STARDOM and FAST/TOOLS Integrated SCADA Solution for Indian Oil Corporation's Multiproduct Oil Pipeline

Executive Summary

Indian Oil Corporation Ltd. Chennai, India

The Chennai-Bangalore Pipeline (CBPL) has been constructed by the Indian Oil Corporation Ltd. (IOCL) to ensure uninterrupted, reliable, and economical transportation of petroleum products to meet the growing demand in and around the city of Bangalore, India.

The pipeline originates at Chennai Petroleum Corporation's Manali refinery near Chennai, passes through Chittoor in Andhra Pradesh, and terminates at IOCL's Devanagonthi terminal on the outskirts of Bangalore. Completed three months ahead of schedule, this 290-km underground pipeline has one booster pump and three main line pumps, and can transport 1.45 million tons of products per year.

IOCL selected Yokogawa's FAST/TOOLS SCADA system to provide integrated and centralized monitoring and control of pipeline operations from the Chennai station. The principal elements in this solution are STARDOM intelligent remote terminal units (RTUs), the FAST/TOOLS SCADA package, and a fiber optic telemetry system. As a backup for monitoring and control communications, a redundant leased line links the Chennai and Bangalore stations. A pipeline leak detection system (LDS) was also installed and commissioned.

The Challenges and the Solutions

Centralized control and monitoring
To achieve a centralized control and monitoring function, servers located in the Chennai and Bangalore stations are linked with each other. Chennai is the master station and is able to control the Bangalore station remotely with the authorization of the Bangalore terminal operator. SCADA operator stations at the Bangalore terminal are capable of displaying status information from the Chennai station.

Integration with LDS
The SCADA servers at the Chennai station are linked to the LDS for real-time display of information on leaks detected in the pipeline. High-priority alerts and other data are exchanged in real time between the LDS and the SCADA servers when leaks are detected.

Integration with IOCL intranet for pipeline monitoring
IOCL offices all over India are able to monitor the pipeline on the company intranet. Once per minute, the SCADA servers at Chennai populate the IOCL intranet server database and a web application displays this real-time pipeline status information. This gives IOCL personnel a clear view of pipeline operations. In this way, STARDOM facilitates the total visualization of data needed for safe and reliable pipeline operations.

Customer Satisfaction

One of manager in the pipelines division- Chennai said, "At all the main stations and RCPs, Yokogawa India completed the turnkey package of supply, installation, testing, and commissioning of the Yokogawa STARDOM RTUs and FAST/TOOLS SCADA, measuring and testing equipment, a field instruments package that included a UPS and energy solution pipeline application software (PAS) and an LDS package, and the interface to the IOCL intranet. The entire project including detailed design, manufacturing, integration testing at the factory, installation, and commissioning was completed ahead of schedule. Yokogawa completed the CBPL project on time and achieved excellent customer satisfaction, and application development."

Integrated Field Equipment

• Yokogawa pressure / temperature transmitters
• Pressure switches
• UPS / flowmeters
• Flow computer
• Tank farm management system
• VFD / relays

Supplied Hardware & Software

• 4 SCADA servers - Unix (redundant) & 10 client stations (Windows)
• 10 STARDOM RTUs with cabinets & panel mount displays
• Large video screen
• Routers / switches / terminal servers / RS232-485 converters
• Field instruments, test and measuring equipment
• FAST/TOOLS SCADA R9

System Configuration

• 1,500 conventional I/Os
• Modbus communications with UPS, flowmeters, flow computer, VFD, tank farm
• Integration of Solatron 7835 densitometer with Lobos 600 flow computer
• Large video screen
• Leak detection system
• Routers / switches / terminal servers

Functions of SCADA

• Centralized monitoring and control
• Gathers data from unmanned stations (RCPs) via fiber optic communications link
• Integration of RCPs / block valve stations (BVS) with V.28 link
• Chennai and Bangalore link via leased line (WAN)
• Integration with LDS for real-time display of leak status information
• Integration with IOCL intranet for real-time display of data in an IOCL web application
• Authorization to control Bangalore station from Chennai station
• Complex report generation on a shift, daily, and monthly basis