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By- Kaushalendra Kumar, DGM (PJ-T&I), PL-HO, Noida Telecommunication, Instrumentation & SCADA Systems in Indian Oil Pipelines Slide 2 Indian Oil Pipelines Indian Oil has a network of over 10000 KM cross- country pipelines throughout the country. Instrumentation Control Systems, SCADA Systems & Telecommunication Systems have a vital role to play in the safe and efficient operations of its cross country pipelines for in time and on-spec delivery of crude oil and petroleum products. Slide 3 Cross-country Pipelines Pipelines Safe, Efficient & Eco-friendly Pipeline Operations Safety of Personnel Safety of Equipment Latest State of the art Instrumentation Reliable SCADA Systems Failsafe Control Systems Dependable Communication Systems Indian Oil Pipelines Slide 4 More Reliable Less Interrupted Safer With accurate Measurements More Efficient With this, our Pipeline Operations are:- Indian Oil Pipelines Slide 5 Slide 6 Slide 7 PAS SCADA-MCS SCADA-SCC PLC BASED CONTROL SYSTEM FIELD INSTRUMENTATION Telecommunication, Instrumentation & SCADA Systems Slide 8 Telecommunication Systems Slide 9 An Instantaneous Reliable & Continuous exchange of voice & data between pumping/ terminal stations as well as with RCP locations. For smooth operation of the pipeline, a dedicated communication system with 99.9% (typ.) availability is installed for providing : Telecommunication Systems Slide 10 Modes of communication in pipelines H.F. Communication system V.H.F. Communication system Public leased circuits on hire Line of Sight Communication system Optical fiber Communication system Satellite Communication system Telecommunication Systems Slide 11 HF Communication System A back-up communication system Very high range up to 1500 km Low cost Only simplex or half duplex possible Requirement of separate frequency for day & night Now phased out in pipelines Telecommunication Systems Slide 12 VHF Communication System Used for communication in a pipeline station / tank farm Base stations and hand held trans-receivers available Suitable for short range - typically 2 km to 25 km Low cost Cannot be used for inter station communication in pipelines Telecommunication Systems Slide 13 Line of Sight Communication Duplex communication Supports voice, data, fax, computer networking and SCADA systems Comparable cost with other modes Obtaining clearances / licenses is time consuming Very high towers up to 100 M Maintenance of tower requires specially skilled manpower Telecommunication Systems Slide 14 Optical Fiber Communication Works by sending signals down hair thin strands of glass fiber. Has incredibly high transmission capacity i.e. bandwidth. Immune to Noise. Freedom from Cross talk. Telecommunication Systems Slide 15 Communication Systems in pipelines- Dual redundant hot standby SDH based systems (up to STM-16, 2.5Gbps backbone links). Equipped with Network Management System (NMS) at a central location for monitoring, control & configuration of communication equipment installed at different locations. Optical Fibre Cable Network (12/ 24 Fibre un-armoured cable, ITU-T G.652D, G.655 single mode fibre). Short haul (40-45 km) & long haul (100-140 km) hops. Telecommunication Systems Slide 16 Overall Cable diameter : 13 14 mm Wavelengths used: 1310 nm/ 1550 nm Attenuation @ 1310 nm : 0.36 dB/km Attenuation @ 1550 nm : 0.23 dB/km Typical Optical Fibre Cable Specifications Slide 17 Telecommunication Systems Slide 18 SDH D/I MUX EPABXEPABX Conference Set Subscriber Lines FCBC 48V Battery Bank PC Printer Telecommunication Equipment Slide 19 E ACDBACDB CHARGER SWITCH EQPT LOAD DISTRIBUTION BOX EQUIPMENT ROOM FUSE BATTERY ENGINE ROOM D.G. SET BATTERY ROOM CHARGER ROOM POWER PLANT RCP Location- Power Set-up Slide 20 Network Management System (NMS) Slide 21 Pictures/ Photographs Slide 22 Slide 23 OFC Blowing in HDPE Duct Slide 24 OFC Splicing Slide 25 Instrumentation Slide 26 Slide 27 PTPS DPT. SEP. FILTER STR. DPT. DM PTTT TM MAINLINE PUMPING UNITS PI PS PI PS PI PS PI PS PIPSPT METER PROVER S L B TO NEXT STATION PI BP SD PI PT SUMP TANK SUMP PUMP LS LT FS PI P&I SCHEMATIC FOR ORIGINATING PUMP STATION WITH TANK FARM, BOOSTER AND ENGINE PUMPING UNITS TANK LS PS PI PS PI PS UCP/IFP PIPSPT Control Loop Slide 28 PRESSURE SWITCHES LEVEL SWITCHES FLOW SWITCHES TEMP. SWITCHES FLOW METERS LEVEL TRANSMITTERS PRESSURE TRANSMITTERS DENSITY METERS Our Process Sentinels Slide 29 Pressure Indicators Pressure Switches Pressure Transmitters Flow Meters/ Flow Computers Meter Prover Temperature Transmitter Temperature Indicator Level Switches Flow Switches Density Meters Control Valve Tank Gauging System Emergency Shutdown System Our Process Sentinels Slide 30 Hazardous environments exist in oil refineries, pipeline installations, offshore platforms, chemical plants, mines etc. Electrical equipment must be suitable for the environment in which they are to be used. Hazardous areas are classified with respect to the potential danger of explosion and the areas are divided into zones according to the probability of the hazardous atmosphere- Zone 0, Zone 1, Zone 2. In North America, hazardous areas are classified by classes, divisions, and groups. Hazardous Area Classification & Protection Standards Slide 31 Instruments, Equipments in pipeline installations are deployed keeping in view the hazardous area classification. Protections like Flameproof-Explosion proof, Intrinsic Safety and Ingress Protection are ensured while selection of instruments & equipments. Each chemical gas or vapour used in industry is classified into a gas group. Also, to ensure that there is no risk of ignition due to hot surfaces, the equipments/ instruments are classified with regard to the maximum surface temperature of any part of the equipment. Hazardous Area Classification & Protection Standards Slide 32 Explosion Protection Methods/ equipment- common types Flameproof - (Ex d) Increased Safety - (Ex e) Pressurisation - (Ex p) Intrinsically Safe - (Ex i) Hazardous Area Classification & Protection Standards Slide 33 Intrinsically Safe EquipmentSafety Barrier Control Equipment Room In case of Intrinsic Safety, the system is designed using safety barriers so that the electrical or thermal energy of a particular instrument loop can never be great enough to cause ignition. Slide 34 Station Control Centre Designed to provide effective & efficient monitoring, safe operation and control of local station and scraper station/ block valves under its control. Acquires data from local PLC and scraper station/ block valves under its control in real time and transmits the same to MCC. Configured with dual redundant hot standby computer systems. Control System Slide 35 Programmable Logic Controllers (PLCs) are installed at attended stations/ scraper stations for interfacing the field devices. Remote Terminal Units (RTUs) are installed at unattended block valve stations for interfacing the field devices. Control System Slide 36 Slide 37 Field Instruments Slide 38 Slide 39 Slide 40 Slide 41 Slide 42 SCADA System Slide 43 SUPERVISORY, CONTROL AND DATA ACQUISITION SYSTEM SCADA System Slide 44 Petroleum Pipeline SCADA networks Dedicated SCADA system is installed to provide effective and efficient monitoring and control of the entire pipeline from Master Control Station (MCS). SCADA system has a MCS and Station Control Centres (SCCs) at attended stations viz. pump stations/ delivery stations/ pump - cum - delivery stations. SCADA System Slide 45 Why is a SCADA System required ? Automated, regular updates of field conditions. Consolidation of information from multiple sources in a single, convenient location. Ability to share process information among multiple spheres of influence Easy to visualize current status of overall system. SCADA System Slide 46 Why is a SCADA System required?.. Automatic alerting of abnormal field circumstances. Ability to directly & immediately respond to abnormal field circumstances through remote control. Maintenance of consistent, accessible archival records. SCADA System Slide 47 Master Control Station (MCS) Designed to provide effective & efficient monitoring, safe operation and control of SCCs/ RTUs for entire pipeline. Configured with dual redundant hot standby computer systems. Adopts distributed architecture using intelligent units; all interconnected through a redundant local area network. SCADA System Slide 48 Slide 49 Medium used for Data Transfer Leased Lines Fiber Optic Communication System Satellite Communication System Digital Microwave Communication System SCADA System Slide 50 RTU STM LINK DG SET CP UNIT SCADA SYSTEM Data Connectivity for SCADA Slide 51 Apart from providing voice & SCADA data connectivity, the Ethernet Channels of communication network are utilised for: Extending SAP Connectivity Extending LAN of Base Stations to other stations for e-mail services Remote viewing of CCTV Cameras Other applications e.g. connectivity to fire alarm system at RCP locations etc. Data Connectivity Slide 52 Slide 53 Real-time Data Server Front End Alarm Management Report Management Configuration History MMI PLC Server/ WorkStation SCADA SOFTWARE SCADA System Application Software Slide 54 Major functions of SCADA system - Data acquisition Man machine Interface Alarm & Event processing Control processing/ commands Trend generation Shift / Daily Reports Management Information Reports SCADA System Slide 55 Man Machine Interface Multiple Windows support. Multiple VDU support. SCADA System Central processing of Alarms Event list giving details of events of pipeline / control system Facility of archiving events / alarms Alarm / Event Processing Slide 56 Real time and historical trends Number of trends on a single screen Trend Generation SCADA System History Archiving of Alarms / events Disk backup facility Triggered on timer / event / user action Slide 57 Reports Daily / Shift reports Automatic report printing facility Export to different file formats for easy information exchange Equipment availability reports Management Information Reports SCADA System Slide 58 Slide 59 MMI Screens Slide 60 Slide 61 Slide 62 By- Kaushalendra Kumar, DGM (PJ-T&I), PL-HO, Noida Slide 63 Slide 64 Slide 65 Slide 66 Slide 67 All our cross-country pipelines are equipped with Pipeline Application Software comprising Leak Detection, Batch Tracking, and Scraper tracking etc. modules. These are based on real-time Hydraulic Simulation Model driven by Instrumentation from the pipeline, data being sourced through SCADA System. The leak detection system has a crucial role to play in the safe and environment friendly pipeline operations. Pipeline Application Software Slide 68 Leak Detection (Pressure-Flow deviation) Detects occurrence of leak and gives estimate of volume, based on differences between the data produced from the Real time model and SCADA measurements. Leak Detection (Volume Balance) Detects occurrence of a leak and gives estimate of volume based upon Mass/ Volume balance. Mass/ Volume In = Mass/ Volume Out : No Leak Mass/ Volume In > Mass/ Volume Out : Leak Pipeline Application Software Slide 69 Pressure Profiling (Upstream Pressure Control) Pu Pd Pressure Profile under development due to leak (dashed lines) Normal Pressure Profile Pressure Profile fully developed due to leak Pressure Pipe Length Slide 70 PRESSURE WAVE METHOD- LEAK CONDITION Slide 71 PRESSURE WAVE METHOD- LEAK NOTIFICATION Km details Slide 72 PRESSURE WAVE METHOD Pr. profile during leak generation in line shut down condition Slide 73 ACTUAL TEST RESULT Slide 74 Batch Tracking Batch Tracking is done by tracking the movement of a known mass of the product in a pipeline. Time when a batch is introduced in the pipeline goes as basic input to the system. Depending upon the flow rate and density of the product at various points, the movement of the product in the pipeline is calculated. Scraper Tracking Scraper Tracking model calculates the position of scrapers in the pipeline. It estimates the arrival time of scraper at the receiving station. It is used to monitor the movement of scrapers and to schedule scraper receiving operations. Pipeline Application Software Slide 75 Slide 76 Slide 77 Accurate, repeatable and reliable safety instruments and measurements are vital for efficient, more reliable, less interrupted & safer operation of pipelines. The rapid and revolutionary changes in the field of Information Technology (IT) have resulted in a great impact on Instrumentation & Process Control. It has always been our endeavor to update the Safety Instrumentation, SCADA & Telecommunication System of our pipelines with latest state of the art technology. Summing Up Slide 78 By- Kaushalendra Kumar, DGM (PJ-T&I), PL-HO, Noida Thank You