mbps) data channels between SCADA SMCS and SCADA Sub-Master/ Remote workstations High-speed data channel for NMC-NMC Communication Certain identified stations/offices are interlinked with video conferencing/CCTV facility.

Depending on the volume of voice and data transmission, the optimal communication system is selected from amongst a number of cable and wireless systems e.g.
Cable System :- Paired Telephone Cable or Optical Fibre Cable Wireless System: - VHF/UFH/Microwave Communication system/ Satellite Communication system [The system chosen depends on the particular requirements of a project like terrain, number of stations, telecom requirements etc.
37

OPTICAL FIBRE COMMUNICATION SYSTEM

The optical fiber communication system currently being provided for the pipelines are based on Synchronous Digital Hierarchy (SDH) in accordance with ITU-T Rec. G 707. The salient advantages of optical fibre communication system are:

Small overall diameter of the cable leads to efficient space utilization Light weight and flexibility of the cable makes cable-laying easy and comparatively cheap. The dielectric medium of fibre is immune to electromagnetic interference and thus enjoys noise immunity. Silica fibres offer low loss and as such very long repeater spacing can be envisaged leading to lower overall system cost. Very high communication bandwidth. Addition of a new station in existing communication system can be done easily.

38

Electrical Control System

Purpose: Real-time centralised monitoring, metering and control of electric power generation and distribution in an industrial plant

39

Challenges in control of large industrial power system

Generation Side

Multiple sources Extra control activities for operator to optimise generation Operator controls are complex

Distribution Side

Multiple load centres at multiple locations Requires complete network status in real time to be available to operator to allow safe and reliable operation Requires centralised control of distribution switchgear with the help of network overview.

40

Handling of network emergencies

Generation Side

Tripping of captive electric generator Tripping of utility grid connection Tripping of steam generator Reactive power imbalance Load control and Tie line control Voltage & reactive power control Electric load shedding Steam load shedding It is necessary to assign shedding priority to all electric loads and process steam consumers in ascending level of severity to plant process
41

Supply side management

Demand side management

Monitoring and Metering Functions

Centralised electrical plant data acquisition & display

Substation-wise On line status of feeders in SLD pictorials Typical displayed parameters: Voltage, active and reactive power, power factor and frequency in selected cases Typically, data acquired and updated every 2-3 sec. Hourly and shift logs ( or as desired by client) in client specified formats Typical logged parameters: Voltage, power(s), energy consumption, peak power, power factor etc. Log reports can be unit-wise, substation-wise or switchboard-wise as feasible Alarms generated due to abnormalities in field Alarms generated due to abnormalities in any ECS subsystem

Centralised routine log report generation

Centralised real time alarm reporting

Sequence-of-Event reporting (Optional feature)

Time resolution of occurrence : 1 msec typical Selected subset of field inputs (contact type)

It is not possible to achieve the above functions without ECS

42

Basic control functions

Circuit breaker OPEN / CLOSE (excluding motor feeders) Circuit breaker OPEN for motor feeders RAISE / LOWER control for grid transformer OLTC, turbine speed / MW & Generator Excitation These control functions, otherwise distributed at various control interfaces in the plant, are centralised at convenient locations. Software based control functions Load control & tie line control
Generate set points for running turbines Advise run mode selection for generators (Isochronuos/ Droop/ Constant MW modes) Set load sharing between various sources. keeping in view availability of steam and import limit from grid Voltage and reactive power control

Allocates reactive power share of various sources such as utility grid, captive generators, shunt capacitors and synchronous motors. Generate set points (or raise / lower)for excitation of Generators and synchronous motors

43

Software based controls (contd..)

Raise / lower grid transformer OLTC Advise on switching ON / OFF of shunt capacitor banks subject to the constraints to be met to the extent feasible: All machines within capability limits Voltage profile in the network within prescribed limits Grid power factor close to unity Infrequent change of grid transformer OLTC Identify all possible island conditions in distribution network Monitor the network in real time to detect if any of the island conditions have occurred. Estimate the power shortfall in the island. Disconnect some loads connected from this island starting from lowest priority such that power shortfall is eliminated. Matching of power shortfall with quantum of load shed. Accurate. Secondary (slow) load shedding based on under frequency sensing Slow load shedding on grid transformer overload and crossing contract demand limit Steam shedding not implemented in ECS

Electrical Load shedding (Contingency analysis based)

44

APPLICATION SOFTWARE
LEAK DETECTION MODULES

Steady state/ Transient state modeling

Transient Modeling enveloping volume/ mass balance

Shutdown state modeling

Shut in leak detection

BATCH SCHEDULING & TRACKING MODULE OPTIMIZATION MODULES

Pump Optimization Module Compressor Fuel Optimization Module

Predictive Module Planning Module Contingency Analysis Pipeline Efficiency Inventory Analysis
45

SUPPLEMENTARY MODULES

VOLUME BALANCE
BASED ON What goes in must come out! EMPLOYS ACCURATE FLOW MEASUREMENTS AT BOTH ENDS Flow In is RECONCILED WITH Flow Out CONSIDERING PIPELINE INVENTORY TO CALCULATE FLOW IMBALANCE V (Leak) = V (Inlet) - V (Outlet) - V (Change in Inventory) LEAK DETECTION IF FLOW IMBALANCE EXCEEDS PREDEFINED LIMIT

46

VOLUME BALANCE (Contd..)

FEATURES RETROSPECTIVE BETTER SUITED FOR PIPELINES WITH LOW PRESSURE GRADIENT SENSITIVITY FOR LEAK DETECTION IS HIGHER FOR LONG TERM VOLUME BALANCE LIMITATIONS NO INFORMATION ABOUT LEAK LOCATION LONG LEAK DETECTION TIME DEPENDENT ON PIPELINE INSTRUMENTATION ACCURACIES AND DRIFTS DOES NOT PROVIDE DYNAMIC INVENTORY CALCULATIONS
REMARKS : TRANSIENT MODELLING ENVELOPING VOLUME BALANCE WOULD CIRCUMVENT THESE LIMITATIONS
47

TRANSIENT MODELLING
EMPLOYS MATHEMATICAL MODEL OF THE PIPELINE (EQ.
OF MASS, MOMENTUM, ENERGY, STATE)

PIPELINE MODEL REQUIRES FLOW, PRESSURE, TEMPERATURE, DENSITY ( PROPERTY ) INPUTS PREDICTED VALUES ARE COMPARED WITH FIELD VALUES AND LEAK ALERT IS GENERATED IF WEIGHTED DEVIATION REMAINS ABOVE THE PREDEFINED IMBALANCE LIMITS FOR DURATION OF TIME. MULTIPLE LEAK ALERTS ARE INTEGRATED FOR GENERATION OF CONFIRMED LEAK ALARM (PREVENTING FALSE LEAK ALARMS). LEAK LOCATION IS DONE BY FINDING THE BEST LOCATION WHERE THE SIMULATED PIPELINE PRESSURE PROFILE MATCHES WITH TELEMETERED PRESSURE PROFILE
48

TRANSIENT MODELLING (Contd..)

FEATURES

RETROSPECTIVE DETECT, LOCATE AND SIZE THE LEAK UNDER STEADY STATE AND EVEN UNDER TRANSIENT CONDITIONS CAN AUTOMATICALLY ADJUST THE THRESHOLDS/ IMBALANCE LIMITS FOR VARIOUS TRANSIENT CONDITIONS (PUMPS START/ STOP, VALVES OPEN/ CLOSE, PIG TRACKING etc.) TO PREVENT FALSE LEAK ALARMS GRADUALLY OCCURRING LEAKS CAN BE DETECTED INSTRUMENT DRIFT ANALYSIS, DYNAMIC LINE PACK CALCULATIONS ARE PROVIDED
49

BATCH SCHEDULING & TRACKING MODULE

MONITORS THE TRANSPORTATION OF DIFFERENT PRODUCT BATCHES THROUGH THE PIELINE

Dispatch a batch to the pipeline (density variation/ manifold valves openings and together with batch schedule) Determine the batch volume (based on actual flow measurement and by density change) Monitors the extent of mixing as a function of time along the length of the pipeline Update the position of batch fronts (based on velocity profile generated by the Transient model) Monitors whether the actual batch transportation is taking place in accordance with the batch schedule

50

BATCH SCHEDULING & TRACKING MODULE (Contd)

Batch graphic on APPS operator MMI provides overview of different batches in the pipeline and expected arrival time Following alarms are configured on APPS operator MMI

Batch is approaching destination Batch has reached destination Batch size exceeds the schedule batch size New batch launched not being identified on the schedule or not in proposed sequence identified by schedule Discrepancy between actual time of batch arrival and expected time of arrival exceeding the limits

51

OPTIMIZATION MODULES
The economic & efficient operation of the pipeline can be carried out by utilizing optimization modules viz. Pump station optimization module ( e.g. for variable speed drives of pumps) & Compressor fuel optimization module (for natural gas pipelines) Pump station Optimization Module Utilizes the pipeline hydraulics & pump performance module to determine the pump stations operation that will achieve the desired delivery flow rate requirements with the objective function of lowest electrical energy consumption The real time monitoring & control in SCADA can also take care of contingencies arising out of closure of the receipt terminals & tripping of pumps with consequent adjustment of speed set points (pump stations) & flow set points (receipt terminals) to permit continuation of pipeline operation.
52

OPTIMIZATION MODULES (Contd...)

Compressor Fuel Optimization Utilizes the pipeline hydraulics & gas turbine compressor performance module to determine the compressor stations operation that will achieve the desired delivery requirements fulfilling the objectives of : Optimum sharing of compressor power among various compressor stations Optimization of the compressor usage for a particular compressor station by utilizing the lowest fuel consumption

53

SUPPLEMENTRY MODULES
Predictive Module Predicts the future operating conditions of the pipeline based on the current state of the pipeline Warn the operator of impending short term constraint violations and future consequences of continuation of current operating conditions Planning Module Helps the operator to maintain the new operating plans covering the operational aspects of reduction or increase of gas supply & gas delivery requirements, deviation of current state with the forecast state etc. by analyzing different strategies & presenting the feasible ones to the operator
54

SUPPLEMENTRY MODULES (Contd)

Contingency Analysis Keeps the operator informed about the consequences of various upsets in the pipeline operation viz. reduction in supply, shutting down of compressor stations Determining the time for which the normal supplies can be made to the consumers before constraint violation takes place Inventory Analysis Generates current pipeline inventory information (accounting for the variations in line pack on the basis of pressure, temp. & density profiles) Comparison of inventory and packing rates against minimum & maximum allowable limits to generate alarms for limit violations, thereby facilitating the dispatcher in responding to changes in supply & demand

55

PIPELINE EFFICIENCY
PURPOSE To detect whether pipeline friction losses in any section have exceeded defined limits FUNCTION Calculate actual friction factor based upon flow, pressure measurements at end points of pipeline section and product density profile as generated by product module Pipeline efficiency factor is compared to a predefined limit violation of limit results in an alarm This module gives requirements/ guidelines for carrying out pipeline pigging operation

56