Typical SCADA System

Applications

Industrial Automation Research Group

Program Studi Teknik Fisika
2007

HANDAL CONSULTING 2-1

 General Functions of SCADA System
 To reduce power cost.
 To reduce staffing.
 To reduce future capital requirements.
 To improve level of service
 To avoid environmental incidents.
 To comply with the regulator requirements.
 It may not be possible to run the business without
SCADA.
 To obtain a competitive edge.
 To replace an existing aging system.

HANDAL CONSULTING 2-2

 SCADA Performance Indicators
 Immediate alarm of lost production.
 Problem localization to minimize time to repair.
 Remote alarm to avoid equipment damage and lost
production.
 Automatic shutdown on detection of serious problem.
 Identification of field operational problems.
 Optimization of production.

HANDAL CONSULTING 2-3

 The two faces of SCADA
 Traditional SCADA for pipelines, power distribution or
anything that spans great distances
• Typical
• Stand-Alone
• Networked
 Local control SCADA for plant or unit operations or
any architecture that is within a defined boundary
• DCS
• PC based
• HMI / PLC

HANDAL CONSULTING 2-4

 Typical SCADA Platform

Programming/Engineering Stations Enterprise PCs

Operator Stations UNIX or Microsoft
Microsoft
WAN

Duel 100BaseT Ethernet

Communications Color Printer

Servers
B & W Printer

SCADA/History/Application Web Interface Server Telecommunications

Servers Circuits
RTU 50 (Multiple Protocols)

Hub

Hub
RTU 50
Hub Hub

Hub

 RTU 10
Hub
IED
Hub

HANDAL CONSULTING 2-5

 Stand Alone SCADA

HMI/SCADA Server

RS-232

Communications Network

RTU 1 RTU 2 RTU 3 RTU 4 RTU n

HANDAL CONSULTING 2-6

 Networked SCADA

Alarm/Event Report
Printer Printer

Print Server Print Server

SCADA Server SCADA Server Redundant Ethernet LAN 802.3

Historical Archiving Data Acquisition

Data Concentrator

Modem & Radio

Fiber Optic
Converter

Modem & Radio Modem & Radio Modem & Radio

Field Data Acquisition RTU 1 RTU 2 RTU 3

& Local control
Serial Line Serial Line Serial Line
Fiber Optic Fiber Optic Fiber Optic
Converter Converter Converter
Fiber Optic Cable

HANDAL CONSULTING 2-7

 Plant Control (DCS world)

Corporate Network – TCP/IP, DecNet, NFS, SNA, X.25, OSI, Novell

DEC PC PC
VAX

Workstations PCs
Computers Control
Room

Fault Tolerant Process LAN (HSE 100MB Fiber)

Personal Table-Top Table-Top

Workstation Workstation Workstation
Spectrum
PC
PLC

— RTU’s Single
— Scales Station
— Bar Code Fault Controllers Fault
— Scanners Tolerant Tolerant
— Etc... Fieldbus Fieldbus

HANDAL CONSULTING 2-8

 Stand Alone HMI / PLC

Programming HMI / MMI

Terminal Operator Console

PLC processor
DIN Rail I/O

HANDAL CONSULTING 2-9

 SCADA & Corporate IT Integration

HANDAL CONSULTING 2-10

 Changing Attitudes to Successful Oil/Gas
Field Automation

 Acceptance of automation by field operations

personnel is essential to its success!
 Remotely monitors the performance of oil/gas wells.
 Making it possible to remotely control the flow of
oil/gas at each well.
 Substantially reduces the number of necessary
operator visits to the well sites.
 Changes the operator roles.
 Safety and protection of the personnel & environment
are improved.

HANDAL CONSULTING 2-11

 Oil/Gas Field Automation
 Improving the flow balance for the field.
 Automating well-test procedure increases production limits.
 Production control suitable for the spot market.
 Consistent oil/gas delivery.
 Field operators are responsible for 50% more sites.
 Saves operators from unnecessary travel to sites.
 Reducing their costs for road clearing and maintenance.
 Increases billing accuracy and reduces the billing cycle.
 Enable to analyze well performance for maintenance scheduling
and for resource reserve analysis.

HANDAL CONSULTING 2-12

 Application Areas of SCADA System
 Well-head control, custody transfer, automatic well-
testing.
 Production monitoring and control, gathering facilities,
enhanced oil recovery.
 Tank farm/terminals – tanker loading/unloading,
fire/gas protection, alarms/shutdown/interlocking, etc.
 Pipeline – pump or compressor control, surge control,
alarm and shutdown protection, metering, etc.

HANDAL CONSULTING 2-13

HANDAL CONSULTING 2-14
 Gas Lift System Related Information

Oil volumes – produced

Oil volumes – inventory
Gas compressor status
Alarm summary (active)
Analog data summary
Well head status, pressure, oil/gas flow rate

HANDAL CONSULTING 2-15

 Sucker Rod Pump Data Acquisition

Alarm Analog Signal

• Pump on/off • Rod load
• Power failure • Motor current
• RTU battery voltage • Well-head pressure
low • Beam-position
• Well-head pressure • Vibration level
• Vibration

HANDAL CONSULTING 2-16

HANDAL CONSULTING 2-17
 Well-head Monitoring and Control
 Well-head pressure.
 Well-head temperature.
 Well-head valve position.
 Well throttling control.
 Hydraulic Emergency Shut Down System.
 Remote stop control.

HANDAL CONSULTING 2-18

HANDAL CONSULTING 2-19
 Process Variables for Well-Head Management
1.Inlet gas lift pressure
2.Gas lift injection differential pressure
3.Casinghead pressure
4.Casinghead temperature
5.Tubing-head pressure
6.Tubing-head Temperature
7.Nozzle outlet differential pressure
8.Well outlet discharge pressure.

HANDAL CONSULTING 2-20

 Leak Detection of Liquid Pipeline
 Rate of change of pressure.
 Rate of change of flow.
 Static volume balance.
 Transient modeling system.
 Visual (Line walking, aerial surveillance, etc.)

HANDAL CONSULTING 2-21

 Leak Detection of Gas Pipeline
 Pressure drop detectors at block valves.
 Rate of change of pressure at block valves.
 Mass/volume balance.
 Transient modeling system.
 Acoustic.
 Portable gas detectors, buried detector.

HANDAL CONSULTING 2-22

 Integration Improvement of
Flow Computer – SCADA System

 Makes a cost effective larger SCADA System.

 Applicable communication protocols: Modbus or
Fieldbus.
 OPC client/server may be the effective standard
interface.
 Expensive, specialized host software packages will
no longer be required to retrieve and display flow
computer data.
 Material/energy flow balance can be monitored
easily.

HANDAL CONSULTING 2-23

 TANK FARM SYSTEM

HANDAL CONSULTING 2-24

 EQUIPMENT MONITORING SYSTEM

Functions:
Continuous Protection Against Catastrophic Failure.
Early Detection of Machine Abnormalities.
Accurate Diagnosis of Problem.
Assessment of Level of Severity.
Accurate Prediction of Future Machine Condition Versus
Time (including time to failure).
Generation of Feedback Information for Control of
Machine Operational Characteristics.
Equipment health monitoring and failure prediction has been a
key technology area for over 15 years.
HANDAL CONSULTING 2-25
 SAFETY INSTRUMENTED SYSTEMS
A failure of some part of automation system may
cause injury to:
- member of public
- member of worker
- equipment
- environment
All process should be equipped with a safety
instrumented system.

HANDAL CONSULTING 2-26

 Design Philosophy of Safety Systems

SHOULD BE ABLE TO OVERRIDE NORMAL

CONTROL SYSTEM.
SHOULD NOT SHARE COMPONENTS WITH
NORMAL CONTROLS.
SHOULD BE AS SIMPLE AS POSSIBLE.

HANDAL CONSULTING 2-27

 MTU #1
MTU #2
Shutdown LC
Logic 202

RTU #2 RTU #1

LY
202

LS LS
203 203

Very complex safety system

HANDAL CONSULTING 2-28

 RTU

S S

R
IAS

LS
203

INLET
SCRUBBER

SCADA system with local loop override

HANDAL CONSULTING 2-29

 FROM RTU

S S

R R
IAS

PSL
FT
208

SCADA system with local shutdown

HANDAL CONSULTING 2-30

 PIPELINE PROTECTION SYSTEM

HANDAL CONSULTING 2-31

 Valve with Satellite Communication
Interface for Pipeline Safety System

HANDAL CONSULTING 2-32

HANDAL CONSULTING 2-33
 Well Details

HANDAL CONSULTING 2-34

 Well Production Revenue

HANDAL CONSULTING 2-35

 INTEGRATED SAFETY SYSTEM

HANDAL CONSULTING 2-36

 GAS PLANT SCADA SYSTEM

HANDAL CONSULTING 2-37

 SCADA System dependent AREAS
(Corporate Resource Planning)

 Business Environment
 Inventory Management
 Process Modeling
 Analysis, Control and Measurements
 Planning

HANDAL CONSULTING 2-38

 Does this sound familiar?

HANDAL CONSULTING 2-39

 An integrated EP Business with processes sufficiently
automated to achieve superior business performance.

HANDAL CONSULTING 2-40

Source: Herb Yuan (Shell)
 Oil fields of the future: real-time oil and gas operations

Onshore
Facilities

Offshore
Facilities

Decision
Centers
new capabilities – much more data;
much
HANDAL more exposure
CONSULTING 2-41
Source: Peter Breunig (CVX)
 Acquir
Time Scales (106 range) e
Control IntOPS Model
Business Headquarters
Slower
cycle Analyz
[months/years] - Supply Chain Management &
e
Capacity Planning Design - Asset life cycle and installed based maintenance or growth
Market and customer demands

- Planning of injection/production plan and resources

Operational Planning - Planning drilling and workover resources

Automation level
[months/years] - Supply Chain Management & Market and customer demands
Time-scale

Scheduling -Opening andof

Scheduling closing wells or partialplan
injection/production completions
and resources
- Adjusting well operating parameters
[days/months] -

Supervisory Control - SCADA systems for coordinating flow stations and pipelines
[minutes/hours] - Gas distribution/optimization on a pipeline network
- Monitoring wellheads, multiples and flow stations

Regulatory Control - Flow, pressure and temperature in wells and separator

[sec/minutes] - Fuel injection to produce heat out of a boiler

Fast Well & Surface facilities

cycle

HANDAL CONSULTING 2-42

Source: Saputelli SPE 83978
 Trondheim

Integrated operations

Bergen

External experts
External experts Service Company’s
onshore operation centre

Stavanger

ta
da
e
Control room offshore

im
Aberdeen

lt
ea
R
Rea
lt ime
data Operator’s
onshore operation centre

* Data integration * Knowledge

* Information * Decisions

Remote * Visualisation * Actions

HANDAL
collaboration CONSULTING
room 2-43
 Simplified single well subsea Measured Flow Rate Oil

Measured Flow Rate Gas

field development
Measured Flow Rate Water
Production Surface
reporting
control Surface Oil/Gas/Water
module equipment

Scope

Umbilical Riser

Subsea
control
module
Measured Wellhead Pressure
Flowline
Measured Wellhead Temperature

X-mas tree

Control signals
Measured Downhole Pressure
Downhole Fluid flow
Measured Downhole Temperature equipment
HANDAL CONSULTING 2-44
 Corporate Resource Planning

HANDAL CONSULTING 2-45

 Benefits of CRP
 Increases Availability
 Increases Productivity
 Proactive Monitoring & Control
 Continuous Process Improvement
 Business Performance Monitoring & Control

HANDAL CONSULTING 2-46

 Future Issues
 Open, non-proprietary systems are expected to
prevail for remote monitoring and control.
 The software should facilitate communications with all
types of field equipment as well as other computer
systems within the company.
 A standard communication protocol is required to
support the standard configuration of future
automation system (Fieldbus protocol).
 Web browser will be one user interface tools.
 Field – Office data integration becomes a crucial
need.

HANDAL CONSULTING 2-47

 Trends in SCADA and Internet
 By 2001, projections show the Internet to have over
200 million hosts and 2 billion people interconnected.
 More industries are executing more financial
transactions, online banking, and sharing vast
amounts of information.
 More companies are developing a number of
software that can exploit the interconnectedness of
the Internet.
 MMI allows a user the ability to connect to a SCADA
system from a remote site to control a process.
 IT managers and system analysts should have a
greater understanding on potential misuses of this
communication medium.

HANDAL CONSULTING 2-48