Telecommunication, Instrumentation & SCADA Systems in Indian Oil Pipelines

By- Kaushalendra Kumar, DGM (PJ-T&I), PL-HO, Noida

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.

Indian Oil Pipelines

st Ins th Sta tru e a te of me rt nt at ion La te

DA CA S le m s b lia yste Re S
Cross-country Pipelines

D Co e p m en n d m Co s un ab Sy e af tem st icat le ls e m io ai Sys n F s Safe, Efficient & Ecofriendly Pipeline Operations

l ro t

Safety of Personnel Safety of Equipment

More Efficient More Reliable With this, our Pipeline Operations are:With accurate Measurements Less Interrupted

Safer

Indian Oil Pipelines

Indian Oil Pipelines

Indian Oil Pipelines

Telecommunication, Instrumentation & SCADA Systems

PAS

SCADA-MCS

SCADA-SCC

PLC BASED CONTROL SYSTEM

FIELD INSTRUMENTATION

Telecommunication Systems

Telecommunication Systems
For smooth operation of the pipeline, a dedicated communication system with 99.9% (typ.) availability is installed for providing : An Instantaneous Reliable & Continuous exchange of voice & data between pumping/ terminal stations as well as with RCP locations.

Telecommunication Systems
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
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
VHF Communication System Used for communication in a pipeline station / tank farm Base stations and hand held transreceivers available Suitable for short range - typically 2 km to 25 km Low cost Cannot be used for inter station communication in pipelines

Telecommunication Systems
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
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
Communication Systems in pipelinesDual 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.

Typical Optical Fibre Cable Specifications

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

Telecommunication Systems

Telecommunication Equipment
FCBC 48V Battery Bank
Printer PC

D/I MUX

E P A B X

SDH Subscriber Lines

Conference Set

RCP Location- Power Set-up

D.G. SET

CHARGER ROOM

ENGINE ROOM

CHARGER

EQUIPMENT ROOM

A C D B

BATTERY ROOM

SWITCH

FUSE BATTERY

EQPT LOAD DISTRIBUTION BOX

POWER PLANT

Network Management System (NMS

Pictures/ Photographs

OFC Blowing in HDPE Duct

OFC Splicing

Instrumentation

LS

P&I SCHEMATIC FOR ORIGINATING PUMP STATION WITH TANK FARM, BOOSTER AND ENGINE PUMPING UNITS
PS PT PT TT

TANK

BP

METER PROVER TM TM

DPT STR

..

DM

SEP. FILTER

BP

DPT

SUMP PUMP
PI FS

LS LT

PI

SUMP TANK
PI PS PT

S L B
SD SD

PI

PS

PT

MAINLINE PUMPING UNITS

PI PS

PS

PI PS

PI PS

PS

PI

PI

PS

PI PS PI

PS PS

UCP/IFP

UCP/IFP

UCP/IFP

TO NEXT STATION

PT

Control Loop

Our Process Sentinels

FLOW SWITCHES PRESSURE SWITCHES
LEVEL TRANSMITTERS

TEMP. SWITCHES

FLOW METERS

PRESSURE TRANSMITTERS

LEVEL SWITCHES

DENSITY METERS

Our Process Sentinels

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

azardous Area Classification & Protection Standar

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 atmosphereZone 0, Zone 1, Zone 2. In North America, hazardous areas are classified by classes, divisions, and groups.

azardous Area Classification & Protection Standar

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.

azardous Area Classification & Protection Standar

Explosion Protection Methods/ equipment- common types

Flameproof (Ex d)

Increased Safety - (Ex e) Pressurisation (Ex p)

Intrinsically Safe - (Ex i)

azardous Area Classification & Protection Standar 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.
Intrinsically Safe Equipment Safety Barrier Control Equipment Room

Control System
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

Control System
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.

Field Instruments

Field Instruments

Field Instruments

Field Instruments

Field Instruments

SCADA System

SCADA System

SUPERVISORY, CONTROL AND DATA ACQUISITION

SYSTEM

SCADA System
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

SCADA System
Why is a SCADA System required ?
Automated, conditions. regular updates of field

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

SCADA System
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
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

SCADA System
Medium used Transfer Leased Lines
Fiber Optic System

for

Data

Communication

Satellite Communication System Digital Microwave Communication System

Data Connectivity for SCADA

CP UNIT RTU STM LINK DG SET SCADA SYSTEM

Data Connectivity
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.

SCADA System
SCADA SOFTWARE
Applicatio n Software
History Report Management

MMI

Alarm Management

Server/ WorkStation

Configuration

Real-time Data Server

Front End

PLC

SCADA System
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
Man Machine Interface Multiple Windows support. Multiple VDU support. Alarm / Event Processing Central processing of Alarms Event list giving details of events of pipeline / control system Facility of archiving events / alarms

SCADA System
Trend Generation Real time and historical trends Number of trends on a single screen History

Archiving of Alarms / events

Disk backup facility Triggered on timer / event / user action

SCADA System
Reports Daily / Shift reports Automatic report printing facility Export to different file formats for easy information exchange Equipment availability reports Management Information Reports

MMI Screens

By- Kaushalendra Kumar, DGM (PJ-T&I), PL-HO, Noida

Pipeline Application Software

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

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

Pressure Profiling (Upstream Pressure Control) P u

Pressure

P d

Normal Pressure Pressure Profile under Profile development due to leak (dashed lines) Pressure Profile fully developed due to leak
Pipe Length

PRESSURE WAVE METHOD- LEAK CONDITION

PRESSURE WAVE METHOD- LEAK NOTIFICATION

Km details

RESSURE WAVE METHOD Pr. profile during leak generation in line shut down condition

ACTUAL TEST RESULT

Pipeline Application Software

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

Summing Up
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.

Thank You
By- Kaushalendra Kumar, DGM (PJ-T&I), PL-HO, Noida