SCADA & APPS

Cross Country Petroleum Pipelines SCADA & APPS

SCADA & APPS

SCADA

To ensure effective and reliable control, management and supervision of the pipeline, the
entire pipeline network is monitored and controlled by a Supervisory Control and Data
Acquisition (SCADA) system.

The SCADA system is a computer based system for gathering and analyzing real
time data. SCADA system monitors & controls the pipeline facilities in a timely manner
and provides centralized alarm & event management and operation & management
reports for all distributed pipeline facilities. A dedicated Optical Fibre Cable
telecommunication system is provided as a medium for SCADA data communication.

OBJECTIVES OF A SCADA SYSTEM

To monitor & control the pipeline facilities viz. Pump Stations, Despatch &
receiving terminals, pigging/ SV/ CP stations etc. in a timely manner.

Alarm & event management and operation & management reports for all the
distributed pipeline facilities.

To ensure proper pipeline shutdown by closing various pipeline facilities in

orderly manner as per desired sequence.

Provide remote-eye to the pipeline operation.

To facilitate running of APPS (APPlication Software) packages viz. Leak

detection & location, batch scheduling & tracking supplementary application
modules.

DESIRED FUNCTIONALITIES OF SCADA SYSTEM

Monitoring
Control
Alarm & event detection
Man-machine interface
Trending
Report generation
Data archiving
Communication Handling & error recovery

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Database configuration & engineering functions

System maintenance & security
Integration with application software

SYSTEM HARDWARE COMPONENTS

SCADA System is designed with the distributed architecture in following key areas:
Computer Servers/ Workstations
o Separate server & MMI (Man Machine Interface) machines for SCADA
system with client server concept implemented at hardware & software
level
o Integrated server & MMI (Man Machine Interface)machine for APPS
system with client server concept implemented at software level
Remote Workstations (RWS)
Terminal Servers & LAN Service Units (LSUs)
Remote Telemetry Units (RTUs)
WAN (Wide Area Network) Routers

SCADA MASTER CONTROL STATION (SMCS)

The SCADA Master Control Station consists of SCADA servers (host systems), operator
consoles, communication equipment and network equipment.

The associated RTUs communicate through the fiber-optic transmission / communication

interface equipment. The SCADA system will have various levels of automation and
communication networks including:

Peer-to-peer monitoring and control between local RTUs and local control
systems
Information availability for real-time applications such as daily and hourly reports
Data availability for the central data management system for corporate networks
Gateway to other controls such Programmable Logic Controller (PLC) systems
Terminals Signals Interfacing

REMOTE WORKSTATIONS

Remote Workstations are interlinked with SMCS. RWS with colour VDUs and printers
are provided to provide complete SCADA MMI capability (displays, graphics & reports)
so that the operators at these locations are fully informed of:

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o All the monitoring variables in the pipeline

o Status of various pipeline equipments
o Alarms for the complete pipeline facilities
o Alarm acknowledgement & controls only permitted under proper identification,
authorization & password control

Gateway to PLC system at RWS is provided in the SCADA system. Terminals Signals
Interfacing is provided for signals from the Terminals.

REMOTE TELEMETRY UNIT (RTU)

In SCADA systems, an RTU is a device installed at a remote location that collects data,
codes the data into a format that is transmittable and transmits the data back to a central
station or MCS. An RTU also collects information from the master device and
implements processes that are directed by the master. RTUs are equipped with input
channels for sensing or metering, output channels for control, indication or alarms and a
communications port.
The pipeline facilities for which SCADA RTUs are provided include:
Despatch terminal The despatch terminal is the start of the pipeline system.
Sectionalising Valve Stations These stations consist of pipeline sectionalising valves
at 30 to 35 kms along the pipeline (to isolate the pipeline in case of accidents) and a
secondary pipe system (bypass) designed to balance pressures when reopening the valve.
Scraper trap stations These stations have a scraper (for pipeline cleaning through a
pig cleaner) launcher and receiver, valve assemblies, and piping.
Pumping stations These stations are essentially composed of large pumps, power
supply drivers, valve and piping assemblies, field flow pressure and temperature
instrumentation, scraper launching and receiving traps, and metering system.
Cathodic protection stationsThese stations should maintain the potential of the
pipeline with respect to the ground at a value below 0.85 volts to protect against
corrosion.
Receiving terminal This terminal is the end of the pipeline.

All the RTUs are interlinked with the SMCS.

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SCADA & APPS SYSTEM ARCHITECTURE

Master Station
SCADA
Man Machine Interface
To Alternate Polling Station
WAN SCADA
SCADAServers
Servers APPS Server/ MMI
WAN System System
Routers
Routers System
Telecom Network
High Speed / Ethernet
Dual
DualLocal
LocalArea
Areanetwork
network
Remote
Remote
Workstations
Workstations Terminal Servers & LSUs To Alternate
polling Station

Data channels as part of Telecom Network

RTU 1 RTU 2 RTU 3 RTU

RTUnn

PLC/ I&ES for SV/ I&ES for IP PLC/ I&ES

PLC/ I&ES
I&ESfor
forDT/
DT/ PLC/ I&ESfor
forReceipt
Receipt
FC CP/ RP station FC Terminal
FC Pump Station
Pump Station FC Terminal
station
I&ES:Instrumentation & Electrical System

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TYPICAL SCADA MASTER CONTROL STATION (SMCS) AT START TERMINAL

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APPLICATION SOFTWARE (APPS)

OBJECTIVES OF APPS

Leak detection and location in all conditions

Batch Scheduling and Batch Tracking
Stock accounting to assess customer wise, batch wise & product wise stock
reconciliation (stock loss/gain and variation) statement and transportation
invoice generation right from order to execution stage
PIG Launch/Receipt and Tracking of PIG.

APPS MODULES

Application Software (APPS) package generally contains following modules:

Leak Detection Modules

Steady state/ transient state modeling
Transient modeling enveloping volume balance
Shutdown state modeling
Shut in leak detection

Batch tracking & scheduling module

Supplementary modules
Inventory analysis
Pipeline transportation efficiency
Pipeline integrity function
Scrapper tracking
Instrument monitoring function

LEAK DETECTION BY VOLUME BALANCE METHOD

Volume Balance method of Leak Detection is based on the principle What goes
in must come out!
Requires 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 is if flow imbalance exceeds predefined limit

FEATURES

Retrospective
Better suited for pipelines with low pressure gradient

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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

LEAK DETECTION BY TRANSIENT MODELLING ENVELOPING VOLUME

BALANCE METHOD

To overcome the above limitations, Transient Modelling Enveloping Volume Balance

method is employed. Leak Detection Module based on Transient Modeling enveloping
volume balance provides higher sensitivity for leak detection and would have
mechanisms and safeguards to prevent false leak alarms. This method

Employs mathematical model of the pipeline (equation 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

FEATURES

Retrospective
Detects, locates and sizes the leak under steady state and even under transient
conditions
Gradually occurring leaks can be detected
Instrument drift analysis, dynamic line pack calculations are provided

LEAK DETECTION MODULE PERFORMANCE INDICES

Properly configured & tuned leak detection module provides best compromise of
Reliability, Sensitivity, Accuracy & Robustness

Reliability: Measure of leak detection system to render accurate decisions about

occurrence of leak in the pipeline while operating within operational envelope for which
it is designed.

Sensitivity: Measure of size of leak that the system can detect and the time required to
issue an alarm when leak of that size occurs.

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Accuracy: Measure of error in the estimate of leak location

Robustness: Measure of the size of the operational envelope and the system ability to
continue to function when data is lost or suspect, for changing conditions of the pipeline.

System that limit alarm generation in response to certain conditions of pipeline, data
communication are not necessarily less reliable but would be considered less robust.
Reliability depends upon settings of thresholds and leak detection technique. Accuracy
depends upon leak detection technique. Sensitivity can be varied easily by adjusting
thresholds and system parameters with consequent effect on response time & false alarm
rate.

LEAK DETECTION SAFEGUARD MECHANISMS

Perform data validation in each execution cycle to filter out bad data & use previous
good/ default data.
Model tuning & adjustment to minimize non-zero discrepancies resulting from causes
other than leaks and accuracy of leak detection depends on Repeatability of
measurements.
Instrument monitoring with drift analysis function as part of model execution together
with data validation prevent false leak alarms upon instrument failures, errors,
calibration data.
The system to accurately track the pressure transients caused by pump start/ stop,
valves open/ close, operational setpoints changes, pigging operation without causing
false alarm and inhibiting sensitivity to leaks.
Leak detection thresholds to be properly determined taking into account instrument
characteristics, bit resolution errors, modeling errors, product & pipeline
characteristics.
Leak detection to be integrated with batch tracking facilitating impact on density
profile due to multi-products and pressure & temperature on pipe & Multiproduct to
be taken into account in dynamic inventory calculations.
System to use several thresholds & averaging times and sufficient time to be given for
development of leak responses ruling out the possibility of factors other than leak to
be used for leak detection algorithm.
Such Multiple leak responses to be integrated through appropriate weightage factors
for generation of confirmed leak alarm.

BATCH TRACKING MODULE

Batch tracking module monitors the transportation of different batches through the
pipeline. The batch tracking module will have following features:

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Batch Tracking & Scheduling for multiple products HSD, SKO, MS etc.
Determination of the batch volume (based on actual flow measurement and by
batch interface detection alarm)
Monitoring the extent of interface mixing as a function of time along the length of
the pipeline
Updating the position of batch fronts (based on velocity profile generated by the
Transient model)
Monitoring whether the actual batch transportation is taking place in accordance
with the batch schedule
Batch graphic on APPS operator MMI provides overview of different batches in
the pipeline through different colours for each product with Batch ID, Dispatch
time, batch volume, scheduled volume, batch position, length, batch volume
received, expected arrival time & actual arrival time

SUPPLEMENTARY MODULES

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

Pipeline transportation efficiency

To detect whether pipeline friction losses in any section have exceeded defined
limits:
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

Pipeline Integrity

To indicate locations of possible overpressures and under pressure conditions

in the pipeline by superimposing modeled pressure profiles on the maximum
allowable operating pressures and min. allowable operating pressures

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Instrument Monitoring function

Instrument drift analysis and preparation of maintenance schedule identifying
instruments which have been drifted to facilitate improving pipeline
operations.
Maintenance schedule identifying instruments for which periodic scheduled
maintenance is due.

Scrapper Tracking function

To track the functions of launching scrapper, movements & recovery of

scrappers in the pipeline.

Stock Accounting

Customer wise, batch wise & product wise stock reconciliation statement and
transportation invoice generation.

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