Pipeline System Automation and Control -...

Pipeline Engineering Monograph Series

Pipeline System Automation and Control

Mike S. Yoon C. Bruce Warren

Steve Adam

Downloaded From: http://ebooks.asmedigitalcollection.asme.org/pdfaccess.ashx?url=/data/books/802639/ on 04/28/2018 Terms of Use: http://www.asme.org/about-asme/terms-of-use

© 2007 by ASME, Three Park Avenue, New York, NY 10016, USA (www.asme.org)

All rights reserved. Printed in the United States of America. Except as permitted under the United States Copyright Act of 1976, no part of this publication may be reproduced or distributed in any form or by any means, or stored in a database or retrieval system, without the prior written permission of the publisher.

INFORMATION CONTAINED IN THIS WORK HAS BEEN OBTAINED BY THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS FROM SOURCES BELIEVED TO BE RELIABLE. HOWEVER, NEITHER ASME NOR ITS AUTHORS OR EDITORS GUARANTEE THE ACCURACY OR COMPLETENESS OF ANY INFORMATION PUBLISHED IN THIS WORK. NEITHER ASME NOR ITS AUTHORS AND EDITORS SHALL BE RESPONSIBLE FOR ANY ERRORS, OMISSIONS, OR DAMAGES ARISING OUT OF THE USE OF THIS INFORMATION. THE WORK IS PUBLISHED WITH THE UNDERSTANDING THAT ASME AND ITS AUTHORS AND EDITORS ARE SUPPLYING INFORMATION BUT ARE NOT ATTEMPTING TO RENDER ENGINEERING OR OTHER PROFESSIONAL SERVICES. IF SUCH ENGINEERING OR PROFESSIONAL SERVICES ARE REQUIRED, THE ASSISTANCE OF AN APPROPRIATE PROFESSIONAL SHOULD BE SOUGHT.

ASME shall not be responsible for statements or opinions advanced in papers or . . . printed in its publications (B7.1.3). Statement from the Bylaws.

For authorization to photocopy material for internal or personal use under those circumstances not falling within the fair use provisions of the Copyright Act, contact the Copyright Clearance Center (CCC), 222 Rosewood Drive, Danvers, MA 01923, tel: 978-750-8400, www.copyright.com.

Library of Congress Cataloging-in-Publication Data

Yoon, Mike. Pipeline system automation and control / by Mike S. Yoon, C. Bruce Warren, and Steve Adam.

p. cm. Includes bibliographical references. ISBN 978-0-7918-0263-2 1. Pipelines--Automatic control. 2. Supervisory control systems. I. Warren, C. Bruce. II. Adam, Steve, 1970-III. Title.

TJ930.Y66 2007 621.8'672--dc22

2007027259


Table of Contents

Preface to Pipeline Engineering Monograph Series v Preface vii Acknowledgment xi About the Authors xii

Chapter 1 SCADA Systems 1 1.1 Introduction 1

1.2 History 3 1.3 System Architecture 5 1.4 Communications 11 1.5 Data Management 19 1.6 Human Machine Interface (HMI) and Reporting 26 1.7 Alarm Processing 38 1.8 Remote Terminal Unit (RTU) 41 1.9 Security 46 1.10 Corporate Integration 51 1.11 SCADA Project Implementation and Execution 52

Chapter 2 Measurement Systems 62

2.1 Introduction 62 2.2 Measurement System and Characteristics 63 2.3 Flow Measurements 67 2.4 Pressure Measurement 84 2.5 Temperature Measurement 86 2.6 Density Measurement 87 2.7 Chromatograph 88

Chapter 3 Station Automation 90 3.1 Introduction 90 3.2 Design Considerations 90 3.3 Station Control System Architecture 93 3.4 Control Solutions 94 3.5 Interfaces 96 3.6 Common Station Control 97

3.7 Pump Station Control 103 3.8 Compressor Station Control 106 3.9 Meter Station 111 3.10 Storage Operation 119

Chapter 4 Gas Management System 124 4.1 Introduction 124 4.2 Transportation Service 126

iii


4.3 Nomination Management System 129 4.4 Volume Accounting System 133 4.5 Gas Control Applications 157 Chapter 5 Liquid Pipeline Management System 163 5.1 Introduction 163 5.2 Liquid Pipeline Operation 166 5.3 Batch Scheduling System 170 5.4 Volume Accounting System 198 Chapter 6 Applications for Operation 213 6.1 Introduction 213 6.2 Fundamentals of a Real-Time Modeling System 214 6.3 Real-Time Transient Model (RTM) 219 6.4 Applications 223 6.5 Training System 244 6.6 General Requirements 253 6.7 Summary 254 Chapter 7 Pipeline Leak Detection System 257 7.1 Introduction 257 7.2 Pipeline Leaks 258 7.3 Leak Detection System Overview 259 7.4 Computational Pipeline Monitoring Methods 265 7.5 Factors Affecting Performance 302 7.6 Performance Evaluation Methods 306 7.7 Implementation Requirements 310 7.8 User Interface 314 7.9 Operational Considerations and Emergency Responses 319 7.10 Summary 322 Chapter 8 Geographic Information Systems 325 8.1 Introduction 325 8.2 Spatial Data Management 326 8.3 GIS Tools to Support Pipeline Design

and Operations 343 8.4 GIS Support for Regulatory Requirements 366 8.5 Summary: The Central Database Paradigm Shift 372 Appendices 376 Glossary 403 Index 419

iv


Preface to Pipeline Engineering Monograph Series The editorial board of the ASME Pipeline Engineering Monograph series seeks to cover various facets of pipeline engineering. This monograph series puts emphasis on practical applications and current practices in the pipeline industry. Each book is intended to enhance the learning process for pipeline engineering students and to provide authoritative references of current pipeline engineering practices for practicing engineers. Pipeline engineering information is neither readily available from a single source nor covered comprehensively in a single volume. Additionally, many pipeline engineers have acquired their knowledge through on-the-job training together with short courses or seminars. On-the-job training may not be comprehensive and courses or seminars tend to be oriented toward specific functional areas and tasks. The editorial board has tried to compile a comprehensive collection of relevant pipeline engineering information in this series. The books in this monograph series were written to fill the gap between the basic engineering principles learned from the academic world and the solutions that may be applied to practical pipeline engineering problems. The purpose of these books is to show how pipeline engineering concepts and techniques can be applied to solve the problems with which engineers are confronted and to provide them with the knowledge they need in order to make informed decisions. The editorial board has sought to present the material so that practicing engineers and graduate level pipeline engineering students may easily understand it. Although the monograph contains introductory material from a pipeline engineering viewpoint, it is reasonably comprehensive and requires a basic understanding of undergraduate engineering subjects. For example, students or engineers need to have basic knowledge of material corrosion mechanisms in order to understand pipe corrosion. Each book or chapter starts with engineering fundamentals to establish a clear understanding of the engineering principles and theories. These are followed by a discussion of the latest practices in the pipeline industry, and if necessary, new emerging technologies even if they are not as yet widely practiced. Controversial techniques may be identified, but not construed as a recommendation. Examples are included where appropriate to aid the reader in gaining a working knowledge of the material. For a more in-depth treatment of advanced topics, technical papers are included. The monographs in this series may be published in various forms; some in complete text form, some as a collection of key papers published in journals or conference proceedings, or some as a combinations of both. The editorial board plans to publish the following pipeline engineering topics:

• Pipe Material

v


• Pipeline Corrosion • Pipeline Integrity • Pipeline Inspection • Pipeline Risk Management • Pipeline System Automation and Control • Pipeline System Design • Geo-technical Engineering • Pipeline Project Management • Pipeline Codes and Standards

Other topics may be added to the series at the recommendation of the users and at the discretion of the editorial board. The books in this monograph series will be of considerable help to pipeline engineering students and practicing engineers. The editorial board hopes that pipeline engineers can gain expert knowledge and save an immeasurable amount of time through use of these books. Acknowledgments We, on the editorial board, wish to express our sincere gratitude to the authors, editors and reviewers for their great contributions. They managed each volume, wrote technical sections, offered many ideas, and contributed valuable suggestions. Financial support from the Pipeline Systems Division (PSD) of ASME enabled us to create this monograph series, providing the crucial remainder to the time and expenses already incurred by the editors and authors themselves. We are indebted to the organizing and technical committees of the International Pipeline Conferences (IPC), which have provided an excellent forum to share pipeline engineering expertise throughout the international pipeline community. We were fortunate to have the skillful assistance of the publication department of ASME not only to publish this series but also to undertake this non-trivial task. Editorial Board

.

vi


Preface Pipeline System Automation and Control discusses the methods for monitoring and controlling a pipeline system safely and efficiently. Pipeline technologies are advancing rapidly, particularly in the area of automation and control, and pipeline operation engineers and managers have to be familiar with the latest automation technologies to decide whether they are suitable for the requirements of the pipeline system they are overseeing. They should have sufficient knowledge to enable them to make informed decisions on the technical aspects of the proposed system, the selection of contractors and/or suppliers, and the operation of the installed system. This book reviews the various automation technologies and discusses the salient features involved in the design, implementation and operation of pipeline automation with emphasis on centralized automation system. The goal of this book is to provide pipeline automation engineers with a comprehensive understanding, rather than expert knowledge, of pipeline automation, so that they can seek expert advice or consult professional literature. The key role of pipeline companies is to transport the products from various product sources to designated markets safely and in the most economical manner possible. During the past few decades, pipeline systems have grown in size and complexity, driven by business requirements consolidating pipelines in fewer entities and by more interconnections between pipeline systems. At the same time, environmental concerns and safety issues require more sophisticated monitoring and control system. As a consequence, the pipeline operation and commercial transactions have become more complicated, with products being exchanged from one pipeline system to another, either physically or virtually on paper. Also, shippers and producers demand accurate information expediently, particularly information on custody transfer and transportation data. In short, the business cycle is becoming shorter, the number of users are increasing, different users require different information, users are spread-out geographically, and accurate information has to be exchanged at a much faster rate. In the past, a SCADA system was used to monitor and control compressor/ pump and meter stations. The system users were typically the pipeline dispatchers, system engineers, local operators, and maintenance staff. They were located at one or more dispatching centers and local operation centers, requiring limited sets of information. Due to the development of communication and computer technologies, potential users of the automation system have increased significantly, covering both internal and external customers. Now, the internal customers include not only traditional users such as the pipeline dispatchers and special interest groups such as management, accounting and marketing, but also external users such as shippers and producers. To make the matters more complex,

vii


the information requirements of these groups are different from those of the dispatching group. In order to meet these requirements, centralized pipeline monitoring and system automation is necessary. Such an integrated system allows the pipeline company to manage transportation services effectively and to improve its operating efficiency and profitability. At the core of the centralized system is a SCADA system. A centralized SCADA system renders numerous benefits. It enables the pipeline operators to perform operating tasks remotely by providing accurate and real-time information, assists them to monitor product movements accurately, and allows for safe operation of the pipeline system including pump or compressor stations. In addition, the SCADA system can facilitate efficient operation and satisfies the pipeline customers by providing reliable and timely information. In short, the SCADA system can help optimize the pipeline system operation. Through the SCADA system, the pipeline operators can monitor and control the entire pipeline system remotely from a central location. It provides the timely information necessary for the operators to perform their operational duties and allow them to take corrective action to achieve the operating objectives. Chapter 1 discusses the functionality, architecture, communication systems and system capability of SCADA. A SCADA system is the key element to satisfy the integrated and centralized automation requirements. A typical centralized control system consists of various sub-systems, which are monitoring and controlling local stations. Most modern day SCADA systems incorporate the latest instrumentation, computer, and communication technologies, in order to provide the dispatchers and local operators with the capability to make timely responses to constantly changing environments and shipping requirements. It is connected to remote local stations via a communication network. A local control system such as a PLC controls the main systems such as a compressor/pump and/or meter station. These control and monitoring systems are instrumented with appropriate measurement devices. The field instrumentation provides various measurements including pressure, temperature, flow rate or volume, and densities or gas compositions. Remote terminal units (RTU) collect the measured values and send them to the host SCADA system through various communication networks. Reliable communication systems are essential for proper operation of a SCADA system. The communication systems handle both data and voice traffic between the central control center and remote sites. This system can consist of one or a combination of communication media such as telephone networks, fiber optic cables, satellite communication, and radio. Without measuring devices, no automation and control system can work. The key measuring devices are flow meters, pressure and temperature transducers, and a densitometer or chromatograph. Chapter 2 briefly discusses the basics of instrumentation required for automation.

viii


Chapter 3 discusses the local control of compressor/pump stations and meter station. Fundamentally, the differences in control systems between a gas and a liquid pipeline are minimal. The measurement and control equipment are similar, and the control and information requirements are similar. The main differences lie in how the fluid is moved and stored. A compressor station is required for a gas pipeline, whereas a pump station is used for a liquid pipeline. Compressor and pump stations are the most complex facilities in pipeline systems. They include compressor/pump units and drivers, auxiliary equipment, various valves, and the power system. In order to operate such complex machineries, monitoring and controlling equipments are a necessity. Meter stations play an important role in pipeline operations, because custody transfer and billings are based on volume measurements. Each meter station contains a meter run with measuring devices, including auxiliary equipment and valves, from which the flow computer or RTU determines the corrected volumes. Most stations are in remote locations, so they are often unmanned in order to operate the pipeline system as economically as possible. Normally, the SCADA measurement system provides real-time measured data and their historical trends. In order for pipeline companies to charge for their transportation services, a computerized volume accounting system is required for custody transfer and billing purposes. The accounting system provides improved measurement accuracy with audit trails, immediate availability of custody transfer volumes, and enhanced security and flexible reporting capability. Since the measurement and accounting of gas and liquid are processed differently, they are addressed in separate chapters; gas accounting in Chapter 4 and liquid accounting including batch operation in Chapter 5. Petroleum liquid pipelines are designed and operated in batch modes to transport multiple products in a single pipeline system. Transportation of multiple products along a batch pipeline system requires batch scheduling and unique operations. In addition to batch volume accounting, Chapter 5 discusses automation issues related to batch operation such nomination, scheduling and batch tracking. The field instrumentation, station control system and host SCADA are the basic components of an automated pipeline system. Chapters 1 to 3 of this book deal with the basic automation system components to meet the minimum but critical requirements for safe pipeline operations. In order to improve operating efficiency, however, several advanced applications are utilized. Chapter 6 introduces these applications, which include a pipeline modeling system with the capability of detecting abnormal operating conditions and tracking various quantities, automated energy optimization with unit selection capability, computerized batch tracking, and station performance monitoring functions. Also, this chapter briefly addresses operator training functional requirements and system architecture. The real-time monitoring capability has been extended to detect abnormal

ix


conditions such as leaks. API 1130 discusses the computational pipeline monitoring (CPM) methodologies and addresses implementation and operation issues. Since all the CPM methodologies are based on the data received from a host SCADA system, they are included in this book as part of pipeline automation and discussed in Chapter 7. This chapter describes the nature and consequences of pipeline leaks and various leak detection techniques with an emphasis on the CPM methodologies. It details the CPM techniques and their limitations, their design and implementation including performance evaluation, system testing, and operational considerations and emergency responses. In addition to the CPM methodologies, Appendix 3 discusses other leak detection methods based on inspection tools such as magnetic flux or sensing devices such as acoustic sensor. It introduces emerging technologies using an artificial intelligence or fiber optic cables. Pipeline companies have started to employ geographical information systems (GIS) for their pipeline system engineering, construction, and operations. The U.S. National Pipeline Mapping System Initiative requires pipeline companies to submit the location and selected attributes of their system in a GIS compatible format. (National Pipeline Mapping System, Pipeline Safety and Hazardous Materials Administration (PSHMA), DOT, Washington D.C., U.S.A.) It uses a database that is referenced to physical locations and provides the analysis and query capability with detailed visual displays of the data. GIS capability has helped pipeline companies engineer pipelines, enhance safety, improve operations, and address emergency situations efficiently. Chapter 8 covers the fundamental concepts of GIS and spatial data management, change management, GIS tools for design and operations, web-based services, and regulatory considerations. The chapter closes with a discussion on the growing use of centralized databases for pipeline facility data management.

x


Acknowledgment The authors are greatly indebted to the Executives of the Pipeline Systems Division (PSD) of ASME International for their encouragement to write this book as part of the Pipeline Engineering Monograph series. We thank the organizing and technical committees of the International Pipeline Conferences (IPC), which have provided an excellent forum to share pipeline engineering expertise throughout the international pipeline community. We were fortunate to have the skillful assistance of the publication department of ASME International not only to publish this series but also to undertake this non-trivial task. Many people and companies were very helpful in shaping the content and style of this book. We thank the following people for their suggestions and reviews as well as providing valuable information and displays; Kevin Hempel, Doug Robertson, Brett Christie, and Ross Mactaggart of CriticalControl Energy Services Inc; Guenter Wagner, Heribert Sheerer and Martin Altoff of LIWACOM Informationstechnik; Warren Shockey of Enbridge Inc.; Jack Blair, formerly of TransCanada Pipelines Ltd.; Ian Clarke of Quintessential Computing Services Inc.; Jim Enarson, an independent consultant; and Shelly Mercer of Colt WorleyParsons for the book cover design. We are greatly indebted to Robin Warren for her assistance in the final editing of the manuscript. The authors acknowledge Larry Stack, Jason Konoff, Bill Morrow and others at Telvent for their contribution to this publication. Mike Yoon is deeply indebted to Alykhan Mamdani and Don Shaw of CriticalControl Energy Services Inc. for providing him with office space, displays and secretarial services and to Guenter Wagner of LIWACOM for providing him with office space and displays. The GIS chapter authored by Steve Adam is co-authored by Barbara Ball and David Parker. The authors would like to acknowledge their colleagues at Colt Geomatics for their contributions to this chapter. The section on Spatial Data Management was built on contributions by Cathy Ha, Michael Jin, Scott MacKenzie, Maria Barabas, and Kevin Jacquard. Assistance on the GIS Tools section was provided by Aaron Ho, Dan Hoang, Craig Sheridan, Jocelyn Eby, Scott Neurauter, Yan Wong, Sabrina Szeto and Robin Robbins. The glossary was meticulously compiled by Yan Wong. Finally, we want to dedicate this book to our wives and families for supporting our efforts and putting up with us through yet another project.

xi


About the Authors

Mike S. Yoon, Ph.D., has served several pipeline companies as an engineering specialist, manager, consultant and/or teacher. Over the past 32 years, he worked in various pipeline system design and project management as well as in management of automation system suppliers. He published several papers including a report on leak detection technologies. He served as Co-Chairman of the International Pipeline Conference (IPC), Chairman of Pipeline Systems Division (PSD) of ASME, and currently serves as Editor-in-Chief of the ASME Pipeline Engineering Monograph series. C. Bruce Warren, B.S. and P. Eng., graduated from University of Saskatchewan. Over the past 11 years, he served as private technology management consultant providing strategic planning and project management services. Previously, he worked in various design, commissioning and maintenance of control systems for electrical generating and pipeline facilities as well as in management roles for pipeline application software supplier for more than 20 years. Steve Adam has spent most of his career applying geomatics and GIS technologies to hydrocarbon and environmental engineering. He has published scientific papers, articles, and book chapters on topics ranging from using satellite imagery for UN peacekeeping to financial analysis of leveraging GIS on pipeline projects. His current focus is to innovate engineering processes using GIS technology. Steve holds a Ph.D. in environmental engineering and is the Manager of Geomatics Engineering with Colt WorleyParsons (Canada).

xii


Pipeline System Automation and Control -...

Documents

Transcript of Pipeline System Automation and Control -...