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SCADA system for gas pipelines
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IMPLEMENTATION OF IMPLEMENTATION OF SCADA IN GAS SCADA IN GAS
PIPELINE PIPELINE
IWUNZE
NWABUEZE
PIPELINE OPERATIONS THROUGH SCADA
BY
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
ABSTRACTABSTRACT
PIPELINE OPERATIONS THROUGH SCADA
Importance of SCADA systemImportance of SCADA system
• To provide effective & efficient monitoring and control of To provide effective & efficient monitoring and control of entire pipeline network. entire pipeline network.
• Remote control of important station equipment, process set Remote control of important station equipment, process set points & block valves from MCC.points & block valves from MCC.
SCADASCADA
• Emergency shutdown of entire pipeline from MCC.Emergency shutdown of entire pipeline from MCC.• Acquisition & display of pipeline parameters, alarms from Acquisition & display of pipeline parameters, alarms from
attended stations, scraper stations, C.P. Stations & block attended stations, scraper stations, C.P. Stations & block valves at MCC.valves at MCC.
• Coordinate security measures with process operationCoordinate security measures with process operation• Provides immediate knowledge of system performance.Provides immediate knowledge of system performance.
PIPELINE OPERATIONS THROUGH SCADA
Scope Scope
In this research we will design a Supervisory Control and Data In this research we will design a Supervisory Control and Data Acquisition (SCADA) system for managing, monitoring and Acquisition (SCADA) system for managing, monitoring and controlling the gas pipeline stations.controlling the gas pipeline stations.
The SCADA Systems should be able to monitor and measure a The SCADA Systems should be able to monitor and measure a variety of pipeline data including flows, motor currents, variety of pipeline data including flows, motor currents, temperatures, water levels, voltages, and pressures. Alarms at temperatures, water levels, voltages, and pressures. Alarms at central or remote sites triggered by any abnormal conditions are central or remote sites triggered by any abnormal conditions are propagated to the HMI computer for operator's attention. propagated to the HMI computer for operator's attention.
SCADASCADA
PIPELINE OPERATIONS THROUGH SCADA
ObjectiveObjective
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.
SCADASCADA
PIPELINE OPERATIONS THROUGH SCADA
Problem StatementProblem 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.
SCADASCADA
PIPELINE OPERATIONS THROUGH SCADA
Report OrgainationReport Orgaination
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.
SCADASCADA
PIPELINE OPERATIONS THROUGH SCADA
Report OrganizationReport 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.
LITERATURE REVIEWLITERATURE REVIEW
PIPELINE OPERATIONS THROUGH SCADA
Report OrganizationReport Organization
Fourth generation: "Internet of Things" SCADA systems have increasingly adopted Internet technology to
significantly reduce infrastructure costs and increase ease of maintenance and integration. Provides security and its not proprietary to any network protocols.
LITERATURE REVIEWLITERATURE REVIEW
PIPELINE OPERATIONS THROUGH SCADA
TANKS
TYPICAL ORIGINATING PUMP STN LINE DIAGRAM
MAINLINE PUMPING SECTION
BOOSTER SECTION STRAINER SECTION
FLOW METER
MASTER METER
SCRAPPER LAUNCHING
BARRELTION
DENSITY METER
MOV
NRV
HOV
PRESSURE/TEMPERATURE INSTRUMENTS
SUMP PUMP &
TANK
PIPELINE OPERATIONS THROUGH SCADA
TANK AND MANIFOLD INTERLOCKS LOGICLS, LT
MANIFOLD
TO BOOSTERS
TANK LINEUP CONDITIONS:
1. Sufficient ullage in the tank ensured by LT.2. Tank Valve will be opened when there is no
Low Alarm3. System will allow only one tank valve at a time.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 incomplete
condition will ensure shutdown of equipments.
PIPELINE OPERATIONS THROUGH SCADA
BOOSTERS
BOOSTERS LINE UP LOGIC
PIPELINE OPERATIONS THROUGH SCADA
1.1. Any one of the tank and manifold valve Any one of the tank and manifold valve should be inn open condition.should be inn open condition.
2.2. Discharge valve of the booster should be Discharge valve of the booster should be closed.closed.
3.3. No faults in the booster alarms should exist.No faults in the booster alarms should exist.4.4. Maximum only 2 Nos. of boosters can start.Maximum only 2 Nos. of boosters can start.5.5. Start command opens cution valve, then to Start command opens cution valve, then to
pump. Once pump runs discharge valve is pump. Once pump runs discharge valve is opened.opened.
6.6. Suction Pressure alarm comes online after a Suction Pressure alarm comes online after a time delay.time delay.
7.7. Any alarm initiation trips the boosters.Any alarm initiation trips the boosters.
MAINLINE PUMP LINE UP LOGIC1. 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.
8. All important alarms are derived from Primary instruments as well as secondary instruments to ensure fail safe operation.
PIPELINE OPERATIONS THROUGH SCADA
PIPELINE OPERATIONS THROUGH SCADA
PIPELINE OPERATIONS THROUGH SCADA
DISCHARGE MOVFAILED 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
PT
PT MAINLINE PUMPING UNITS
PI
PS
PI
PS
PI
PSPI
PS
PI PS PTBP
BP
AUTOMATIC CONTROL OPERATION
TANK
PSPI
PS
PI
PS
PS PS
TM
PID LOOP
SP
FP
DP
SET POINT CONTROLLERS
LOW
SIGNAL
SELECTOR
GOVERNOR / VFD / CONTROLVALVE
PIPELINE OPERATIONS THROUGH SCADA
PIPELINE OPERATIONS THROUGH SCADA
S T
R.
SRB
TM
TM
DPI
PI
SD
SD
PTPS
PT PIPS
PCV
DM
LS, LT
PT
BP
FC
LOW
SIGNAL
SELECTOR
TYPICAL CONTROL LOOP OF RECEIVING STATION
PIPELINE OPERATIONS THROUGH SCADA
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 InstrumentsIndependent Control System Irrespective of SCADAPIPELINE OPERATIONS THROUGH SCADA
27
CONTROL SYSTEMDuring the scan, a PLC …
Monitors Inputs
Changes Outputs
Executes ProgramScan
PIPELINE OPERATIONS THROUGH SCADA
TYPICAL SCADA ARRANGEMENT
MCC
COMMUNICATION SERVER
BVRTU
SCC,Originating
StationBV
RTUSCC,
Intermediate Station
BVRTU
SCC,Delivery Station
COMMUNICATION LINK
PIPELINE OPERATIONS THROUGH SCADA
DUAL REDUNDANT 100 MBPS ETHERNET LAN
Interface between Printers & Dual LAN
OPERATOR WORKSTATIONS (32BIT)
19” Fat Mon.
In owner’s OFC based communication system provision shall be made for Ethernet Interface
point to point redundant communication with each PLC of SCCs
Multi drop redundant communication with RTUs of block valves
DOT MATRIX PRINTER
DUAL REDUNDANT SCADA MCS cum SCC SERVERS (32
BIT)15” Flat Mon.
TYPICAL MCS cum SCC CONFIGURATION
CPU, Memory, comm. Module, I/O controller, power supply
RTU / RTU / PLC
MODBUS Interface to third party devices e.g. flow computers, RTG, VFD etc.
APPLICATION SERVERS (32 BIT)
15” Flat Mon.
LASERJET PRINTER
Communication Server / FES
PSU
CPU
COM
IOC
PSU
CPU
COM
IOC
I/O MODULES
FIELD DEVICES
50”TFTScreen Display
SIC terminal (32 BIT)15” Flat Mon.
V.28/Ethernet
Ethernet
ENGG/PROGRAMMING TERMINAL 15” Flat
Mon.
PIPELINE OPERATIONS THROUGH SCADA
30
SCADAMajor functions of SCADA system –
• Data acquisition / Communication
• Alarm & Event processing
• Control processing/commands
• Trend generation
• Shift / Daily /Maintenance Reports
• Management Information Reports
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 SYSTEMLEAK DETECTION SYSTEMTypical 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 : To detect leak and location
Pressure Drop method : To detect leak only
PIPELINE OPERATIONS THROUGH SCADA
LDS Functional OverviewLDS Functional OverviewDynamic flow balance methodDynamic flow balance method
A simple LDS could be based upon detecting A simple LDS could be based upon detecting an imbalance between a measured inlet flow an imbalance between a measured inlet flow and a measured outlet flow (ie Net Volume and a measured outlet flow (ie Net Volume Line Balance)Line Balance)
Qin Qout
PIPELINE OPERATIONS THROUGH SCADA
Pu
Normal Pressure Profile
Pressure Profile fully developed due to leak
Pressure
Pipe Length
LDS Functional OverviewLDS Functional OverviewIdeal Pressure Control UpstreamIdeal Pressure Control Upstream
With ideal pressure control upstreamWith ideal pressure control upstream UPD = PDUPD = PDCALCCALC - PD - PDMEASMEAS
UPD UPD is Unexpected Pressure Downstreamis Unexpected Pressure DownstreamPDPDCALCCALC is Calculated Pressure Downstreamis Calculated Pressure DownstreamPDPDMEAS MEAS is Measured Pressure Downstreamis Measured Pressure Downstream
UPD = 0 implies no leakUPD = 0 implies no leak
PDMEAS
UPD
PDCALC
PIPELINE OPERATIONS THROUGH SCADA
LDS Functional OverviewLDS Functional OverviewIdeal Pressure Control UpstreamIdeal Pressure Control Upstream
The pressure profile is capable of indicating leaks, butThe pressure profile is capable of indicating leaks, but small leaks have minimal effect on pressuresmall leaks have minimal effect on pressure the leak cannot be locatedthe leak cannot be located difficult to filter out normal pressure variationsdifficult to filter out normal pressure variations
Profiling the flow using flow control downstream Profiling the flow using flow control downstream increases the model accuracyincreases the model accuracy
PIPELINE OPERATIONS THROUGH SCADA
LDS Functional OverviewLDS Functional OverviewPressure Profiling (Upstream Pressure Control)Pressure Profiling (Upstream Pressure Control)
Pu
Pd
Pressure Profile under development due to leak (dashed lines)
Normal Pressure Profile
Pressure Profile fully developed due to leak
Pressure
Pipe Length
PIPELINE OPERATIONS THROUGH SCADA
LDS Functional OverviewLDS Functional OverviewIdeal Flow Control DownstreamIdeal Flow Control Downstream
With ideal flow control downstreamWith ideal flow control downstream UFU = QUUFU = QUMEASMEAS - QU - QUCALCCALC
UFU UFU is Unexpected Flow Upstreamis Unexpected Flow UpstreamQUQUCALCCALC is Calculated Flow Upstream is Calculated Flow Upstream QUQUMEAS MEAS is Measured Flow Upstreamis Measured Flow Upstream
UFU = 0 implies no leakUFU = 0 implies no leak
QUCALC Normal Flow Profile
Flow Profile fully developed due to leak
Flow
Pipe Length
UFU
QUMEAS
PIPELINE OPERATIONS THROUGH SCADA
LDS Functional OverviewLDS Functional OverviewFlow Profiling (Downstream Flow Control)Flow Profiling (Downstream Flow Control)
QU
QDFlow Profile under development
due to leak (dashed lines)
Normal Flow Profile
Flow Profile fully developed due to leak
Flow
Pipe Length
PIPELINE OPERATIONS THROUGH SCADA
MODEL BASED LEAK MODEL BASED LEAK DETECTIONDETECTION
PIPELINE OPERATIONS THROUGH SCADA
LDS Functional OverviewLDS Functional OverviewResponse Time SeriesResponse Time Series
response
time
threshold.
leakoccurs
t 1 t 2
detection time
level 1 level 2 level 3 level 4
event periods
response levels
PIPELINE OPERATIONS THROUGH SCADA
PRESSURE DROP METHOD- leak notified
PIPELINE OPERATIONS THROUGH SCADA
Typical leak sensitivity data on dynamic Typical leak sensitivity data on dynamic flowflow
% leak% leak LocationLocation timetime
2%2% + + 10 km10 km 20-30 mins20-30 mins
5%5% + + 5 km5 km 15-20 mins15-20 mins
10%10% + + 2 km2 km 5 mins5 mins
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
SYSTEM RELIABILITY1. 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 APPLICATIONSOFTWARE .
3. STATION LEAKAGES CANNOT BE DETECTED. CCTV WITH MOTION SENSOR – GENERATE ALARM
4. PROPER MAINTENANCE OF STATION WITH TO REGARD LEAKS/EQUIPMENT CAN ENSURE RELIABLE FUNCTIONING OF SCADA SYSTEM
45
PIPELINE OPERATIONS THROUGH SCADA
Data is acquired from field sensors / instrumentsData is acquired from field sensors / instruments Data is processed for monitoring and control of Engines/Motors, Valves Data is processed for monitoring and control of Engines/Motors, Valves
etc.etc. Supports operator decisions; reports and isolates abnormal situationsSupports operator decisions; reports and isolates abnormal situations Operator settable alarms for station from centralized master station for Operator settable alarms for station from centralized master station for
pressure and flowpressure and flow Emergency shutdown of entire pipeline from MCC in a defined sequence Emergency shutdown of entire pipeline from MCC in a defined sequence
starting from the terminal station so as to keep the line pressurized .starting from the terminal station so as to keep the line pressurized . Acquires and displays repeater data such as pressure, temperature, MOV Acquires and displays repeater data such as pressure, temperature, MOV
status, intrusion alarms. status, intrusion alarms. The block valve under the respective station can be locally controlled by The block valve under the respective station can be locally controlled by
the station control centre in case master-station communication fails.the station control centre in case master-station communication fails.
OPERATIONAL INFORMATION AND CONTROLOPERATIONAL INFORMATION AND CONTROLSYSTEM CAPABILITIES AND BENEFITSYSTEM CAPABILITIES AND BENEFIT
SYSTEM CAPABILITIES AND BENEFITSYSTEM CAPABILITIES AND BENEFIT OPERATIONAL INFORMATION AND CONTROLOPERATIONAL INFORMATION AND CONTROL
Data is communicated over dedicated Communication channels Data is communicated over dedicated Communication channels to local and centrally located system at remoteto local and centrally located system at remote
When the communication between master and local station/ When the communication between master and local station/ repeater fails, the system maintains the previous state of repeater fails, the system maintains the previous state of operationi.e. there shall not be operational shutdwn.operationi.e. there shall not be operational shutdwn.
Communication failure indication shall be messaged to the Communication failure indication shall be messaged to the operator.operator.
While controlling the SCC from MCC by way of commands or While controlling the SCC from MCC by way of commands or change of set points, confirmation is sought from the address change of set points, confirmation is sought from the address before execution of command/ change of set point takes place.before execution of command/ change of set point takes place.
Bump less transfer from local station control to Master station Bump less transfer from local station control to Master station and Vice versa.and Vice versa.
Can remotely prove the flow meters and effect calibration Can remotely prove the flow meters and effect calibration factors.factors.
SYSTEM CAPABILITIES AND BENEFITSYSTEM CAPABILITIES AND BENEFIT MAINTENANCE BENEFITSMAINTENANCE BENEFITS
Data is stored as history Data is stored as history Archives data and alarms for future analysisArchives data and alarms for future analysis Generates hourly and daily shift reportsGenerates hourly and daily shift reports Generates equipment running hour reportGenerates equipment running hour report Acquires and displays parameters of CP system such Acquires and displays parameters of CP system such
as power availability, PSP etc.as power availability, PSP etc. Remote and auto start of DG set in RCPsRemote and auto start of DG set in RCPs Event database will maintain all alarms, alarm Event database will maintain all alarms, alarm
acknowledgements, return to normal process, acknowledgements, return to normal process, operator control actions.operator control actions.
On-line data base can be modified from Master.On-line data base can be modified from Master. Permits security level log-ins.Permits security level log-ins.