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Chapter VII T & I SYSTEMTELECOM, INSTRUMENTATION & CONTROL SYSTEMS

For any process Industry, Instrumentation and Control systems play the keyrole, akin to the human eye and brain through sensing, monitoring, controlling

and recording comple process parameters that combined together, pro!idethe desired outputs on "hich an organisation sur!i!es and gro"s# $ike"ise in

pipelines, sophisticated Instrumentation and Control systems along"ith hi%

tech 'S systems and state o( the art telecommunication systems areinstalled (or the monitoring, control and sa(ety o( pipeline operations and (or

achie!ing throughput goals in the most economic manner#

INSTRUMENTATION & CONTROL

)ll station E*uipment, M+Vs and piping are pro!ided "ith pneumatic

electronic instruments o( analogdigital type "ith associated controls, (or (ail%sa(e operation o( the E*uipment and the pipeline as a "hole# The

instrumentation system is broadly classi(ied as under-

. Mainline pumping unit % Monitoring and control instrumentation#

. 'rocess monitoring and control instrumentation#

. Station auto control instrumentation . Instrumentation (or auiliary systems

A. CONTROL AND MONITORING INSTRUMENTATION FOR MAINLINEPUMPING UNIT.

Since the area o( operation is ha/ardous, the Instrumentation systemcomprising Engine 0ear 1o 'ump mounted sensors and logic elements

used (or Engine parameter monitoring sa(ety ser!icing and control, aremostly o( pneumatic type# The operation o( Engine is controlled locally (rom

nit control panelinter(ace panel and remotely (rom station control panel#

UNIT CONTROL PANEL (UCP)

The unit control panel consists o( di((erent pneumatic elements like multiport

!al!es, indicating relays, pilot relays, pneumatic timers, logic gates etc# toachie!e the operations in a gi!en se*uence as per the re*uirement# Various

monitoring instruments such as pressure gauges, temperature gauges,pyrometer, speed indicator etc# are mounted on the C'#

The Engine can be operated on 2$+C)$3 (rom the C'# The di((erentsensing elements like pressure, temperature, le!el, !ibration sensors etc#

mounted on the M$ pumping unit recei!e air supply !ia pneumaticindicating relays incorporated in the C'#

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The sensors mounted on the engine !ents the air supply "hen the sensed

parameter (alls belo" or eceeds the set point as the case may be andactuates the pneumatic indicating relay# In healthy condition, "hen the

sensed parameters meet the operational re*uirement, sensors do not !ent

air# The pneumatic indicating relay has t"o positions corresponding to the

healthy alarm conditions (or display o( alarm status 45E6 (or alarm and05EE7 (or healthy8# It also pro!ides pneumatic output correspondingly toactuate other logic elements in order to per(orm the desired logic (unctions

i#e# gi!ing alarm, tripping the engine etc# as per the logic design#

+I$ MIST 6ETECT+5 system is installed to detect +I$ MIST in the engine

crank case and initiate alarm and tripping command "hen the concentrationo( the +I$ MIST eceeds a preset !alue 49:; a!erage8#

For monitoring engine speed, magnetic pick up is used as a sensor and

number o( pulses induced in the pick up sensor due to cutting o( magnetic

(ield by a gear connected to the engine cranksha(t is processed in inter(acepanel and the signal is obtained (or speed indication on C' as "ell as in

SC'#

$ist o( alarm and trip !alues o( station parameters are listed in )nneure%I

OPERATION FROM STATION CONTROL PANEL (SCP/MMI)

4)8 M)I7$I7E 'M'I70 7ITS

Control and se*uence $ogics are incorporated in Station Control 'anels

4SC'8 through electronic hard"are and in 'rogrammable $ogic Control 4'$C8systems through ladder logic so(t"are (or starting stopping o( the mainline

pumping units and openingclosing o( suction discharge other M+Vs#

The inter(ace panel bet"een SC' and C' con!erts the electrical signals to

pneumatic signals and !ice !ersa# command, the suction !al!e starts opening# )(ter the !al!e opened (ully, the

engine takes the start command# )(ter the engine picks up a speed o( ?@@5'M, the discharge !al!e starts opening# I( any o( the parameters (or normal

operation goes out o( limit or se*uence timing is not matched, engine getsthe trip command and C' sho"s (ailed to start and se*uence incomplete

indications# pon correct completion o( se*uence the discharge !al!e opens

(ully and engine picks up speed# +perator can then set the engine speed asper operational re*uirement# Speed control can be (rom control panel i(

engine is controlled (rom remote and (rom C' i( engine is in local# Thespeed control is automatic i( the engine is run on =)uto> 4'I6 control8 mode

based on set points#

418 +TAE5 EBI'ME7T

Facilities are pro!ided on station control panel 4SC'8 (or startstop o( booster

pumps, opening closing o( station tank(arm M+Vs, startstop o( aircompressors, remote operation o( (uel etraction system etc#

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B. STATION MONITORING & CONTROL INSTRUMENTATION

Station control panels 4SC'8 are '$C 4programmable logic congroller8 based

control systems and are installed at !arious stations o( SM'$ (or monitoring

and control o( station operations#

The pump stations at Vadinar amnagar 0auridad SurendranagarViramgam Sidhpur )buroad Dot 5aola Sendra 5amsar and deli!ery

station at Doyali are ha!ing control panels supplied by Ms 5ock"ell)utomation $td# )t Chaksu, 5e"ari and 'anipat, control systems consisting o(

)lpha series "orkstation ha!ing redundant hot standby computers 46EC @@@

@@G8 "ith so(t"are "atch%dog timers, printers, SV0) V6s, (unctional keyboards mouse etc ha!e been designed, supplied and installed by Ms )sea

1ro"n 1o!eri $td# )t Mathura, )11 supplied Micro SC)6) system "ith M)??@5T is installed (or monitoring & control o( station operations#

The control systems are basically microprocessor based dual redundant'rogrammable $ogic Controller 4'$C8 systems "ith Man%Machine Inter(ace

4MMI8 consoles, consisting o( 'entium 'C based "orkstation, S0V) Monitor,keyboardmouse and e!entalarm printing system#

Facilities eist (or close online monitoring o( process parameters like pressure,

temperature, density, (lo" rate, tank le!els etc# "hich together indicate healtho( dynamic processes o( pipeline operation and maintain sa(ety o( the system#

The operator can control remote (unctions (rom the graphic displays on MMI

including starting and stopping mainline pumps and other station e*uipment,opening & closing o( M+Vs and changing set points o( controllers to achie!e

the desired throughput# 5eal time data presentation (or all status alarms and(ield data recei!ed (rom processors and all operator inputs are displayed on

the MMI in a special colour#

Various instruments such as turbine (lo" meters (or measurement o( (lo",

pressure(lo" control !al!es (or pressure (lo" control, 5adar Tank 0augingsystems, density measuring system, smartintelligent pressure and

temperature transmitters, etc# (orm an integral part o( station parametermonitoring and control instrumentation#

For calibration o( turbine (lo" meters, unidirectional meter pro!er systems are

installed at Vadinar, Viramgam, Doyali, Mathura, Chaksu and 'anipat by

incorporating correct Meter (actors#

C.STATION AUTO CONTROL

)uto control system is pro!ided in the station control panels to achie!e thedesigned operation o( a pump stationTerminal station depending upon the

station parameters as per operational re*uirements# The auto control systemaccepts the !alues o( the important process !ariables !i/# station suction

pressure, discharge pressure and (lo" rate, compares them "ith their set

points and the most critical o( the resultant o( these comparisons "ill go!ernthe speed o( the Engine position o( the control !al!e, so as to keep minimum

di((erence "ith the most critical parameter#

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D. INSTRUMENT FOR AUXILIARY SYSTEMS

Instrumentation and control systems are also pro!ided (or !arious auiliary

systems such as Compressors, Fuel etraction system, Station Tank (arm

M+Vs, 'ressureFlo" Control !al!es, Emergency 0enerator, Fire Fighting

Motors, Sump tank pump, Surge relie( system, 'ig launching and recei!ingsystem, Fuel storage system etc#

E. UPS (Uninterr!te" P#$er S!!%) SYSTEM

E!ery 'umping station is e*uipped "ith 'S System to meet the po"er

re*uirements o( critical systems such as '$C system, Inter(ace panels, SC)6)system5T, Con(erence unit and AF sets "hich do not operate in the e!ent o(

Mains !oltage (luctuations or Mains (ailure#

)n uninterrupted po"er supply system ser!es basically the (ollo"ing

(unctions-

4i8 To pro!ide stable )C po"er supply (ree o( harmonics spikes etc# to thecritical E*uipment regardless o( the input po"er source !ariations#

4ii8 To continue pro!iding this po"er during mains (ailure (or a speci(ied

time period as determined by re*uirement o( the station and capacity o(1attery backup# This guards critical e*uipment against po"er (ailures,

!oltage (re*uency (luctuations, lightning spikes, surges and helps in

their smooth operation#

'S system "ith online In!erter and Sealed Maintenance Free 4SMF8 batterybank in compact designed cabinet ha!e been pro!ided at all stations# This 'S

systems ha!ing e((iciency o( about H@;, occupy less space and pro!ide Arsback up po"er supply at J@@; load# The 'S unit consists o( a 1attery

charger, in!erter, SMF battery bank and a static trans(er s"itch (or trans(er to

bypass line "ithout any break in case o( in!erter rouble(ailure or deepdischarge o( batteries#

(i) N#r'% #!erti#n )C input po"er is con!erted to 6C po"er by

charger# 6C po"er is used (or the charging o( batteries and at the same

time con!erted to stable )C po"er by in!erter#

ii) In *+e # !#$er i%re 6C po"er (rom batteries "ill be con!erted

to )C po"er by in!erter#

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TELECOMMUNICATION SYSTEM

GENERAL

Communication system plays !ital role at di((erent stages (or in(ormationechange and co%ordination in the success(ul operation o( cross country

pipeline#

Uninterr!te", n"i+tre" *#''ni*ti#n "rin

. Start%up and shutdo"n o( pump stations#

. 'eriodic monitoringcontrolling operational parameters o( stations to

achie!e the designed optimum throughput#

. 6ealing "ith any eigencies !i/# (ire, pipe burst, sabotage etc#

. 0enerating o( MIS reports (or management decision making#

The details o( telecommunication system in SM'$ are gi!en belo" in brie(-

SMPL

S%01ir'' Se*ti#nThe communication in SV section is basedon 1S7$ $eased $ine# Multipleing e*uipment in SV section are Sagem

make# Communication channels (rom SV section are (urther routed toVC and VD sections at Viramgam using so(t"are patching at channel

le!el and hard"ire patching at ?Mbps le!el#

2#%i01ir'' Se*ti#n The communication System in DoyaliL

Viramgam Section is +ptical Fibre based Telecommunication System4S6A type telecommunication system implemented on +FC8# The

communication system in this section is comprising o( Fibcom makeSTM transmission e*uipment and Sagem make multipleing

e*uipment#

1ir''0Si"3!r Se*ti#n The communication System inViramgamLSidhpur Section is +ptical Fibre based TelecommunicationSystem 4S6A type telecommunication system implemented on +FC8#

The communication system in this section is comprising o( Fibcom makeSTM transmission e*uipment and Sagem make multipleing

e*uipment#

Si"3!r0C34+ Se*ti#n- The communication System in Sidhpur%

Chaksu Section is +ptical Fibre based Telecommunication System 4'6Aand S6A type telecommunication system implemented on +FC o(

M''$8# The communication system in this section comprises o(transmission e*uipment o( Fibcom and 7okia make and multipleing

e*uipment o( Sagem and 7okia make#

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C34+0Pni!t Se*ti#n- The communication System in Chaksu%

'anipat Section is +ptical Fibre based Telecommunication System 4'6Aand S6A type telecommunication system implemented on +FC o(

M''$8# The communication system in this section comprises o(

transmission e*uipment o( Fibcom, 7okia and )11 make and

multipleing e*uipment o( S)0EM and )11#

C34+0Mt3r Se*ti#n- The communication System in Chaksu%

Mathura Section is based on 6igital Micro"a!e system# Thecommunication system is this section is comprises o( micro"a!e radio

e*uipment o( 7okia make and multipleing e*uipment o( )11 make#

F*i%itie+ A-i%%e $it3 C#''ni*ti#n ++te'

- Voice Channels- 6ialing SC)6)

- Con(erence channel- For operational purpose

- 6ata channels- E%mailS)'

15F C#''ni*ti#n S+te'

)ll stations are pro!ided "ith VAF

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Salaya%Viramgam%Doyali%Chaksu section and Chaksu%Mathura%'anipat sections

o( SM'$#

The SC)6) system monitors and controls processes comprising di((erent sub%

processes that are geographically separated# The SC)6) system "as installed

in SM'$ (or monitoring and control o( pipeline operations o( !arious stations,including block !al!es, centrally (rom 5akot# The heart o( the system is theMaster Computer System 4MCS8 at 5akot (or Salaya%Viramgam%Doyali and

Viramgam%Chaksu sections and at Chaksu (or Chaksu%Mathura and Chaksu%'anipat sections# Chaksu master computer is hooked up "ith 5akot Master

computer through interlink so(t"are (or monitoring selected parameters at

5akot# In addition, ?9 remote telemetry units 45Ts8 are installed at 'umpStations 6eli!ery Stations 1ooster Stations, block !al!e locations along the

pipeline to achie!e the obecti!e o( centrali/ed monitoring and control# Thecommunication bet"een Master and 5Ts is achie!ed through dedicated

communication systems# The 5T acts as inter(acing e*uipment bet"een the

(ield instrument signals and the MCS#

The SVDC SC)6) system is built around Client Ser!er architecture "ith t"o6EC )$'A) ?J@@ ? systems as ser!ers and 6EC )$'A) ?@@ J99 and

6EC VE7T5IS F' 'entium systems as Clients# The ser!er so(t"are is +penVMS operating system and runs the +pen 5'MC so(t"are "hile the Client

So(t"are runs under

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L 6ata )c*uisition#L Man Machine Inter(ace#

L E!ent and )larm noti(ication#

L 7ormal operating (unctions like alarm ackno"ledgment, display o(

pictures, display o( alarms and alarm summaries#L +n demand and period logging o( picture mimics, reports etc#L Current trend and historic trend

L Super!isory control and set point (unctionsL Support o( hot standby system

L Support o( "all mimic

L Support o( Management In(ormation System 4MIS8 programL 'ri!ileged operator (unctions such as recon(iguration o( Variables and

graphics#L Creation o( data base and graphics

L Support (or connecti!ity to other SC)6) system#

S+te' O!erti#n+

5emote telemetry units are inter%connected to the (ield instruments to collect

the process in(ormation and transmit the same to the Master Computer# Theycan then issue control commands to the process, under instructions (rom

Master Computer# The system allo"s operator inter!ention#

The Master Station scans 5Ts in pre%determined se*uence and collects up%

to%date status o( !arious parameters# It carries out data processing, con!ertmeasured units into engineering units, detects high%lo" limit !iolation, alarm

and e!ent processing, data logging and (ile creation#

(A) M#nit#rin Fn*ti#n4a8 +pen Close status o( M+Vs

5un Stop status o( pumps

+n line 1y%pass status o( (lo" meters as "ell as o( stations Tank le!el 7ormal Aigh

Centri(uge Compressor 5un Stop Engines running on crude diesel etc#

Sump tank le!el 7ormal Aigh

4b8 )nalog In(ormation

Station suction discharge pressures 4Mainline as "ell as $oopline8 Station temperatures

Flo" rates etc# Engine speeds#

Tank le!els#

4c8 Flo" Meter in(ormationFuel take%o(( count

(B) C#ntr#% Fn*ti#n+

Start Stop control o( mainline pumps+pen Close control o( M+Vs

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Emergency shutdo"n o( a station

Speed 45'M8 control o( mainline engines

C) A!!%i*ti#n T+4+

The system carries out the (ollo"ing pipeline application tasks-Flo" measurement$eak detection under line balance and batch break

S!er-i+#r C#ntr#% n" Set !#int n*ti#n+

Control actions can be initiated by the operator either by gi!ing controlcommands 4using keyboard mouse8 or by triggering action areas in a

graphic#

SC)6) so(t"are pro!ides (acilities to enable the operator to control the plant

through select%check back%eecute cycle# Follo"ing control procedure isadopted-

The operator selects the rele!ant picture containing the action area o(

the control procedure#

The operator points and clicks the mouse at the corresponding action

area# The +perator gi!es a dri!e command using keyboard and mouse#

The system then displays the current state !alue o( the point and asks

(or the net state!alue#

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The purpose o( (lo" measurements is to calculate and maintain an

accurate record o( the *uantity o( crude oil (lo"ing past Salaya, 5akot,Viramgam, Chaksu, and Doyali and to pro!ide timely in(ormation to the

operator# 5esulting data is also used in monitoring 'ipeline Integrity#

Turbine (lo" meters are used to measure (lo" and the !olume o( oil(lo"ing through the pipeline#

8. STEADY STATE MONITORING

Various aspects o( the pipeline application so(t"are depend upon steady

(lo" in the pipeline or are triggered by a !ariation in the (lo"#

Meter pro!ing initiates on temperature, pressure and (lo" rate changes#The concept o( Steady State is used to make these !ariations precise#

Each process !ariable 4temperature, pressure, (lo" rate, density8 is

initially considered 7+T to be in a Steady State#

9. ENGINE FUEL TA2E OFF

Crude oil is regularly dra"n (rom the pipeline to pro!ide (uel (or theengines "hich dri!e the mainline pumps# This (uel take o(( occurs at all

originating and intermediate pumping stations# The *uantity o( (ueldra"n o(( is measured by positi!e displacement !olume meters#

:. STATIC PRESSURE TESTS

Static 'ressure Tests are able to localise leaks and can detect !ery smalllosses# In order to carry out a static pressure test each leg o( the pipe

can be shut do"n# The oil in the pipe is le(t pressurised# )ny drop in thepressure may indicate the presence o( a leak#

;. LINE BALANCE

$ine 1alance is used to detect medium si/ed leaks "hile the pipeline isoperating in steady state condition# It is sometimes kno"n as in(lo" to

the pipeline is e*ual to the total net (lo" out o( it, under steady (lo"ingconditions# ) leak "ill cause the measured in(lo" to be greater than the

measured out(lo"#

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METER PRO1ER OPERATION

Meter 'ro!er is pro!ided (or calibration o( turbine (lo" meter to ascertain

accuracy o( *uantity deli!ered in the tank# 6etailed *uality procedures is

gi!en in 'rocedure and

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Engine Speed Aigh N9@5'M

NN 5'M :N@ 5'M N9@ 5'M ?: 5'M :H@ 5'M

Engine +il Mist 6etected 7) 7) 7) 9@; 9@; FIGE6

Engine $ube +il 'riming $e!el 7) 7) 7) FIGE6 FIGE6 7)

Fuel 'ipe 5apture 7) 7) 7) FIGE6 FIGE6 FIGE6Engine +!erload FIGE6 FIGE6 FIGE6 7) 7) 7)

acket