Overview of

Instrumentation, SCADA
& Telecommunication Systems of Pipelines

Anish Aggarwal
GM(Project – Sys. & Gas)
IndianOil Pipelines Division
 Cross - country Pipelines
• For transportation of large volume of
crude oil/ petroleum products from one
place to another cross country pipelines
are laid.
• In comparison to other modes of
transportation, pipelines are:
¾Most economical
¾Safe
¾Fast
¾Environment friendly
 Typical Cross-country Pipeline
A typical cross-country pipeline would have
• An originating pump station (Mother
station)
• One or more intermediate stations –
Booster/ Delivery station
• RCPs (Repeater cum Cathodic Protection
stations) in between
• A terminal (delivery) station
 Typical Cross-country Pipeline
For safe and reliable movement of products
through cross-country pipelines, requirement of
reliable control system & telecommunication
system at each station as well as at the Master
Control Station is essential to provide:
• Efficient & safe operation of the pipeline
• Remote monitoring and control of the
pipeline
• Inter station communication
• Data transfer for SCADA and PAS
 Instrumentation, SCADA
& Telecommunication Systems
PAS

SCADA-MCS

SCADA-SCC

PLC BASED CONTROL SYSTEM

FIELD INSTRUMENTATION
Indian Oil Pipelines
Indian Oil Pipelines
A Typical Pipeline Installation
A Typical Pipeline Installation
A Typical Pipeline Installation
Instrumentation Systems
 Objectives for Safe Operations

A Well Designed Plant Safety Systems

Viable + Eco friendly + Society Tolerable + Accident free

Productive Operations
 Purpose of Instrumentation in Pipeline
• Monitoring of process parameters:
¾ Pressure – Pressure transmitters & indicators
¾ Temperature – Temp. transmitters & indicators
¾ Flow – Flow meters e.g. turbine meters, PD
meters, Ultrasonic flow meters
¾ Density- Density meters
¾ Level – Level transmitters, radar tank gauging
systems
 Contd….

• Protection of line pipe, tanks & Equipment:

¾ Pressure Switches
¾ Flow switches
¾ Level switches
¾ Oil mist detectors
¾ Efficient and smooth operation of pipeline
• Leak detection
 Safety Instrumentation

Emergency Shutdown

• At each pipeline installation, an Emergency Shutdown

System (ESD) is provided to ensure station / pipeline
shutdown in case of emergency situations.
• If the safety limits are exceeded, the control system
automatically shuts down the pumping units and
stations through emergency shutdown logics.
 Safety Instrumentation

Emergency Shutdown
In pipelines, Emergency Shutdown occurs primarily in
case of any one of the following conditions:
• Actuation of any one of the emergency switches installed at
different locations in the station including control room
• Actuation through SCADA system
• Sump tank level high-high
• Station Discharge line pressure high-high
• High-High Level Alarm of Storage Tanks
• Suction header pressure low-low
• Delivery line pressure high-high
• Flow in surge line etc.
 New Instruments

ONLINE SULPHUR ANALYSER

• Euro IV compliant fuels having a sulphur content of 50
ppm would be introduced in select cities from Apr’ 2010.
• The present method of cutting interface by measuring
density of samples drawn from the pipeline cannot be
used in case two similar grade of products differing only
in sulphur content.
• It is planned to install Sulphur analyzers for online
monitoring of the sulphur content of the products and
thereby helping in interface cutting of Euro – III &
Euro-IV products.
Telecommunication Systems
 Telecommunication Systems
For smooth operation of the pipeline, dedicated
communication system with 99.9% (typ.) availability
is installed for providing :

• An instantaneous

• Reliable &

• Continuous exchange of voice & data

between pumping/ terminal stations as
well as with RCP locations.
 Telecommunication Systems
Modes of communication in pipelines

• H.F. Communication system

• V.H.F. Communication system
• Public leased circuits on hire
• Ultra high frequency (U.H.F) system
• Microwave Communication system
• Optical fiber Communication system
• Satellite Communication system
 Telecommunication Systems

Communication Systems in pipelines-

• Dual redundant hot standby STM-1 based systems.
• Equipped with Network Management System (NMS)
at a central location for monitoring, control &
configuration of communication equipment installed
at different locations.
• 12 Fibre Optical Fibre Cable
Telecommunication Equipments

Battery
FCBC Bank
48V
Printer

PC

E
P
D/I MUX
A
B
X

STM -1

Subscriber
Lines
Conference
Set
 Data Connectivity for SCADA

CP UNIT RTU

STM LINK
DG SET
SCADA SYSTEM
 Telecommunication Systems

Data Connectivity
• Apart from providing voice & SCADA data
connectivity, the Ethernet Channels of
communication network are utilised for:
¾ Extending SAP Connectivity
¾ Extending LAN of Base Stations to other stations
for e-mail services
¾ Remote viewing of CCTV Cameras
¾ Other applications e.g. connectivity to fire alarm
system at RCP locations etc.
Control System
 Control System

Enhanced Safety with :

• Highly reliable Dual redundant hot
standby PLC based Control
Systems having dual redundant
power supplies, dual CPUs working
on a dual redundant network.
• Rugged and Reliable Remote
Telemetry Units (RTUs) installed at
Block Valve installations for
monitoring the important
parameters of mainline and control
over these block valves through
MCS/ SCCs.
 Programmable Logic Controller (PLC)
• PLC provides regulating and discrete process control
functions to the field units
• Input/ Output modules of PLC are connected to basic
primary sensors and also to final control element in
the field
• PLC is equipped with communication ports for
communication with SCC and also to connect to
LAPTOP to perform local station operations,
programming and maintenance of the system
 Contd….
• PLC provides PID loops
• PLC control sequence software will continue to respond
automatically to internal parameters as well as to field
settings even in case of failure of communication with
SCC maintaining safe operation of the station.
SCADA System
 SCADA System
• 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 MCC and Station Control Centres
(SCCs) at attended stations viz Pump Stations/ delivery
station/ pump - cum - delivery stations/ terminal
stations.
• Programmable Logic Controllers (PLC)/ Remote Terminal
Units (RTUs) are installed at attended stations/ scraper
stations/ block valve stations for interfacing the field
devices with the control system.
 Typical SCADA System Schematic

MCS

COMMUNICATION INTERFACE MIMIC

REMOTE REMOTE LOCAL REMOTE

SCC SCC SCC SCC
PLC PLC PLC PLC

BVs BVs BVs BVs

 Main Objectives of SCADA System
The main objectives of a cross country petroleum
pipeline SCADA system are:
• To provide effective & efficient monitoring and control
of entire pipeline network
• To optimise use of equipment and manpower and to
protect equipment.
• To check pipeline integrity
• Remote control of important station equipment,
process set points & block valves from MCS
 Contd….

• Emergency shutdown of entire pipeline from MCS

• Acquisition & display of pipeline parameters, alarms
from attended stations, scraper stations, C.P. stations
& block valves at MCS
 Master Control Station
MCS system is:
• Designed to provide effective & efficient monitoring, safe
operation and control of SCCs/ RTUs for entire pipeline
• Configured with a dual hot standby computer system
• Adopts distributed architecture using intelligent units; all
interconnected thro’ a redundant local area network
(LAN)
• Equipped with software running under multi-
programming, multi-tasking real time environment
 Contd….
• Includes self diagnostic facilities to check and indicate
healthiness of the total system
• Acquires data from SCCs/ RTUs in real time either
through communication circuits
• Displays/ records data dynamically in graphic and text
formats for the entire pipeline
• Archiving of data
 Typical MCS Configuration
DUAL REDUNDANT CONTROL REDUNDANT MCS OPERATOR SCC OPERATOR ENGINEERING STATION-IN-CHARGE
SYSTEM MCS cum SCC WORKSTATIONS FOR DESPATCH WORKSTATIONS TERMINAL TERMINAL
SERVERS PURPOSE

DUAL REDUNDANT
100 MBPS ETHERNET LAN
ROUTER’S

FRONT END
GPS SERVER
SYSTEM` LASERJET
` PRINTER COLOUR
DESKJET PRINTER TO SCC’s
TO RTU’s DOT MATRIX
PRINTER ON POINT TO
DYNAMIC
POINT BASIS
MIMIC

FLOW FLOW
DUAL REDUNDANT PLC COMPUTER- COMPUTER-2

MODULES
FIELD 1

I/O
DEVICES

DUAL I/O LAN

 Station Control Centre (SCC)

SCC system is:

• Designed to provide effective & efficient monitoring, safe
operation and control of local station and Scraper Station/
block valves, if any, under its control
• Configured with a dual hot standby computer system
• Adopts distributed architecture using intelligent units; all
interconnected thro’ a redundant local area network
(LAN)
• Includes self diagnostic facilities to check and indicate
healthiness of the total system
 Contd….
• Acquires data from local PLC and Scraper Station/ block
valves RTUs under its control in real time and transmits
the same to MCS
• Displays/ records data dynamically in graphic and text
formats for the local station and block valves under its
control
• Archiving of data
 Typical SCC Configuration
DUAL DUAL REDUNDANT OPERATOR STATION-IN-CHARGE
REDUNDANTCONTROL WORKSTATION TERMINAL
SYSTEM SERVERS

DUAL REDUNDANT
100 MBPS ETHERNET LAN

FRONT END SERVER TO MCS

ROUTER
COLOUR DUAL REDUNDANT
DESKJET PRINTER PLC
DOT MATRIX
PRINTER

I/O LAN

TO RTU
I/O MODULES

PROGRAMMING
TERMINAL FIELD
DEVICES

FLOW
COMPUTER
 SCADA System

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

• Facility of grid and precise reading

• On-demand trending

• Easy to configure
 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

 SCADA System

History
• Logging of Alarms / events

• Disk backup facility

• Cyclic or on change logging

• Triggered on timer / event / user action

MMI Screens
 Pipeline Application Software

• Application software generates real time dynamic

models as well as predictive/ trainer session
models
• Some of the typical dynamic models are
¾ Leak Detection
¾ Batch tracking
¾ Scraper Tracking
¾ Pressure Drop Estimation
¾ Pipeline Performance Analysis
 Pipeline Application Software

• Predictive/ trainer session models combine

dynamic models and ‘hypothetical’ operations to
analyse the outcome of Operator action in a safe
and controlled manner.
• Offline simulation models can also be used to
train operators.
 Pipeline Application Software
• Automatic Look Ahead Model
¾ Uses “current state” from real time model and simulates future
operation conditions of pipeline.
¾ Used to warn operator of impending short term violation of
constraints etc.

• Predictive Model
¾ It is an Off-line model. Uses same equation as Real Time Model
and simulates pipeline operations based changes to the “current
state” or archived historical states previously generated.

• Leak Detection (Pressure-Flow Deviation)

¾ Detects occurrence of leak and gives estimate of volume, based on
differences between the data produced from the Real Time Model
and SCADA measurements.
 Pipeline Application Software
• Leak Detection (Volume Balance)
¾ Detects occurrence of a leak and gives estimate of volume based upon
Mass/Volume Balance.
¾ Mass / Volume In = Mass / Volume Out : No Leak
¾ Mass / Volume In > Mass / Volume Out : Leak
• Batch Tracking
¾ Batch tracking is done by tracking the movement of a known mass of
the product in a pipeline. Time when a batch is introduced into 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
product in the pipeline is calculated.
• Scraper Tracking
¾ Scraper tracking model calculates the position of scrapers in the
pipeline. It estimates the arrival time of each scraper at its receiving
station. Used by the operator to monitor the movement of scrapers
and to schedule scraper-receiving operations.
 Pipeline Application Software

Batch Tracking

Q Q
D Batch Tracking
Module
D

Density
Flow Rate
Batch Dispatch time
Batch/Interface volume
Batch/Interface position
Batch Arrival Time
 Pipeline Application Software

Scraper Tracking

Q
Sig Q
ID Scraper Tracking Sig
Module

Scraper Launch Signal

Scraper Dispatch Time
Flow Rate
Scraper Position
Scraper Arrival Time
 Web Enabled SCADA System

• With the advancement of technology, Web Enabled

SCADA systems are the recent trend in the industry.
• Such a system gives access and control of a plant from
anywhere in the world through the web.
• The system picks up data from the operational SCADA
system master stations or local control station by
employing proxy servers and transports this data to web
pages through a suitable communication medium.
 Contd….
• On the web page, suitable interactive graphics are
created to give user friendly man machine interface for
monitoring or control of a plant or pipeline.

• Can connect to multiple servers and multiple clients

inside the organization and at remote locations to
monitor and control the system processes

• Tight security is enabled so that only authorized users

can control the process
 Contd….
• Can send MIS report, maintenance report, breakdown
reports through auto emails

• Allows multiple simultaneous viewers in real time

worldwide

• Lowers cost by eliminating costly telephone and leased

line remote access
 Contd….
• Due to increasing attack of the viruses through Internet,
special steps are required to be taken during design/
installation of Web Enabled SCADA systems to ensure
that the system will not be damaged due to virus
attacks.
• The security system installed as part of the Web Enabled
SCADA system needs to be monitored/ upgraded
continuously as any damage to the control system due
to virus attack may prove disastrous.
 Contd….
• Fall back arrangements also need to be put in place as
part of original system and the same to be taken care of
during design/ installation of the system.
 Summing Up

• Accurate, repeatable and reliable safety instruments and

measurements are vital for efficient, more reliable, continuous &
safe 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 continuously update the
Instrumentation, SCADA & Telecommunication System of our
pipelines with latest state of the art technology.
Thank You