Pipeline operation through scada

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Pipeline operation through scada

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  • This slide has an animated product wave-front passing from inlet to outlet - explain how real systems are continually line packing and unpacking and thus introduce the idea of normal operational variations in measured values etc
  • Introduce the idea of unexpected values forming the basis of alarms Simple principle determines downstream UP response UPd = 0 does imply no leak but that doesn't mean that UPd > 0 implies a leak filtering will also come into the equation later
  • Now there is a need for more information - introduce the ideal of using flow readings
  • ANIMATED SLIDE showing pipe with associated pressure/distance graph 1st click - normal profile, gas in pipe 2nd click - leak develops, pressure upstream is constant under assumed pressure control, downstream pressure drops 3rd click - new profile due to leak
  • Much the same as before... An unexpected flow response will indicate the leak size (if its not coming out the other end then it must be going somewhere - but remember about line-packing etc) Once again it still requires clever filtering
  • ANIMATED SLIDE showing pipe with associated flow/distance graph 1st click - normal profile, gas in pipe 2nd click - leak develops, flow downstream is constant under assumed flow control, upstream flow must increase 3rd click - new profile due to leak
  • Each filter will generate response levels depending on how the leak response compares to its threshold A leak situation is generated for any response level > 1 otherwise it is a no leak situation t1 and t2 must be > than the filter averaging period + 1 scan time (15s)
  • Pipeline operation through scada

    1. 1. PIPELINE OPERATIONS THROUGH SCADA K Kumar DGM(T&I), PL . HOPIPELINE OPERATIONS THROUGH SCADA
    2. 2. SCADA Objectives 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 SCC / MCC. • Emergency shutdown of entire pipeline from MCC. • Acquisition & display of pipeline parameters, alarms from attended stations, scraper stations, C.P. Stations & block valves at MCC.PIPELINE OPERATIONS THROUGH SCADA
    3. 3. TYPICAL ORIGINATING PUMP STN LINE DIAGRAM STRAINER FLOW MASTER BOOSTER SECTION SECTION METER METER TANKS DENSITY METER MAINLINE PUMPING SECTION SUMP PUMP & TANK MOV PRESSURE/TEMPERATURE INSTRUMENTS SCRAPPER LAUNCHING NRV BARRELTION HOVPIPELINE OPERATIONS THROUGH SCADA
    4. 4. TANK AND MANIFOLD INTERLOCKS LOGIC LS, LT TANK LINEUP CONDITIONS: 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 time. TO BOOSTERS 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 MANIFOLD condition will ensure shutdown of equipments.PIPELINE OPERATIONS THROUGH SCADA
    5. 5. BOOSTERS LINE UP LOGIC BOOSTERS 1. Any one of the tank and manifold valve should be inn open condition. 2. Discharge valve of the booster should be closed. 3. No faults in the booster alarms should exist. 4. Maximum only 2 Nos. of boosters can start. 5. Start command opens cution valve, then to pump. Once pump runs discharge valve is opened. 6. Suction Pressure alarm comes online after a time delay. 7. Any alarm initiation trips the boosters.PIPELINE OPERATIONS THROUGH SCADA
    6. 6. MAINLINE PUMP LINE UP LOGIC 1. 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
    7. 7. PIPELINE OPERATIONS THROUGH SCADA
    8. 8. PIPELINE OPERATIONS THROUGH SCADA
    9. 9. DISCHARGE MOV FAILED TO CLOSE WITH IN PRESET TIME? (120 SEC)PIPELINE OPERATIONS THROUGH SCADA
    10. 10. PIPELINE OPERATIONS THROUGH SCADA
    11. 11. PIPELINE OPERATIONS THROUGH SCADA
    12. 12. PIPELINE OPERATIONS THROUGH SCADA
    13. 13. PIPELINE OPERATIONS THROUGH SCADA
    14. 14. PIPELINE OPERATIONS THROUGH SCADA
    15. 15. AUTOMATIC CONTROL OPERATION PT PT MAINLINE PUMPING UNITS BP PI PS PTTANK TM PI PS PI PI PS PI PI PS PI PS PS PS PS PS BP PS PID LOOP SET POINT CONTROLLERS FP LOW GOVERNOR / SP SIGNAL VFD / CONTROL VALVE SELECTOR DPPIPELINE OPERATIONS THROUGH SCADA
    16. 16. PIPELINE OPERATIONS THROUGH SCADA
    17. 17. TYPICAL CONTROL LOOP OF RECEIVING STATION PT PS PI PI SD SRB SD PCV PT BP LOW S DPI T R. SIGNAL FC SELECT OR T T M LS, M LT PS PT DMPIPELINE OPERATIONS THROUGH SCADA
    18. 18. PIPELINE OPERATIONS THROUGH SCADA
    19. 19. 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 InstrumentsPIPELINE OPERATIONS THROUGH SCADA Independent Control System Irrespective of SCADA
    20. 20. CONTROL SYSTEM During the scan, a PLC … Monitors Inputs Scan Executes Program Changes Outputs 20PIPELINE OPERATIONS THROUGH SCADA
    21. 21. TYPICAL SCADA ARRANGEMENT MCC COMMUNICATION SERVER COMMUNICATION LINK SCC, SCC, SCC, Originating BV BV Intermediate BV Delivery Station RTU RTU Station RTU StationPIPELINE OPERATIONS THROUGH SCADA
    22. 22. APPLICATION SERVERS (32 DUAL REDUNDANT SCADA OPERATOR ENGG/PROGRAMMING BIT) MCS cum SCC SERVERS (32 WORKSTATIONS (32BIT) SIC terminal (32 BIT) TERMINAL 15” Flat 15” Flat Mon. BIT) 19” Fat Mon. 50”TFT 15” Flat Mon. Mon. 15” Flat Mon. Screen Display DUAL REDUNDANT 100 MBPS ETHERNET LAN In owner’s OFC based Interface between communication RTU / PLC Printers & Dual LAN system provision CPU, Memory, P C C I P C C I shall be made for comm. Module, I/O S P O O S P O O Ethernet Interface controller, power U U M C U U M C supply DOT MATRIX point to point PRINTER redundant communication Communication with each PLC of Server / FES SCCs Ethernet LASERJET PRINTER Multi drop I/O MODULES redundant communication with RTUs of MODBUS Interface block valves FIELD DEVICES to third party V.28/Ethernet devices e.g. flow computers, RTG, VFD etc. TYPICAL MCS cum SCC CONFIGURATIONPIPELINE OPERATIONS THROUGH SCADA
    23. 23. SCADA Major functions of SCADA system – • Data acquisition / Communication • Alarm & Event processing • Control processing/commands • Trend generation • Shift / Daily /Maintenance Reports • Management Information Reports 23PIPELINE OPERATIONS THROUGH SCADA
    24. 24. 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
    25. 25. 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 : To detect leak and location Pressure Drop method : To detect leak onlyPIPELINE OPERATIONS THROUGH SCADA
    26. 26. 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 QoutPIPELINE OPERATIONS THROUGH SCADA
    27. 27. LDS Functional Overview Ideal Pressure Control Upstream Pu Normal Pressure Profile Pressure Pressure Profile fully developed due to leak PDCALC Pipe Length UPD  With ideal pressure control upstream PDMEAS  UPD = PDCALC - PDMEAS UPD is Unexpected Pressure Downstream PDCALC is Calculated Pressure Downstream PDMEAS is Measured Pressure Downstream  UPD = 0 implies no leakPIPELINE OPERATIONS THROUGH SCADA
    28. 28. 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 accuracyPIPELINE OPERATIONS THROUGH SCADA
    29. 29. LDS Functional Overview Pressure Profiling (Upstream Pressure Control) Pu Normal Pressure Profile Pressure Profile underPressure development due to leak (dashed lines) Pressure Profile fully developed due to leak Pd Pipe LengthPIPELINE OPERATIONS THROUGH SCADA
    30. 30. LDS Functional Overview Ideal Flow Control Downstream Flow Profile fully developed due to leak QUMEAS UFU QUCALC Normal Flow Profile Flow Pipe Length  With ideal flow control downstream  UFU = QUMEAS - QUCALC UFU is Unexpected Flow Upstream QU CALC is Calculated Flow Upstream QU MEAS is Measured Flow Upstream  UFU = 0 implies no leakPIPELINE OPERATIONS THROUGH SCADA
    31. 31. LDS Functional Overview Flow Profiling (Downstream Flow Control) Flow Profile fully QU developed due to leak QD Normal Flow Profile Flow Profile under development Flow due to leak (dashed lines) Pipe LengthPIPELINE OPERATIONS THROUGH SCADA
    32. 32. MODEL BASED LEAK DETECTIONPIPELINE OPERATIONS THROUGH SCADA
    33. 33. LDS Functional Overview Response Time Series response . threshold time t1 t2 event periods leak level 1 level 2 level 3 level 4 response levels occurs detection timePIPELINE OPERATIONS THROUGH SCADA
    34. 34. PRESSURE DROP METHOD- leak notifiedPIPELINE OPERATIONS THROUGH SCADA
    35. 35. 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 5 minsPIPELINE OPERATIONS THROUGH SCADA
    36. 36. 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
    37. 37. 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 HIREDCOMMUNICATION TO SCCs WILL HELP IN OPERATING FROM MCC WITHOUT APPLICATION SOFTWARE .3. STATION LEAKAGES CANNOT BE DETECTED. CCTV WITH MOTION SENSOR – GENERATE ALARM4. PROPER MAINTENANCE OF STATION WITH TO REGARD LEAKS/EQUIPMENT CAN ENSURE RELIABLE FUNCTIONING OF SCADA SYSTEM
    38. 38. 38PIPELINE OPERATIONS THROUGH SCADA
    39. 39. 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.
    40. 40. 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.
    41. 41. 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.

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