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 crosscountry 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
Cross-country
Pipelines
Safe, Efficient & Eco-friendly
Pipeline Operations
Safety of Personnel
Safety of Equipment
More Efficient
More Reliable
Less Interrupted
With this,
our Pipeline
Operations are:-
Safer
With accurate
Measurements
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 :
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An Instantaneous
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Reliable &
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Continuous exchange of voice & data
between pumping/ terminal stations as well
as with RCP locations.
Telecommunication Systems
Modes of communication in pipelines
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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
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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 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
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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
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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
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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
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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
Battery
Bank
FCBC
48V
Printer
PC
D/I MUX
E
P
A
B
X
SDH
Conference
Set
Subscriber
Lines
RCP Location- Power Set-up
D.G. SET
E
ENGINE
ROOM
A
C
D
B
CHARGER
ROOM
CHARGER
EQUIPMENT
ROOM
BATTERY
ROOM
SWITCH
FUSE
BATTERY
POWER PLANT
EQPT LOAD
DISTRIBUTION
BOX
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
BP
TANK
DPT
METER
PROVER
TT
DM
..
.
TM
STR
TM
SEP. FILTER
BP
DPT
SUMP PUMP
FS
PI
LT
PI
PS
PT
PI
LS
SUMP
TANK
PI
MAINLINE PUMPING UNITS
PS
S
L
B
SD
PT
SD
PI
PS
PS
UCP/IFP
PI
PI
PS
PS
PS
PI
PI
PS
PS PS
UCP/IFP
Control Loop
PI
PS
UCP/IFP
PI
TO
NEXT STATION
PT
Our Process Sentinels
FLOW SWITCHES
FLOW METERS
PRESSURE
SWITCHES
PRESSURE
TRANSMITTERS
LEVEL
TEMP. SWITCHES
TRANSMITTERS
LEVEL SWITCHES
DENSITY METERS
Our Process Sentinels
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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
Hazardous Area Classification & Protection Standards
• 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
• 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
Explosion Protection Methods/ equipmentcommon types
• Flameproof -
(Ex d)
• Increased Safety - (Ex e)
• Pressurisation -
(Ex p)
• Intrinsically Safe - (Ex i)
Hazardous Area Classification & Protection Standards
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 standby
computer systems.
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 stations/ pump - cum - delivery
stations.
SCADA System
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
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 for Data Transfer
• Leased Lines
• Fiber Optic Communication System
• Satellite Communication System
• Digital
System
Microwave
Communication
Data Connectivity for SCADA
CP UNIT
RTU
STM LINK
DG SET
SCADA SYSTEM
Data Connectivity
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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
MMI
Alarm
Management
Configuration
Application
Software
History
Real-time
Data Server
Report
Management
Front
End
Server/
WorkStation
PLC
SCADA System
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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
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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
Pressure Profiling (Upstream Pressure Control)
Pu
Pressure
Pd
Pipe Length
PRESSURE WAVE METHOD- LEAK CONDITION
PRESSURE WAVE METHOD- LEAK NOTIFICATION
Km details
PRESSURE 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 movement of scrapers and to schedule scraper
receiving operations.
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