International Journal of Civil, Mechanical and Energy Science (IJCMES)

Infogain Publication (Infogainpublication.com)

[Vol-2, Issue-2, March-April, 2016]

ISSN : 2455-5304

Application of SCADA in Refineries

Anish Singh1, Shivam Rastogi2, Vaibhav Shukla3, Aditya Pratap Singh4, Achintya
Sharma5
1,2,3

Department of APE-Upstream Engineering, University of Petroleum and Energy Studies, Dehradun, Uttrakhand, India
4,5
Department of Mechanical Engineering, Amity University, Uttar Pradesh, Noida, Uttar Pradesh, India

Abstract Technology is the great growling engine that

drives the contemporary world. Rightly said technology
is always in motion and is ever evolving. Newer
enhancements and developments help us achieve the
unachievable and thus keeps on setting new standards
and redefines the present ones. Technology is something
infused into our daily lives and plays a crucial role in
improving the standards of our work and progression.
Latest advancements in the world of Computer Science
and Informatics has hit the world with a storm. Thus
incurring those advancements in the field of
Petrochemicals and Oil & Gas is the need of the hour and
these involvements can make the current industry
productive. Acquisition and Interpretation of data are the
important aspects handled by using computer
frameworks. The Al grade modern automation technology
works on the principal of remotely controlling and
remotely accessing various equipments using coded
communication signals and channels. Data Acquisition
system combined with storage compartments and
hardware helps in the collection and secure data as well
as creating a back-up. It can also be called a type of
Industrial Control System (ICS). These systems use
computer based architecture to connect various
components to a single controlling and processing unit.
But it differs from other types of ICS as it tends to
comprise multiple sites, equipment and can work across a
larger span of area. The paper deals with its
implementation of SCADA in the refineries and as a
whole in the downstream sector to improve its efficiency
in fields of Health, Safety and Environment (HSE) as well
as improved surveying and security. With proper
implementation, it can revolutionize the current
petrochemical industry.
KeywordsSCADA, refineries, oil & gas, HSE, ICS,
automation, Remote Controlling.
I.
INTRODUCTION
Petrochemical refineries or oil refinery is a processing
unit or plant where crude petroleum and gas is processed
and refined into more useful and cleaner products like
gasoline, petrol, diesel, kerosene, etc. They are
comparatively very large, spawning huge industrial
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complexes with extensive and interconnected piping

system running across the compound.The industry deals
with excessive amounts of explosives and also with high
amountsof toxins. Safety of the worker is always a crucial
concern for the company. Thus, a petrochemical refinery
is the heart of the downstream sector in petroleum
domain. Improvements in technology are leading to more
advanced and efficient industries and often increases and
boosts productivity. Conventionally, industries rely on
human resource for controlling, monitoring and
inspecting various components of the refinery. But
replacing it with a computer system reduces the error rate
significantly and most importantly improves the response
rate. Data collection is both smoother and faster.
II.

THE NEED FOR A COMPUTERIZED

SYSTEM IN REFINERIES
Preventive and reactive measure: As the industry deals
with the refining of hydrocarbon, it is always with the
threat of a severe calamity to strike and an automatic
shutdown system is required for controlling the disaster.
Moreover, dependency on the human for activation of
automatic shutdown as well as to initiate safety
procedures will create a delay which at some times, could
be critical. Thus, a system is required which needs to be
fast and efficient. Enhancing the overall efficiency of the
system: A system required which functions to identify the
damaged or broken part of the processing system. All
parts of the system should be under surveillance (for, e.g.,
Gas detectors for checking the corrosion, leakage, etc.).
Doing so would act as the initial step in crisis prevention
and would improve the efficiency as the component be
easily identified and replaced.
Recording and analysis of data: Many times we need to
determine the properties of materials as well as create
logs to store them. Mostly, these properties are
interrelated and can be calculated simultaneously. Thus,
comes the requirement of a mechanism for recording as
well as storing the data altogether.
Security: Security is a prime aspect of any industry. It
includes both limited access to specific areas, as well as a
system to keep a check on who and where someone is
entering. As industry deals with many explosive as well
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ass other harmful substances, a tight security is required
and is the first step to preventing any mishap.Mustering
head counts and individual identification: As the
refineries are colossal in the area, a system is needed for
identifying each worker, locating as well
ell as keeping a
scout on them.
Better security: As we are in the digital era, cyber-attacks
cyber
are an ever growing threat. Thus, the industry needs an
efficient system to tackle and prevent them.
III.
DESIGN
Rightly called the backbone of modern day industry, an
SCADA system at its most basic, is a software system
that used in controlling, monitoring and analysing an
industrial process. These systems utilized in every
industrial process in the world like water,, energy,
ene
oil and
gas and much more.The
The SCADA system communicates
with the various units attached to it (controllers) that are
out on the field with the help of radio signals. The
SCADA system will gather real-time
time information from
these field controllers and can interpret and provide data
in a format the user wants it to be a process. The SCADA
allows the user to see what the process is doing, react to
alarms, control the process, change settings and more.
The SCADA system will also have some storage devices
devic
(cloud or solid drive) which allow it to track the process
information over the long term during real-time
real
analysis
and thus store it. This data can be used by it to create
charts, graphs and in this way the user can know what
happened in the past as well
ll along with the current data
which can help him draft
raft a plan for future actions. It can
also be called a type of Industrial Control System (ICS).
But it differs from other types of ICS as it tends to
comprise multiple sites, equipment and can work
wor across a
larger span of area.
IV.

COMPONENTS
ENTS OF THE SCADA
ARCHITECTURE
SCADA design operates on a system cohesively build
across different software and hardware components.
Some essential
ial elements of the system are:
Remote
te terminal units (RTUs): The equipment is attached
to process units so that the data can be gathered and
collected from the group.
Programmable Logic Controller (PLCs): These help
in converting sensor signals to digital data. The
telemetry hardware is not integrated into them thus
making them more versatile and thus used in place
of RTUs.
Telemetry device connects RTUs and PLCs to a
supervisory system (control system). Examples of
wireless telemetry media employed in SCADA
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systems include satellite (VSAT), licensed and
unlicensed radio, cellular
lular and microwave.
A data acquisition server which works on telemetry
is used to provide a wireless connection between the
various components
omponents of the system.
Human Machine Interface (HMI): a critical aspect of
SCADA architecture, it includes the ways by which
user can operate and control the process and also can
see the data gathered by surveillance of the process.

Fig. Primary SCADA architecture

V.
WORKING
SCADA systems level at several software and hardware
elements that allow industries to
Monitor, collect and improvise data.
Interact with and control machines and devices,
pumps, motors, and more, connected through HMI
(human-machine
machine interface) software.
Record events into a log file. The information from
sensors or manual inputs collected sent to the PLCs
(Programmable logic controllers) or RTUs (remote
terminal units) which send that information to
HMI(Human Machine Interface)
In
with SCADA
installed. Thus, effective SCADA can help in saving
both time and money.
VI.

PRIMARY APPLICATION
APPLICATIO OF SCADA IN
REFINERIES
The main ways in which SCADA has improved and can
enhance performance are:
SCADA tremendously increases the safety and
control systems of the pipelines. Not only it can
detect minor to major leaks in pipes, but it can also
takee automatic action if programmed to do so in the
case of a calamity or the user action to a persistent
problem is delayed. It increases application of safety
shutdown systems in the major locations, Lower
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dependency on specialists or manual worker in case

of any mishap. Alarm systems
stems will also be more
robust.
It can be an efficient tool to help monitor the flow of
crude oil and natural gas through pipelines. It can be
used to collect data like flow rate, pressure,
temperature, level, speed, Valve statu
tus, Pump status
and much more.
time data along with data in the
It can provide real-time
form of charts, graphs collected over time.
SCADA can be easily integrated with the CCTV
systems and thus improves the security of the
refinery. It can also be usedd to control the opening
and closing of gates or doors so that only certain
people with required authority can enter the
particular part of the refinery.
Workers provided with unique IDs punched against
card readers. Card readers integrated with gates
gate can
be used to restrict people from entering certain
locations thus improving the security of the
premises. As workers will be required to punch the
cards before entering the premises, these cards can
also be used to muster head counts in the case of a
calamity
alamity as the system will be able to provide data
regarding where the card was last punched in the
premises.
SCADA can also provide power and energy
management solutions.
It can provide gas and fire detection and also provide
emergency shutdown if necessary.
Advanced
process control functions improve the performance
of highly matrixed and non-linear
linear processes to help
h
maximize asset performance. Easy and fast
switching between valves of interconnected
pipelines and thus giving rise to the rapid flow of
materials through pipes.

VII.
SCADA ARCHITECTURE
Though SCADA being very useful in itself, modern
improvisations make it easier to use, portable and enhance
its efficiency many folds.
olds. Some of the developments:
Web-based
based deployment: Instead of being installed
by a worker if the service provider, the clients can
download SCADA by the web on any of their
devices as modern day SCADA is JAVA based and
can run on any PC and only takes a few minutes to
install.
Unlimited
ted
Licensing:
Pricing
has
significantly gone down as nowadays company tend
to charge for the service as a whole (for the client)
rather than individual
ividual components (tags). Thus, the
user can add unlimited tags.
Security & Stability: These days SCADA comes
with Industrial-grade
grade security technology with a
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[Vol-2,
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robust, unified architecture and built-in
built redundancy.
Real-time
time data and monitoring: real-time
real
status
controls and analytics
lytics gives the power to analyse
analys
quickly and easily display the status of the facility.
facilit It
also helps the client to stay in touch with the service
wherever he is with constant
constan notifications.
Rapid Development: With SCADA architecture
becoming easier to use and simpler in structure, they
can be easily modified with the comparatively lesser
l
amount of time. Moreover, up gradation in a single
client will still allow access to
t the rest of the
architecture.

VIII.

MODERN DAY SCADA ARCHITECTURE

Fig. SCADA Architecture

IX.
ACTUAL USAGE OF SCADA
The largest oil refinery of Indian Oil located at Gujarat
and the monitoring of its energy consumption is inspected
on a daily basis and is a continuous process. To be able to
maintain the position of being most power efficient
refinery, there is a need to automate a central SCADA
system monitoring
nitoring over the subsystems.
subs
The significant
challenges that the company wanted to meet with a new
automated SCADA system included the following:
Improve operational efficiency
Reduce operations and maintenance costs
Reduce outages
tages with auto-sectionalizing
auto
Improve coordination with
w plant substation
Reduce outage minutes with restoration
r
of
significant load
Improve load balancing
Gujrat refinery, to improve its efficiency, chose
Honeywells Experion PKS with built-in
built
SCADA to
provide a cloud-based control and to improvise
improv
its
communications systems. With the deployment of
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Honeywells Solution SCADA, Gujrat Refinery was
successfully transformed into a centralized system
working efficiently and more and thus benefitting
benefit
the
business on the whole.
Employment of SCADA for efficient sourr gas detection in
Saudi Arabia.As
As there is a continuous demand for a
higher production of oil and gas, situations may arise
when newer fields may lie in an Emergency Planning
Zone next to an inhabited township. Thus, to be
b able to
balance constantly the safety of the residents with
optimum production poses a challenge. One such problem
observed in the region of Saudi Arabia. With optimum
planning and cutting edge technology, experts were able
to form a contingency plan where
re they developed a
harmony between the safety of the individuals from gas
leaks and quality production. They utilized environmental
and gas monitors which were linked together through an
integrated system named SCADA, providing a real-time
real
analysis.With the
he utilization of both radio frequency and
web-based system, real-time
time information was made
accessible to the operator for tracking, monitoring and
assessment. Since the information is instantly available,
prompt actions in case of any emergency can be taken
tak to
avert any on-field
field disaster. A continuous record
maintained in the cloud, and an SMS notification feature
for the constant update to the operator also installed in the
SCADA.The
The outburst of digitization in the oil fields has
widened the scope for newer
er technologies both in drilling
as well as safety technology, which have led to the
treatment of sour wells in the most efficient way possible.
Large manpower and resources employed in the past
times, but with the application of SCADA, a reliable
system formed
ormed which can reduce the labour
labo and errors
associated with it. Moreover, a change in perception of
the public, from angst to content, has been observed due
to the constant efforts of the experts to safeguard the
community. With the application of these Portable
P
monitoring systems, the people can heave a sigh of relief.
The following case analyses
es the primitive and advance
community safety systems and discusses the significance
of using SCADA for detection of gas leaks to protect
communities near the producing fields.

X.
APPLICATION OF EQUIPMENT
H2S is a colourless,
rless, toxic and very flammable gas which
is hazardous even at low concentrations. It is one of the
primary cause of occupational catastrophe in Oil and Gas
operations. As the complexity of the wells has increased
manifolds, the primitive technologies like fixed detection
system are incompetent in providing safety to the nearby
settlements. Figure 1, depicts a fixed detection system
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which can detect only up to a certain range, thus offering

a limited protection.

As a precautionary method, the previous technologies

were employed with communication systems which were
incapable for larger distances.The
distance
current remote
monitoring units equipped with robust communication
systems monitored by the SCADA system
sys
which acts a
medium to connect between various platforms. Thus, the
present regime provides real-time
real
data which is essential
for quick decision making of an individual
individua and on the
whole, a network. The units deployed in a network in the
vicinity of the drill site and they monitor the environment
as well as the contamination gas levels in the atmosphere.
The SCADA being the critical link transmits the data
from these units to a central database which can be either
automatic or operator handled. Thus, aggrandizing
agg
Emergency Preparedness, Planning, and Response.
The purpose of the SCADA enlisted in the following
ways:
Keeps a track of the readings of the gas detectors and a
leak is detected an immediate response message
transmitted
nsmitted to the central system. If the response time
exceeds the permissible limit, then it will initiate
automatic shutdown procedure
cedure in case of a major leak.
With the integrated GPS system, the movement of a gas
cloud
oud can be accurately detected. It also shows a real-time
voltage reading of the solar panel which ensures the
proper current supply to the unit and also informs about
timely maintenance.Radio Frequency and web
technologies used in the transmission of real-time
real
data to
the central unit further transferred to the cloud service of
SCADA, accessed by any authorized personnel
pers
connected
to that server. It also provides an SMS notification feature
to the operators in case of any emergency.

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SCADA System

Remote Monitoring Unit

The following table shows the detection time taken by
SCADA and response time by the operator:
Leak
Flow
Detecti Respon LDS
Company
Size
MSm3 on
se Time Gas
Specificati
(Shell
/d
Time
s
Volu
on
Gas
s
me
DEP)
Volume %
%
Small
N/A
1-5
Leak
Mediu 5.25
1440
6900
13
5-25
m
Leak
Large
10.5
720
3400
26
25-50
Leak
Major 17.5
360
1600
44
50-100
Leak
Detection time: It is the average time taken to detect a
discrepancy in the system (leak in this case). But to avoid
unnecessary action or lockdown even in the event of a
minor incident, the system takes an average reading for a
duration of time. During this period,, the user is alarmed
about it.
Response Time: In case the system detects a fault for
some time and no action is taken by the user, the
automatic steps were taken by the system is present
pre
according to the severity by the user.
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Economic Aspect:
The
he economic viability of SCADA analysed
analyse through the
cost of its components which is quite feasible.
Ethernet
Wlan
Ethernet/PoE Port
$35
$35
Installation
$200
$250
Controller
$1,300
(50
users)
Access Points
$15,000
(50
APs)
CCTV Cameras
Gas Detectors
RTUs

$255
$210
$1,850

$255
$210
$1,850

PLUs

$1,250

$1,250

Manual
input
system
Central Server

$1000

NA

SCADA has been able to reduce dependency on humans

and thereby to lead to a decrease in errors which further
helps in preventing the loss that the company would
woul have
to bear because of it.
XI.
CONCLUSION
Rightly said SCADA is the backbone of the modern
industry.It provides the solution to many problems where
human error can seep in.As modern industries
industr
require a
robust system to improve the overall efficiency as well as
improve the quality as well as some tasks performed,
SCADA systems provide it intuitively.With overcoming
limitations like power supply and internet stability, it can
become a top-notch real-time
time monitoring system.
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Simple Sematic Web Architecture and Protocol for
Sematic web services.
[2] Gligor, A,Turc
,Turc ,2012. Development of a service
oriented SCADA system,
system in Emerging Markets
Queries in Finance and Business ,vol.3,pp.256-261.
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[3] Robles, R.J., Choi,M.K.,2009Assessment of the
vulnerabilities of SCADA,Control System and
Critical Infrastructure System, in Int. Journal of
Grid and Distributed Computing , vol.2, No. 2
Osvaldo
Gervasi,
Editor,SERC,Republic
of
Korea,pp.27-34.
[4] Turc, T., Gligor,, A., Dumitru, C., Morar, A.,
2010.Development of extensible virtual instruments
for SCADA applications, in Proc. of 2010 IEEE

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International Journal of Civil, Mechanical and Energy Science (IJCMES)

Infogain Publication (Infogainpublication.com)

[Vol-2, Issue-2, March-April, 2016]

ISSN : 2455-5304

International Conference on Automation, Quality

and Testing, Robotics(AQTR), vol.3,pp.1-5.
[5] Turc, T., Gligor,A.,2011.Development of Service
Oriented Web-Based SCADA Application, in
Scientific Bulletin of Petru Major University of
Tirgu Mures ,vol.8, nr. 2, Petru Major University
Press, pp.119-122.

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