IMPLEMENTATION OF
SCADA IN GAS
PIPELINE
BY
IWUNZE
NWABUEZE
PIPELINE OPERATIONS THROUGH SCADA
ABSTRACT
Gas distribution and management has always been
a problem to many countries. Poor infrastructure
and inefficient management of gas supply result
in inconvenience and unsatisfied customers due to
insufficient supply of gas to different places across
the state at right time, thus increasing cost of
supply. So, in order to overcome these challenge,
we need to design or introduce improvements to an
existing system architecture that operate on real
time data communicated from remote places to
central or main control centre. For this purpose
SCADA systems will be used
PIPELINE OPERATIONS THROUGH SCADA
SCADA
Importance of SCADA system
To provide effective & efficient monitoring
and control of entire pipeline network.
Remote
control
of
important
station
equipment, process set points & block valves
from MCC. shutdown of entire pipeline from
Emergency
MCC.
Acquisition & display of pipeline parameters,
alarms from attended stations, scraper
stations, C.P. Stations & block valves at MCC.
Coordinate security measures with process
operation
Provides immediate knowledge of system
performance.
PIPELINE OPERATIONS THROUGH SCADA
SCADA
Scope
In this research we will design a Supervisory Control
and Data Acquisition (SCADA) system for managing,
monitoring and controlling the gas pipeline stations.
The SCADA Systems should be able to monitor and
measure a variety of pipeline data including flows,
motor currents, temperatures, water levels,
voltages, and pressures. Alarms at central or
remote sites triggered by any abnormal conditions
are propagated to the HMI computer for operator's
attention.
PIPELINE OPERATIONS THROUGH SCADA
SCADA
Objective
The main objective of the thesis is for easy control
and monitor of processes on how gas is safely
distributed. So, in order to overcome problems
caused due to poor infrastructure of gas supply
system, we need to design or introduce
improvements that operate on real time data
communicated from remote places to central or main
control center. For this purpose SCADA systems are
used.
PIPELINE OPERATIONS THROUGH SCADA
SCADA
Problem Statement
Poor control and monitoring or inefficient
management of gas supply result in inconvenience
and unsatisfied customers due to insufficient supply of
gas to different places across the state at right
time, increasing cost of supply.
PIPELINE OPERATIONS THROUGH SCADA
SCADA
Problem Statement
There are six chapters in this thesis. Chapter1
provides introduction. Chapter 2 discusses the
literature review of past related work. Chapter 3
includes description of the SCADA system and its
components and architectures. Chapter 4 presents
description, analysis and upgrade to gas pipeline.
Chapter 5 presents the communication system design
for remote stations. Finally, in chapter 6, conclusions
and suggestions for future work are given.
PIPELINE OPERATIONS THROUGH SCADA
LITERATURE REVIEW
Report Organization
First generation: "Monolithic
First generation SCADA systems were developed as "turn key" operations that
ran on minicomputer and are independent systems with no connectivity to
other systems. The communication protocols used were strictly proprietary at
that time
Second generation: "Distributed"
SCADA information and command processing was distributed across multiple
stations which were connected through a LAN and are shared in real time. The
network protocols used were still not standardized and are proprietary.
Third generation: "Networked"
Several distributed architecture SCADAs running in parallel, with a single
supervisor and historian, could be considered a network architecture. This
allows for a more cost effective solution in very large scale systems.
PIPELINE OPERATIONS THROUGH SCADA
LITERATURE REVIEW
Report Organization
Fourth generation: "Internet of Things"
SCADA stands for Supervisory Control and Data Acquisition. As the
name indicates, it is not a full control system, but rather focuses on the
supervisory level. It is a software package installed on networked
computing platforms, like personal computers (PCs) or small
dedicated devices which are hardened for industrial environments.
SCADA provides a high level layer on top of the Programmable Logic
Controllers (PLCs) layer which is positioned over the plant hardware
devices.
Supervisory control first evolved in electric utility systems
PIPELINE OPERATIONS THROUGH SCADA
LITERATURE REVIEW
Report Organization
Application of the SCADA System in Waste water
Treatment Plants : This has a positive impact on the
operations, maintenance, process improvement and
savings for city Wastewater Operations. The application
discusses the system's evolvement, the external/internal
architecture, and the human-machine-interface graphical
design. The system also successes in monitoring the city
sewage and sludge collection/distribution systems, wetweather facilities and wastewater treatment plants,
complying to the standard requirements on the discharge,
and effectively reducing the operations and maintenance
costs.
PIPELINE OPERATIONS THROUGH SCADA
LITERATURE REVIEW
Report Organization
Application of the SCADA System in Waste water
Treatment Plants : This has a positive impact on the
operations, maintenance, process improvement and
savings for city Wastewater Operations. The application
discusses the system's evolvement, the external/internal
architecture, and the human-machine-interface graphical
design. The system also successes in monitoring the city
sewage and sludge collection/distribution systems, wetweather facilities and wastewater treatment plants,
complying to the standard requirements on the discharge,
and effectively reducing the operations and maintenance
costs.
PIPELINE OPERATIONS THROUGH SCADA
TYPICAL ORIGINATING PUMP STN
LINE DIAGRAM
BOOSTER SECTION
STRAINER
SECTION
FLOW
METER
MASTER
METER
TANKS
DENSITY
METER
MAINLINE
PUMPING SECTION
SUMP
PUMP &
TANK
MOV
PRESSURE/TEMPERATURE
INSTRUMENTS
NRV
HOV
PIPELINE OPERATIONS THROUGH SCADA
SCRAPPER
LAUNCHING
BARRELTION
TANK AND MANIFOLD INTERLOCKS LOGIC
LS,
LT
TANK LINEUP CONDITIONS:
TO BOOSTERS
MANIFOLD
PIPELINE OPERATIONS THROUGH SCADA
1. Sufficient ullage in the tank ensured by LT.
2. Tank Valve will be opened when there is no
Low Alarm
3. System will allow only one tank valve at a ti
4. During changeover 25% valve opening gives
5. command for the closure of other tank valve
6. Manifold valve operation is also similar.
7. Failure of above operation, sequence incom
condition will ensure shutdown of equipmen
BOOSTERS LINE UP LOGIC
BOOSTERS
1.
2.
3.
4.
5.
6.
7.
PIPELINE OPERATIONS THROUGH SCADA
Any one of the tank and manifold
valve should be inn open condition.
Discharge valve of the booster
should be closed.
No faults in the booster alarms
should exist.
Maximum only 2 Nos. of boosters
can start.
Start command opens cution valve,
then to pump. Once pump runs
discharge valve is opened.
Suction Pressure alarm comes
online after a time delay.
Any alarm initiation trips the
boosters.
MAINLINE PUMP LINE UP LOGIC
Mainline Pumps are either Engine Driven or Motor
Driven.
2. In case of Engine Driven Pump, a self contained control
panel
ensures the healthy status of all engine/pump
parameters.
3. In case of Motor Driven Pump, the health of the
equipment is
monitored directly by the SCC.
4. Precondition to start : Discharge valve should be closed,
No fault
condition exist confirms the availability of the
equipment.
5. Start command opens suction valve, then to pump. Once
pump runs opens discharge valve.
6. Any failure in the sequence will not allow the pump to
start.
7. While pump running, any alarm of the pump/station like
high discharge, ESD, Sump Tank Level Hi-Hi etc. will trip
the system and isolates the system by closing the
valves.
PIPELINE OPERATIONS
THROUGH SCADA
1.
PIPELINE OPERATIONS THROUGH SCADA
PIPELINE OPERATIONS THROUGH SCADA
DISCHARGE MOV
FAILED TO CLOSE
WITH IN PRESET TIME?
(120 SEC)
PIPELINE OPERATIONS THROUGH SCADA
PIPELINE OPERATIONS THROUGH SCADA
PIPELINE OPERATIONS THROUGH SCADA
PIPELINE OPERATIONS THROUGH SCADA
PIPELINE OPERATIONS THROUGH SCADA
PIPELINE OPERATIONS THROUGH SCADA
AUTOMATIC CONTROL OPERATION
PT
PT
TANK
MAINLINE PUMPING UNITS
BP
PI
TM
PI
PS
PS
BP
PI
PI
PS
PS
PS
SET POINT
CONTROLLE
RS
FP
SP
SIGNAL
SELECTOR
DP
PIPELINE OPERATIONS THROUGH SCADA
PI
PS PS
PID LOOP
LOW
PI
GOVERNOR /
VFD /
CONTROL
VALVE
PS
PI
PS
PS
PT
PIPELINE OPERATIONS THROUGH SCADA
TYPICAL CONTROL LOOP OF RECEIVING STATION
PT
PS
PI
PI
SD
SRB
SD
PCV
PT
S
T
R.
BP
SIGNAL
FC
T
M
T
M
PS
LOW
DPI
LS
,
LT
PT
DM
PIPELINE OPERATIONS THROUGH SCADA
SELECT
OR
PIPELINE OPERATIONS THROUGH SCADA
LOCAL CONTROL SYSTEM /
PROGRAMMABLE LOGIC CONTROL SYSTEM
OBJECTIVES ARE -LOGIC CONTROL - PROCESS CONTROL
COMMUNICATION WITH SCC
Digital I/Os
Analog I/Os
CPU & Communication interface
Field Instruments
PIPELINE OPERATIONS THROUGH SCADA
Independent Control System Irrespective of SCADA
CONTROL SYSTEM
During the scan, a PLC
Monitors Inputs
Scan
Executes Program
Changes Outputs
29
PIPELINE OPERATIONS THROUGH SCADA
TYPICAL SCADA ARRANGEMENT
MCC
COMMUNICATION
SERVER
COMMUNICATION LINK
SCC,
Originatin
g
Station
BV
RTU
PIPELINE OPERATIONS THROUGH SCADA
BV
RTU
SCC,
Intermedia
te
Station
BV
RTU
SCC,
Delivery
Station
APPLICATION SERVERS (32
BIT)
ENGG/PROGRAMMING
15
Flat
Mon.
TERMINAL 15 Flat
Mon.
DUAL REDUNDANT SCADA
MCS cum SCC SERVERS (32
BIT)
15 Flat Mon.
OPERATOR
WORKSTATIONS (32BIT)
19 Fat Mon.
SIC terminal (32 BIT)
15 Flat Mon.
50TFT
Screen
Display
DUAL REDUNDANT
100 MBPS ETHERNET LAN
RTU / PLC
CPU, Memory,
comm. Module, I/O
controller, power
supply
In owners OFC
based
communication
system provision
shall be made for
Ethernet Interface
Interface between
Printers & Dual LAN
P
S
U
C
P
U
C
O
M
I
O
C
P
S
U
C
P
U
C
O
M
I
O
C
DOT MATRIX
PRINTER
Communication
Server / FES
LASERJET
PRINTER
Ethernet
Multi drop
redundant
communication
with RTUs of
block valves
I/O MODULES
MODBUS Interface
to third party
devices e.g. flow
computers, RTG,
VFD etc.
point to point
redundant
communication
with each PLC of
SCCs
FIELD DEVICES
V.28/Ethernet
TYPICAL MCS cum SCC CONFIGURATION
PIPELINE OPERATIONS THROUGH SCADA
SCADA
Major functions of SCADA system
Data acquisition / Communication
Alarm & Event processing
Control processing/commands
Trend generation
Shift / Daily /Maintenance Reports
Management Information Reports
32
PIPELINE OPERATIONS THROUGH SCADA
APPLICATION SOFTWARE
LEAK DETECTION & LOCATION MODULE
Sensing Pipeline Leakage and Location
BATCH TRACKING/INTERFACE ANALYSIS
Calculation of motion and position of batches
PIG TRACKING
Tracks Movement of pig
LOOK AHEAD MODEL
To predict future trends of pressures and flow with
respect to pump changes
PIPELINE EFFICIENCY
Recommends for cleaning of pipeline
PREDICTIVE MODEL
Simulates the hydraulic dynamics of the pipeline (Offline)
PIPELINE OPERATIONS THROUGH SCADA
LEAK DETECTION SYSTEM
Typical Leak detection system consists following
software
modules :
WHEN LINE IN OPERATION
Pressure & Flow Profile Module / Pressure Wave
Module -To detect leak and location
Volume balance method : To detect leak only
UNDER SHUT IN CONDITION
Pressure wave module :
location
To detect leak and
Pressure Drop method :
To detect leak only
PIPELINE OPERATIONS THROUGH SCADA
LDS Functional Overview
Dynamic flow balance method
A simple LDS could be based upon detecting
an imbalance between a measured inlet flow
and a measured outlet flow (ie Net Volume
Line Balance)
Qin
PIPELINE OPERATIONS THROUGH SCADA
Qout
LDS Functional Overview
Ideal Pressure Control Upstream
Pu
Normal Pressure Profile
Pressure
Pressure Profile fully
developed due to leak
Pipe Length
With ideal pressure control upstream
UPD = PDCALC - PDMEAS
UPD
is Unexpected Pressure Downstream
PDCALC is Calculated Pressure Downstream
PDMEAS is Measured Pressure Downstream
UPD = 0 implies no leak
PIPELINE OPERATIONS THROUGH SCADA
PDCALC
UPD
PDMEAS
LDS Functional Overview
Ideal Pressure Control Upstream
The pressure profile is capable of
indicating leaks, but
small leaks have minimal effect on
pressure
the leak cannot be located
difficult to filter out normal pressure
variations
Profiling the flow using flow control
downstream increases the model
accuracy
PIPELINE OPERATIONS THROUGH SCADA
LDS Functional Overview
Pressure Profiling (Upstream Pressure Control)
Pu
Pressure
Pd
Normal Pressure Profile
Pressure Profile under
development due to leak (dashed
lines)
Pressure Profile fully
developed due to leak
PIPELINE OPERATIONS THROUGH SCADA
Pipe Length
LDS Functional Overview
Ideal Flow Control Downstream
QUMEAS
Flow Profile fully developed
due to leak
UFU
QUCALC
Normal Flow Profile
Flow
Pipe Length
With ideal flow control downstream
UFU = QUMEAS - QUCALC
UFU
is Unexpected Flow Upstream
QUCALC
is Calculated Flow Upstream
QUMEAS
is Measured Flow Upstream
UFU = 0 implies no leak
PIPELINE OPERATIONS THROUGH SCADA
LDS Functional Overview
Flow Profiling (Downstream Flow Control)
QU
QD
Flow Profile fully
developed due to leak
Normal Flow Profile
Flow Profile under development
due to leak (dashed lines)
Flow
Pipe Length
PIPELINE OPERATIONS THROUGH SCADA
MODEL BASED LEAK
DETECTION
PIPELINE OPERATIONS THROUGH SCADA
LDS Functional Overview
Response Time Series
response
leak
occurs
level 1
threshold
t1
t2
level 2
level 3
detection time
PIPELINE OPERATIONS THROUGH SCADA
time
event periods
level 4
response levels
PRESSURE DROP METHOD- leak notified
PIPELINE OPERATIONS THROUGH SCADA
Typical leak sensitivity data on dynamic
flow
% leak
Location
time
2%
+ 10 km
20-30 mins
5%
+ 5 km
15-20 mins
10%
+ 2 km
PIPELINE OPERATIONS THROUGH SCADA
5 mins
APPLICATION SOFTWARE
LEAK DETECTION & LOCATION MODULE
Sensing Pipeline Leakage and Location
BATCH TRACKING/INTERFACE ANALYSIS
Calculation of motion and position of batches
PIG TRACKING
Tracks Movement of pig
LOOK AHEAD MODEL
To predict future trends of pressures and flow with
respect to pump changes
PIPELINE EFFICIENCY
Recommends for cleaning of pipeline
PREDICTIVE MODEL
Simulates the hydraulic dynamics of the pipeline (Offline)
PIPELINE OPERATIONS THROUGH SCADA
SYSTEM RELIABILITY
1.
MAJOR EQUIPMENT LIKE PLC, SCADA SERVER
ARE AVAILABLE IN HOT STANDBY MODE. ONLY
STANDBY IS NOT AVAILABLE FOR RTUs.
2. FAILURE OF COMMUNICATION WILL INHIBIT
THE CONTROL COMMANDS. ALTERNATE HIRED
COMMUNICATION TO SCCs WILL HELP IN
OPERATING FROM MCC WITHOUT
APPLICATION
SOFTWARE .
3. STATION LEAKAGES CANNOT BE DETECTED.
CCTV WITH MOTION SENSOR GENERATE
ALARM
4.
PROPER MAINTENANCE OF STATION WITH TO
47
PIPELINE OPERATIONS THROUGH SCADA
SYSTEM CAPABILITIES AND BENEFIT
OPERATIONAL INFORMATION AND CONTROL
Data is acquired from field sensors / instruments
Data is processed for monitoring and control of Engines/Motors,
Valves etc.
Supports operator decisions; reports and isolates abnormal
situations
Operator settable alarms for station from centralized master station
for pressure and flow
Emergency shutdown of entire pipeline from MCC in a defined
sequence starting from the terminal station so as to keep the line
pressurized .
Acquires and displays repeater data such as pressure, temperature,
MOV status, intrusion alarms.
The block valve under the respective station can be locally
controlled by the station control centre in case master-station
communication fails.
SYSTEM CAPABILITIES AND BENEFIT
OPERATIONAL INFORMATION AND CONTROL
Data is communicated over dedicated
Communication channels to local and centrally
located system at remote
When the communication between master and
local station/ repeater fails, the system maintains
the previous state of operationi.e. there shall not
be operational shutdwn.
Communication
failure
indication
shall
be
messaged to the operator.
While controlling the SCC from MCC by way of
commands or change of set points, confirmation is
sought from the address before execution of
command/ change of set point takes place.
Bump less transfer from local station control to
Master station and Vice versa.
Can remotely prove the flow meters and effect
calibration factors.
SYSTEM CAPABILITIES AND BENEFIT
MAINTENANCE BENEFITS
Data is stored as history
Archives data and alarms for future
analysis
Generates hourly and daily shift reports
Generates equipment running hour report
Acquires and displays parameters of CP
system such as power availability, PSP etc.
Remote and auto start of DG set in RCPs
Event database will maintain all alarms,
alarm
acknowledgements,
return
to
normal process, operator control actions.
On-line data base can be modified from
Master.
Permits security level log-ins.
