Canvas - l&t Electrical& Automation

18/11/2015 CANVAS - L&T ELECTRICAL& AUTOMATION

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Issue 4

Dear Reader,

Oil and Gas (O&G) comprising crude oil, petroleum products and refineries is one of the core sectors of the India economy. Itplays a significant role in the country's economic development as well as in addressing its energy concerns.

The Indian O&G sector is projected to touch US $ 139,814.7 million by 2015 from US $ 117,562.9 million in 2012, thereby,providing vast business and investment opportunities in its entire value chain. The growing energy demand presentsopportunities like exploration for domestic production growth, development of discovered fields, transportation of crude oil, gasand products, refining to service the petroleum product demand retailing infrastructure.

To meet India's growing demand for hydrocarbon, it is vital to have in place infrastructure such as import terminals, pipelines,intermediate storage terminals, etc. from source to consumers. The Indian government has earmarked US $ 5 billion in theHydrocarbon Vision 2025 to facilitate the growing demand of the pipeline and terminal sectors.

On account of increased activities in exploration, refining and transportation of O&G, safety concerns have become a criticalfactor. To prevent recurrence of incidences like the fire tragedy at IOCL - Jaipur, the industry is working on M.B. Lal Committeerecommendations'. Some of its key recommendations pertaining to enhancing automation level, security and surveillancesystem, emergency shutdown system, remote operation etc. are being implemented.

Further technological advancements make it possible to build huge infrastructure which increases productivity while ensuringthe safety and quality.

We at C&A are fully geared to support the Indian O&G sector in its efforts to become a world player in the automation space.Our expertise spans commissioning of more than 25 terminals and over 18000 KM pipelines in India and abroad, coupled withcompetencies in Drives, Instrumentation, Control System, SCADA, Safety System and MIS.

This issue's cover story highlights the benefits of moving SCADA application to a cloud-based environment which cansignificantly cut costs while increasing reliability and scalability.

Enhancing productivity and safety, eliminating human errors and repetitive tasks, saving time, etc. are some of the key factorsin Terminal Automation. The case study section features just one out of the many successful projects we have handled -Terminal Automation System at HPCL.

Our parent company - Larsen & Toubro is uniquely positioned as a key contributor to the Indian O&G sector's sustainablegrowth. By continually partnering with oil companies, we develop and provide technology solutions to these companies forgrowing their business profitably.

Wishing you continued success during 2014 and hoping that our association yields value to India's growth story.

Happy Reading !

Sandeep Bhat



Leveraging the 'cloud' for SCADA

Moving SCADA applications to the cloud can enhance Reliability and Scalability while cutting costs significantly

Cloud computing is becoming more common and mostdesirable technology in communication environment wherecomputing resources such as hardware or/and software areprocessed as service over networks. With cloud computing,one can eliminate the pain of managing one's hardware andsoftware.

Businesses are running all kinds of apps in the cloud, likecustomer relationship management (CRM), HR, accounting,and much more. The Cloud environment provides highscalability with the ability to react to on-demand resourcerequirements in near real-time, fast and easy deployment ofnew applications, increased responsiveness and loweroverall cost to the business.

As cloud computing grows in popularity, companies areevaluating the applicability of cloud-based solutions formanufacturing and process control systems.

SCADA (supervisory control and data acquisition)implementation within cloud environment is relatively newand drawing attention. By moving SCADA infrastructure to acloud-based environment, it can save companies moneyand time by eliminating the need for building andmaintaining their own dedicated server rooms, whilereducing SCADA administration costs and overall risks. Inaddition, users can significantly achieve greater reliabilityand enhanced functionality.

Clients can get full access for customisation of their ownSCADA application. All data is housed in a databasehistorian within the cloud. As needs evolve, the system canbe fully convertible at any point in the future to atraditionally-hosted solution on a company's dedicatedservers.

Cloud computing can support SCADA applications in twofashions:

The SCADA application is running on-site,directly connected to the control network anddelivering information to the cloud where it canbe stored and disseminated, or

The SCADA application is run entirely in thecloud and remotely connected to the controlnetwork.

Figure 2

The implementation illustrated in Figure 2 is common todistributed SCADA applications where a single, localSCADA deployment is not practical. The controllers areconnected via WAN links to the SCADA application runningentirely in the cloud. These applications are commonlyimplemented using private or hybrid cloud architectures.

Typical Applications..

Utility ( Electricity, Water & Gas ) SCADA

Automatic Meter Reading

Building Management System

Renewable (Solar, Wind, Small Hydro Plant)

Asset Management / Condition Monitoring

Benefits of cloud computing for SCADA

High efficiency - Cloud is based on clusteringand virtualization, offer high efficiency and highutilization due to the sharing of pooledresources, enabling better workload balancingacross multiple applications

High availability- Another benefit of clusteringis that applications can take advantage of ahigh availability architecture that minimizes oreliminates planned and unplanned downtime,



Figure 1

The first method is by far the most common and isillustrated in Figure 1. The control functions of the SCADAapplication are entirely isolated to the control network.However, the SCADA application is connected to a servicein the cloud that provides visualization, reporting, andaccess to remote users. These applications are commonlyimplemented using public cloud infrastructures.

improving user service levels and businesscontinuity

On-demand resources - Users are able to addresources on demand as and when needed withno downtime

Fast deployment -- With ready, standard,reusable and shared IT backbone, applicationdeployment is greatly accelerated and newapplication can be run in a few minutes

Ease to Maintain -- As it centrally managed, itbecomes easy to manage updates andpatches, and provides testing advantagesthrough the ability to clone machines

Integrated solution for Oil & Gas

Control & Automation (C&A) business of L&T Electrical &Automation offers integrated automation,telecommunication, electrical and instrumentation systemsfor Oil & Gas (upstream, mid & downstream) encompassingtotal solutions right from input power supply to the last fieldinstrument. It delivers value from its big bouquet of solutionsthat are based on different technology platforms andincorporate the benefits of wide ranging experience. Thesolutions for Oil & Gas portfolio covers:

1. E, C&I Solution for Terminals

Our solutions offer scalability and high availability, fromsingle-node installations to multi-tier systems. Security isat the centre of our solutions with state-of-the-art featuresalong with sophisticated front-end communications,geographical redundant configurations and automaticswitchover.

Our Offering Comprises:

Pipeline SCADA Software SCADA formonitoring of the Pipeline

Leak Detection System.

Turnkey Instrumentation.

Safety PLC for ESD/ Shutdown Operation.

Entire Pipeline Modelling

Fire and Gas System including Gas detectors

Communication system between Outstation andControl Room.

Management Information System

Telecom system including EPBAX and PAGA



C&A undertakes turnkey execution for loading/unloadingterminals, along with specific requirements of F&G and ESDoperation. Packages are tailored to meet the specific needsof the clients.

The Integrated Terminal Solution delivers value fromconception to implementation and operation for distributionand bulk terminals, such as refinery off-sites, fuel storageand distribution sites, petrochemical storage, loadingfacilities and marine, rail and truck loading.

Our terminal and tank farm experience includes productssuch as crude oil, refined oil, liquefied natural gas,petroleum gas and chemical tank farms, utilizing loadingsystems for ships, trains, trucks and pipelines. With dataintegration as the system's core, combinesautomatic control and business management functions


-Terminal Automation Software -Highly scalable, configurable, reliable with 99.99%of time.

Terminal Security and Access Control

Instruments for Tank Measurement including radarlevel transmitters, pressure / temperaturetransmitters, Mass flow meters, Gauges, etc.

Accurate Flow measurement for custody transfer.

Loading Arms, Batch Controllers, Card Readers,Earthing Relays

Remote Valve control

TUV Certified PLC system

Hydrocarbon Gas detectors (HC, H2,H2S) with firealarm panel.

Complete Integrated solution by integrating varioussub-systems

Variable Speed Drives for flow control.

Electrical Power Distribution System includingMCCs

Perimeter Intrusion detection system.

Lifecycle Services including system upgrades andlong term AMC contract.

2. Integrated Telecom & Automation solution for CrossCountry Pipelines.

Cross country pipeline is a complex ecosystem requiringdiverse technology solutions and services for differentoperations. This invariably results in deployment of separateinformation systems for a given operation. For enhancing theefficiency, one has to take into consideration all thisinformation in real time.

C&A is one of the largest integrators of solutions forpipelines. Having executed over 18,000 Km of pipelines inIndia and abroad, C&A is one stop solution for Oil and Gaspipelines including Pump and Block valve stations. Ourvalue services range from providing top notch pipelinemanagement solutions comprising electrical, automationequipment and intelligent instrumentation.

Surveillance System

Perimeter Intrusion detection system.

Lifecycle Services including system upgrades andlong term AMC contracts.

3. Electrical Control System.

Refineries need electrical power which is sourced fromutilities, captive power plants and renewable energysystems. The emphasis is on efficient use of all suchpower sources along with effective management of loads,power quality and assets.

, provides a complete Power ManagementSolution (PMS) for cost effective & efficient energyutilization by maintaining continuous & reliable operation,avoiding penalty in case maximum demand is exceeded,improving power quality, reducing maintenance cost,reducing manpower cost and thus increasing profitability interms of lower production costs. For some refineries, costsconstitute as much as 20-30% of total operating costs andhence even small improvement in operational efficiency canhave a dramatic impact on its bottom line.

provides comprehensive information onoptimization potentials and utilization parameters to becorrelated with KPIs viz., energy efficiency, productionrates, process efficiency, power quality, asset optimizationand further supports the decision-making process with up-to-date information.


Real time Control & Monitoring

Synchronization and load sharing using mix ofElectrical and automation components .

Energy accounting involving group energyconsumption tracking and saving

Power Quality Monitoring

Asset Management

Economic Dispatch

Load Forcasting

Availability Based Tariff

Renewable Integration and Generation Forecasting



HPCL deploys Larsen & Toubro's Terminal Automation Solution for largest black oil

terminal in Vizag

Background

Hindustan Petroleum Corporation Ltd. (HPCL) is aGovernment of India enterprise with a 'navratna' status, aswell as a Fortune 500 and Forbes 2000 company. Itsannual turnover during FY 2012-13 was Rs. 1,90,048crore. It operates two major refineries producing a widevariety of petroleum fuels and specialties. The capacity ofthese refineries in Mumbai (West Coast) is 6.5 MillionMetric Tonnes Per Annum (MMTPA) and inVishakapatnam (East Coast) 8.3 MMTPA respectively.

The Need

Since the terminals are becoming more strategic thanever before, HPCL decided to develop the modern blackoil terminal on a 38-acre plot of land within a record timeof 15 months using all advanced project managementtechniques. The primary focus was on accuracy andavailability of operation while maintaining high safety andsecurity standards at the storage terminals.

HPCL placed the order to supply and commission theTerminal Automation System for Black Oil Terminal atVizag with Control & Automation (C&A) business unit ofL&T Electrical & Automation (EAIC), an independentcompany of Larsen & Toubro Limited (L&T).

The primary task was to complete design, engineering,supply, installation, testing and commissioning ofTerminal Automation Solution in less than eight months tohandle 94,000kL products like FO-180/380/500, Bitumen,LVFO, FO Blend, LSHS, HFHSD, LDO, JBO and LubeOil. This project had strategic importance as it hascreated space for Visakha Refinery expansion for theproduction of EURO IV grade fuel (Diesel Hydro TreatmentUnit Project).

The Solution

The project goals were safe and efficient operation of theTerminal while at the same time reducing manualintervention and reducing pollution and labour cost. HPCLchose to implement C&A's proven Terminal Automationsolution comprising automation, field instrumentation andsafety systems.

Completion of the project in a short period involveddelivering C&A's proven solutions - the -SIL certified software with high level of integrity along withmetering instruments like DCV, Thermal Jacketed MassFlow Meter suitable for black oil application, Fire AlarmSystem, Weigh Bridge system for Mass Based loading,VFD Interface, Tank Body and Header Line ValveAutomation etc.

System configuration

Click to enlarge

A range of technologies supplied to the Black Oil Terminalcomprise:

the and terminal managementsystem

Tank level gauges, Pressure Transmitters, Truckloading metering and control system.

SIL 3 certified Shutdown System

Fire & Gas systems

Industrial security with access control solutions,CCTV and Digital Video Manager

Access Control System, Fire Alarm System:

Benefits

The solutions have enhanced HPCL'sefficiency by reducing operational time while maintaining asafe and healthy environment.

All the terminal operations including MOV were fullyautomated which has helped in improving the terminal'sefficiency.

Post HPCL's inauguration of the terminal on 20thSeptember, 2010, it has been used to successfully fill65000 lorries. On an average, the terminal handles around60 tank lorries per day.

C&A has so far delivered Terminal Automation Solution atHPCL Black Oil Terminal, LPG Terminal at Vizag, WhiteOil Terminals at Ajmer and Jaipur which has helped thesecompanies to increase the efficiency of their terminalswith zero accidents reported so far.

http://www.lntebg.com/CANVAS/Bay.htm



The system is built around the , an integratedplatform, that automates and controls petroleum terminalsfor Tank Trucks, Wagons, Tubes for Black Oil. Thesolution helps to operate and control a total of 29 TLFloading points, 4 TW loading points and 33 product tanksfrom receiving to storage to distribution of different fuels.

With its user friendly Graphical User Interface, users cangenerate different reports like tank trucks, product fillingand bay idle reports for the terminal operators to monitorterminal's efficiency.

Certificate of appreciation from HPCL

To operate this Terminal safely, and effectively wedecided to have Terminal Automation System whichprovides real-time monitoring, control and management ofthe entire product handling process from receiving tostorage to distribution. Receiving product from refineryand jetty and also pumping product to Jetty and TTloading.

What sort of challenges will the systemhelp you to overcome? / Kindly tell us in detail ofthe benefits you seek from Terminal AutomationSystem implemented?

Mr. K V Sreenivas Raju - L&T's is required tohelp our various operations like Tanker Truck Loading /Un Loading , Material transfer and tracking , Inventorymanagement, and ERP interface. It is required to improveoperational safety, accuracy, system optimization andoverall efficiency by reducing manual intervention.

Tell us something about your experience with L&TAutomation on this project

Mr. K V Sreenivas Raju - We are satisfied with L&T'steam performance and continued support, which helpedus in achieving our project milestones.

L&T has to further imporve in providing dedicated teamwho have application domain knowledge and has matureengineering capability that aid in accomplishing ourproject objective of building efficient and securedTerminal.

L&T was selected by Hindustan Petroleum CorporationLimited (HPCL) to provide Terminal Automation Solution forits new Black Oil Termial at Visakhapatnam. We spoke toMr. K V Sreenivas Raju, Chief Manager - Projects to capture

their experience on L&T�s Terminal Automation solution as

well as working with the L&T Team.

Please give us a brief about your company and blackoil terminal Operations

Mr. K V Sreenivas Raju - Hindustan PetroleumCorporation Limited (HPCL) is an integrated oil refining andmarketing company. In 2010 we set up a new terminal atVisakhapatnam, which is largest exclusive black oil terminalin India with a product handling capacity of about 94,000kL.The terminal has provision for loading product of customized



needs of marketing to cater industries from eastern hub.

What are your reasons to adopt an integrated terminalautomation system at BOT?

Mr. K V Sreenivas Raju - Terminals represent an importantlink in the petroleum supply chain. The Black oil Terminalproject has strategic importance as it creates space forVisakha Refinery expansion for production of EURO IVgrade fuel (Diesel Hydro Treatment Unit Project).

With more number of terminals coming in India, we hopeL&T will augment it's TAS project execution team.

Our Offerings

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You may also send an e-mail to: [email protected]

The views expressed in this magazine are not necessarily those of the managment of Larsen & Toubro Limited. The contents of this magzine should not be

reproduced without written permission from the company. Only for circulation among the customers and business partners of Larsen & Toubro Group of

Companies.

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