Developing a Pipeline Supervisory Control Center

Transcription

1 Developing a Pipeline Supervisory Control Center API PUBLICATION 1113 THIRD EDITION, FEBRUARY 2000

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3 Developing a Pipeline Supervisory Control Center Downstream Segment API PUBLICATION 1113 THIRD EDITION, FEBRUARY 2000

4 SPECIAL NOTES API publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed. API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations under local, state, or federal laws. Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet. Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent. Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. Sometimes a one-time extension of up to two years will be added to this review cycle. This publication will no longer be in effect five years after its publication date as an operative API standard or, where an extension has been granted, upon republication. Status of the publication can be ascertained from the API Downstream Segment [telephone (202) ]. A catalog of API publications and materials is published annually and updated quarterly by API, 1220 L Street, N.W., Washington, D.C This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this standard or comments and questions concerning the procedures under which this standard was developed should be directed in writing to the general manager of the Downstream Segment, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the general manager. API standards are published to facilitate the broad availability of proven, sound engineering and operating practices. These standards are not intended to obviate the need for applying sound engineering judgment regarding when and where these standards should be utilized. The formulation and publication of API standards is not intended in any way to inhibit anyone from using any other practices. Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard. All rights reserved. No part of this work may be reproduced, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, N.W., Washington, D.C Copyright 2000 American Petroleum Institute

5 FOREWORD This publication was created to assist anyone responsible for developing or revamping a pipeline supervisory control center. This publication presents lists of general considerations appropriate for designing a center. The lists are not all-inclusive but should help stimulate further, detailed analyses. API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any federal, state, or municipal regulation with which this publication may conflict. Suggested revisions are invited and should be submitted to the general manager of the Downstream Segment, American Petroleum Institute, 1220 L Street, N.W., Washington, D.C iii

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7 CONTENTS Page SECTION 1 GENERAL SECTION 2 DEVELOPING SYSTEM ARCHITECTURE SECTION 3 DEVELOPING SYSTEM RELIABILITY SECTION 4 DEVELOPING SECURITY AND DISASTER RECOVERY CAPABILITY SECTION 5 DEVELOPING THE CONTROL ROOM DESIGN SECTION 6 DEVELOPING THE HUMAN-MACHINE INTERFACE SECTION 7 DEVELOPING THE DATA-RECORDING SYSTEM v

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9 Developing a Pipeline Supervisory Control Center SECTION 1 GENERAL 1.1 SCOPE A pipeline supervisory control center is a center for monitoring and controlling a pipeline system. This publication presents six lists of general considerations appropriate for developing or revamping a pipeline supervisory control center. The lists are not all-inclusive but should help stimulate further, detailed analyses. Although the items in each list need not be considered in numerical order, the lists themselves should be considered in the order in which they are presented. 1.2 DEFINITION OF TERMS Some of the terms used in this publication are defined in through check-back routine: A routine that displays on the CRT the command to be executed and then allows the controller to either remove the command or confirm it CRT: A cathode ray tube or flat panel display EDI: An electric data interchange fail-over: A transfer of control from a failed system to its backup LED: A light-emitting diode HMI: A human-machine interface open system: A system based on vendor-independent hardware and operating system software PLC: A programmable logic controller RTU: A remote terminal unit SCADA: Supervisory control and data acquisition UPS: An uninterruptible power supply The terms dispatcher, operator, and controller all refer to the individual who is responsible for supervisory control of the pipeline. The term controller will be used in this document. 1

10 2 API PUBLICATION 1113 SECTION 2 DEVELOPING SYSTEM ARCHITECTURE No. Item Notes 1 Decide whether to install a centralized system or a decentralized system. 2 Decide whether to use a single computer system or a distributed computer system. 3 Decide whether to use a hot standby configuration. 4 Determine which computer operating systems are acceptable. 5 Consider using a historical database system that is compatible with the corporate database system. 6 Consider whether to use smart field devices such as microprocessor-based RTUs, flow computers, PLCs, and smart instrumentation devices. 7 Consider whether each data user will communicate directly with the field device or will data users access field data through the SCADA system. 8 Determine which if any functions should be distributed to the field to best allow for speed, accuracy, and future expansion. 9 Determine data-transmission protocol and determine whether standard protocols between various computers, remote terminal units, and programmable logic controllers will be enforced. Consider the option of using a publish/subscribe approach to facilitate data sharing. Publish/subscribe is a technique in which all processes and devices that supply data publish it to the network, and components which require data subscribe to it, with the actual supply of the data managed by a broker. 10 Determine whether remote communication will be by means of satellite or by terrestrial means, such as leased lines, microwave, and spread spectrum or high-frequency radio. Determine whether the appropriate means of backup remote communication will include satellite, terrestrial means, or both. 11 Consider using an EDI to link with external information systems. 12 Consider data integration with management information systems and power optimization systems. 13 Consider capabilities for on-line training, testing, and maintenance. 14 Consider the software structure or architecture and the ease with which future features and functionality could be added to it. 15 Consider using open systems technology to support portability to other platforms. 16 Consider data integration with leak-detection and batch-tracking systems. 17 Consider capabilities for remote or dial-in maintenance.

11 DEVELOPING A PIPELINE SUPERVISORY CONTROL CENTER 3 SECTION 3 DEVELOPING SYSTEM RELIABILITY No. Item Notes 1 Consider using a redundant system, in either a hot backup configuration or a cold backup configuration, in case of a computer failure. 2 Consider using the further redundancy of a third computer system located at a different site to mitigate threatening circumstances, such as a disaster, a fire, and threatening weather. Determine the maximum acceptable delay to activate the third system (i.e., travel, system start-up). 3 Decide the maximum acceptable delay, in case of a failure, before a redundant computer or communications link is available. 4 Determine whether technicians are available for manual fail-over in case there is no automatic fail-over. Determine if controllers can perform this function. 5 Consider the impact of changes to system logic caused by technicians through remote access means. Limit remote access, provide additional levels of security, and record audit trails for all changes as necessary. 6 Consider using modems with diagnostic capabilities and data reliability checks on your system s communications. 7 Decide what the maximum time should be between when an event occurs in the field and when the system notifies the controller of the event, and determine whether all events should be treated in the same way. 8 Decide what the maximum time should be between when a command is issued and when it s received in the field. 9 Determine the accuracy, in terms of percent, of the analog readings in the system. 10 Consider having the control center audited by someone independent of the pipeline system group. 11 Determine the percentage of expansion capacity that should be available in the system when it begins operation. 12 Consider using backup support systems for the control center, such as backup support communications, power, and air-conditioning systems. 13 Consider all single-point equipment or component failures and their effect on system operation. 14 Consider using redundant on-line data storage. 15 Consider the periodic backup of critical data and of system parameters that the controller can change. 16 Consider establishing a procedure that would be implemented when communication with any remote site is lost. 17 Consider the use of preconditioning logic to allow critical switches to be made without being affected by temporary communications outages. This logic would be implemented as close to the switch as possible, removing the need to telemeter the data to a central site for processing and automated response. 18 Consider the potential effect of all types of data rollover, especially those related to dates. 19 Develop a plan addressing how system maintenance will be provided, including maintenance on on-line systems, and any provisions for preventive maintenance. 20 Consider providing on-line spares or backups of critical equipment such as HMIs, workstations, servers, and modems.

12 4 API PUBLICATION 1113 SECTION 4 DEVELOPING SECURITY AND DISASTER RECOVERY CAPABILITY No. Item Notes 1 Consider limiting access to the control room to authorized personnel. 2 Consider using a UPS that has a generator backup for the control center with the capacity to power the center for some predetermined period of outage. Determine what functions need to be supported by the UPS (air conditioning, voice communication, lighting, ). 3 Consider using automatic fire-detection and suppression systems. If they are installed, consider the testing period, maintenance, and training required for them. 4 Consider the possibility of water damage and how to minimize the damage. 5 Determine the need for a readily available contingency plan that outlines the procedures necessary for pipeline control from an alternate operations location in case the control room becomes inoperative. This would include consideration of the possibility of equipping remote sites with HMIs for local control. 6 Determine the emergency procedures required by the center, including a procedure for control center evacuation, and determine the frequency with which they will be reviewed. Consider holding mock drills. 7 Determine the need for backup supervisory control capability, including backup communications links. 8 Consider that controllers may need training in procedures for handling bomb-threat telephone calls. 9 Consider using checklist or report forms for recording emergency calls and telephone threats. 10 Determine whether any intruder alarms need to be installed at unattended locations. 11 Carefully consider using software security to avoid tampering, lost data, and intrusion. 12 Consider using off-site data storage and consider how often the data should be updated. 13 Consider using an automatic telephone-recording system. 14 Consider the need for video surveillance capability at central and remote sites. 15 Consider establishing written procedures covering damage-prevention measures to be taken in case a natural disaster, such as a hurricane, is imminent. 16 Have all emergency telephone numbers associated with each pipeline accessible from the CRT. 17 Consider the reaction times of appropriate emergency response agencies, such as the fire department and utility companies. 18 Consider the failure of the corporate voice communications system. Determine if the corporate voice communication system has a UPS.

13 DEVELOPING A PIPELINE SUPERVISORY CONTROL CENTER 5 SECTION 5 DEVELOPING THE CONTROL ROOM DESIGN No. Item Notes 1 Consider having a specialist design the control room by taking input from personnel who will work in the room. Specialist knowledge should include issues related to rotating or 12-hour shifts. 2 Specifically consider lighting levels and glare from windows and lights. Consider using indirect lighting. 3 Consider the color of the work surface or desktop and consider the reflection on computer screens of light from the counter top. 4 Consider a method to control humidity for improving room comfort and reducing static electricity. 5 Because the temperature and humidity requirements of humans and machines are different and because of smoke and other people-generated contaminants, consider placing the equipment and computer areas in a room that is separate from the room for the controllers. 6 Determine which computer room the equipment controllers will frequently access, so that the equipment can be placed as near to the control room as possible to reduce traffic in the computer room. 7 Consider separating the temperature and humidity controls for the dispatching area from those for the equipment and computer areas. 8 Consider ways to suppress the noise levels in the control room. 9 Consider installing an automatic fire detection and extinguishing system and consider the time delay required for its activation. 10 Decide whether all commonly viewed items in the control room should be at the controller s eye level or viewing angle. 11 Determine whether all primary controls should be within arm s length of the controller. 12 Determine how many CRTs are required for controllers to perform their duties 13 If more than one CRT is required, consider using a single keyboard and mouse for all CRTs. 14 Consider using a large projection screen to display information of use to all controllers in the room, to free up screen space on individual consoles. 15 Consider clustering the primary controls and displayed information logically. 16 Consider a control room design that enables the controller to perform all primary duties while seated. 17 Compare the advantages of windows, probably equipped with blinds, in the control room against the disadvantages of the potential glare and heat transfer the windows would allow and their impact on control room security. 18 Decide whether to permit smoking, eating, and drinking in the control room. Also, consider the proximity of break rooms and restrooms to the control room. 19 Consider the space requirements and physical layout of all telephone, radio, and other telecommunications gear on the controller s workstation. 20 Consider building a mock console before final fabrication of the controller console so the controllers can test the console. 21 Consider a console design that addresses ventilation for the CRTs and other equipment in the console. 22 Consider future expansion in planning control room size and location. 23 Consider using a separate area and console for training, engineering, and technical support, possibly in one or two rooms adjacent to the control room. Consider making the training console identical to an operational console so that it can be used as standby equipment if necessary. 24 When designing the floor plan for the control room, consider minimizing or avoiding through-traffic. 25 Consider installing individual light controls on the console so that while seated at his or her console, the controller can adjust its lighting without changing the general control room lighting. 26 Consider using a raised floor in the control room and in the computer room. 27 Consider making critical equipment and functions in the control center and computer areas clearly and easily visible or providing the critical equipment and functions with alarms. 28 When locating the UPS battery banks, consider potential damage to control center electronics from fumes. 29 Consider computer room security separately from control room security. 30 Consider having some area lighting powered by a UPS in case of power loss. 31 Consider using floor space for demonstrations given to visitors.

14 6 API PUBLICATION 1113 SECTION 6 DEVELOPING THE HUMAN-MACHINE INTERFACE No. Item Notes 1 Consider using colored, high-resolution CRTs to display graphics. 2 Determine the color standards, such as which color will designate the active status. 3 Determine the need for a customized push-button panel, light pens, touch sensitive screens, or other special equipment necessary for entering information into the SCADA system. Weigh the pros/cons of customized equipment versus off-the-shelf equipment. 4 Consider incorporating both visual and audible alarms. Consider multiple tones to distinguish alarm priorities. 5 Consider incorporating a voice synthesizer to enunciate critical alarms. 6 Consider that the controller may require the ability to monitor some data more frequently than others. 7 Consider installing a check-back routine between the system and the controller to minimize the execution of erroneous commands. 8 Consider having a communications-failure indicator and alarm. 9 Consider the best way to provide on-the-job or organized classroom training for the system controllers. Take into account the DOT requirements for controller certification. 10 Consider providing a training station that simulates field activity for training. 11 Determine the need to make provisions in the system for color-blind controllers. 12 Decide how to represent data using tabular data screens, piping displays, LEDs, and other alternatives. 13 Decide whether the system should execute any commands automatically, without controller intervention. 14 Determine whether a controller may require the ability from his or her own workstation to monitor or control the line section of another controller. 15 Consider the level of field maintenance required for equipment that is necessary to support the control center. 16 Consider using protection against the accidental execution of commands. 17 Consider the times required to update and refresh a CRT. 18 Consider using intelligent logical cross checks and software interlock to avert controller error. 19 Consider using standardized formats for all similar displays. 20 Consider access to corporate electronic mail systems and other standard applications (word processing, spreadsheet, etc.). Determine if this access should be through the SCADA consoles or through a stand-alone device. 21 Consider how workload levels should be distributed among the controllers. 22 Consider providing a device that will create a hard copy of any image on a CRT screen. 23 Consider recording alarms, controller-initiated commands, and events in either a hard-copy log or a disk-file log. 24 Plan the layout and organization of all displays, to group information logically, and to call attention to changes in field data, especially for long or complex pipelines. 25 Consider developing naming standards for locations, companies, pipeline systems, etc. 26 Consider developing naming standards for database point names. 27 Consider prioritizing types of system alarms through a scheme such as color coding or making only toppriority alarms audible, so that emergency alarms are readily distinguished from less critical alarms. 28 Consider developing display standards for device symbols, colors, line thickness, general layout, etc.

15 DEVELOPING A PIPELINE SUPERVISORY CONTROL CENTER 7 SECTION 7 DEVELOPING THE DATA-RECORDING SYSTEM No. Item Notes 1 Determine appropriate policies regarding the need to keep records of analog signals; delivery schedules; batch tracking, batch changes, or both; tank activity; daily telecommunication instructions; ticket information; upset conditions; and other pertinent activities, conditions, or data. Some of these policies need to satisfy various government regulatory bodies and management guidelines. 2 Consider designing the system so that it enables you to trace the sequence of events before, during, and after any accident or serious equipment failure. 3 Consider whether the records will be kept on hard copy or on electronic media. 4 Determine whether immediate review of past analog data on the computer is required and, if it is required, determine how long into the past the review should extend. 5 Consider using computer-captured data to simulate and analyze hypothetical situations. Consider providing SCADA and the capability to play back SCADA-captured data for training with situation reenactment. 6 Consider providing the capability to search records for certain types of data or events. Evaluate the available products that are specifically designed for efficient long-term data archival, quick retrieval, and thorough analysis. 7 Determine the retention period of all historical data. Consider both on-line and off-line retention periods. 8 Consider the regulatory requirements regarding frequency and retention time for high and low value extremes in measurements. 9 Consider the load of external access to historical data on the SCADA system.

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