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.
HMI with FAST/TOOLS
Pump facility
STARDOM units
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
Industries
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Oil & Gas
Yokogawa has a wealth of experience in every part of the oil and gas business, from offshore and onshore facilities to pipelines, terminals, and deepwater operations. We provide solutions that enhance safety, ensure accurate and reliable operation, and increase plant efficiency.
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Oil & Gas Midstream
Yokogawa's innovative technology platforms and industry leading execution is well regarded in the global marketplace as a solutions partner pioneering the integration of technologies for all aspects of the oil & gas ecosystem from reservoir to enterprise. Proven solutions that include predicative business modeling, plant optimization and highly reliable automation platforms are assisting midstream operators to run their businesses at the optimal efficiencies. Yokogawa is helping clients to develop their automation roadmaps ensuring years of highly effective asset utilization and sustainability.
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Onshore
The onshore upstream industry faces ever higher demands and greater challenges with increasingly difficult and hostile environments in which it must operate.
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Pipeline
The right pipeline control and instrumentation can make a huge difference in terms of performance and profitability. Yokogawa has dedicated technology that can optimize the performance of all elements of a pipeline solution, including compressors, pumps, valves, and intermediate storage and distribution facilities.
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Wellhead & Separation
The wellhead provides the structural and pressure-containing interface for the drilling and production equipment. The surface pressure control is provided by a christmas tree, which is installed on top of the wellhead. Isolation valves and choke equipment physically control the flow of well fluids when the well goes into production. Various automation packages are added to locally or remotely monitor, control and optimize production from each well or multi-well pad. Oilfield separators employ a pressure vessel to separate well fluids produced from oil and gas wells into gaseous and liquid components which are then transferred to pipelines or localized storage depending on the areas infrastructure.
Related Products & Solutions
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FCJ All-in-one PLC/RTU
The brick type model FCJ autonomous controller fulfills the basic requirements of the utility control. It also provides the reliability for the SCADA communication with network redundant capability.
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Low Power Consumption Autonomous Controller (FCN-RTU)
- Low power consumption model of field control node (FCN) autonomous controller
- Meets requirements at inhospitable remote locations which lack power
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Process Control PLC/RTU
- Process control PLC and Remote Terminal Unit (RTU)
- Maximize operational excellence
- Process plants
- Remote locations