SCADA Field Operations PDF

Table of Contents {#table-of-contents.TOCHeading} ================= [Scope: 3](#scope) [Definitions: 3](#definitions) [Vessel Unloading Automation 4](#vessel-unloading-automation) [General 4](#general) [Procedure 4](#procedure) [Vessel Loading Automation 6](#vessel-loading-automation) [Genera...

Table of Contents {#table-of-contents.TOCHeading} ================= [Scope: 3](#scope) [Definitions: 3](#definitions) [Vessel Unloading Automation 4](#vessel-unloading-automation) [General 4](#general) [Procedure 4](#procedure) [Vessel Loading Automation 6](#vessel-loading-automation) [General 6](#general-1) [Procedure 6](#procedure-1) [Truck Loading Automation 8](#truck-loading-automation) [General 8](#general-2) [Procedure 8](#procedure-2) [Truck Un-Loading Automation 9](#truck-un-loading-automation) [General 9](#general-3) [Procedure 9](#procedure-3) [Railcar Loading Automation 9](#railcar-loading-automation) [General 9](#general-4) [Procedure (Top Loading) 10](#procedure-top-loading) [Procedure (Bottom Loading) 10](#procedure-bottom-loading) [Railcar Un-Loading Automation 11](#railcar-un-loading-automation) [General 11](#general-5) [Procedure (Top Unloading) 11](#procedure-top-unloading) [Procedure (Bottom Loading) 12](#procedure-bottom-loading-1) [Tank to Tank Automation 12](#tank-to-tank-automation) [General 12](#general-6) [Procedure 13](#procedure-4) [Circulation Automation 13](#circulation-automation) [General 13](#general-7) [Procedure 13](#procedure-5) [Purging to Tank 13](#purging-to-tank) [General 13](#general-8) [Procedure 13](#procedure-6) [Vessel to Tank/Railcar Automation 14](#vessel-to-tankrailcar-automation) [General 14](#general-9) [Procedure 14](#procedure-7) [Cleaning 14](#cleaning) [General 14](#general-10) [Procedure 15](#procedure-8) [Tank Out of Service 15](#tank-out-of-service) [General 15](#general-11) [Procedure 15](#procedure-9) [Tank Empty 16](#tank-empty) [General 16](#general-12) [Procedure 16](#procedure-10) Scope: ====== The **SCADA (Supervisory Control and Data Acquisition)** philosophy guide serves as a comprehensive reference for all stakeholders involved in the design, implementation, and operation of SCADA systems within our organization. Its primary objectives are: 1. **Consistency**: Establishing uniform practices and principles across all SCADA installations ensures consistent behavior, reduces errors, and enhances system reliability. 2. **Best Practices**: By adhering to well-defined guidelines, we can optimize system performance, minimize downtime, and improve overall operational efficiency. 3. **Risk Mitigation**: The guide outlines strategies to mitigate risks associated with alarm management, HMI design, and control strategies. 4. **Operational Excellence**: A well-structured SCADA philosophy contributes to seamless day-to-day operations, effective troubleshooting, and informed decision-making. This guide is intended for: - **Control Engineers**: Involved in SCADA system design, configuration, and maintenance. - **Operators**: Responsible for monitoring and interacting with the SCADA system. - **Managers and Supervisors**: Overseeing control room operations and ensuring compliance with established practices. The guide is organized into several key sections, each addressing critical aspects of SCADA philosophy: 1. **Alarm Philosophy**: Defining how alarms are generated, prioritized, and managed. 2. **HMI Style Guide**: Providing principles for designing intuitive and effective HMI screens. 3. **Control Philosophy**: Outlining dos and don\'ts for functional design specifications (FDS). Definitions: ============ 1. **Control Room Operator:** Operator that has been adequately trained in SCADA. 2. **FDS:** Functional Design Specifications. A document that describes how a process or control system will operate, detailing the functional requirements from a user's perspective. 3. **Fully Automated:** Tank systems that are equipped with High Suction, Low Suction, Recirculation, By-pass (if applicable), truck and rail actuators, pumps, and safety instruments that are controlled through SCADA. 4. **HMI:** Human Machine Interface used to control functions 5. **Non-Automated:** Tank systems that are only equipped with pump control through SCADA and no safety instruments. 6. **Operator:** Competent person in charge of field operations 7. **SCADA:** Supervisory Control and Data Acquisition. 8. **Semi-Automated:** Tanks systems that are equipped with only truck and rail actuators, pumps and some safety instruments that are controlled through SCADA. Vessel Unloading Automation =========================== General ------- Commanding this function can be done from the operator station in the control room (not from the HMI in the field). 1. The button for dock line approval will be enabled when the function is selected. 2. The transferred quantity is based on the mass in the tank. 3. Selecting the function is done on the function handler of the destination tank. 4. The dock line connected to the tank is selected on the parameter screen. (T1.6 Dock line) 5. The Marine bypass valve (XV08) is used when there are two P01 pumps (Land and Marine). Procedure --------- 1. Before the Vessel to Tank function is selected, pre-load conference needs to be completed so the final nomination can be calculated and agreed upon with the Vessel and Terminal a. Note: Assign the associated dock line for that specific move in the Parameter screen to the proper tank. (T1.6 Dock Line) 2. Once dock hose is connected and pressure tested and line up is confirmed with all manual valves in the correct position, the Control Room Operator can the proceed to initiate the Vessel to Tank function. b. Note: The Control Room Operator is defined as an employee who has been trained and understands the functioning of SCADA. 3. The Control Room Operator will then proceed to go through the steps of setting up the vessel to tank function. c. Note: Each step will have an Operator Message explaining what step needs to be done. d. Reference the FDS Section 4.6.3 for start and stop conditions. 4. The Control Room Operator will communicate with the Dock Operator to confirm the correct valve is approved on the HMI in the dock shack. e. Note: Dock line confirmation can only be done on HMI in dock shack f. Note: Control Room Operator must wait for acknowledgement from dock operator before proceeding any activity. I.E. Open/close actuators, start pumps, start functions, etc. 5. Before pressing the "Start" button, look over the data entered to confirm the correct information was entered. g. At this point, the Control Room Operator will communicate with the Dock Operator that they are setup and ready and confirm that the Dock Operator is ready to receive product from the vessel. 6. Control Room Operator will confirm that the correct actuators are opening and confirm product moving into the tank along with the Lead Operator and Dock Operator. h. Reference the FDS Section 4.6.4 for the functionality of the actuator and pump i. Note: Vessel to Tank function will not stop the function when the batch is reached 7. Upon completion of movement, the function is ended by the Control Room Operator. i. Follow the Operator Messages to complete the function. ii. Note: The function handler will direct the Control Room Operator to perform a Purge to Dock function, but that function is currently unavailable. 8. If the line requires pigging, the Control Room Operator will perform a Purge to Tank function. j. Reference the FDS Section 4.9 for functionality of the actuators and pump 9. Control Room Operator with communicate with the Dock Operator to confirm the correct valve on the HMI in the dock shack. k. Note: Note: Dock line confirmation can only be done on HMI in dock shack 10. Control Room Operator will communicate with Dock Operator and Lead Operator to which actuators are ready to be open. l. Note: If the Control Room Operator is unable to perform the opening and closing of actuators, the responsibility will be handed over to the Dock Operator. m. The Control Room Operator will then communicate with the Dock Operator to resume responsibility of the function and will not proceed until acknowledgment from Dock Operator. n. Note: Terminal is currently operating in a hybrid setup of "Fully Automated", "Semi-Automated", and "Non-Automated" tank systems. See Definition Section o. All Dock actuators can be controlled in SCADA. This allows the Purging to Tank function to be used for all 3 tank systems. p. Fully Automated tanks with a pig trap that allows the pig to be trapped by a gate valve, the Control Room Operator will communicate with the Lead Operator to open/close actuators when necessary. q. Fully Automated tanks without pig trapping by Gate Valve, the Control Room Operator will put all necessary actuators in Operator Mode. iii. Operator Mode will prevent the Purging to Tank function from shutting down due to the manually opening/closing of the tank actuators. r. Semi-Automated and Non-Automated tanks, the Control Room Operator can perform the Purge to Tank function as these tanks will have manual valves and not cause an alarm shutdown. 11. Upon completion, the Control Room Operator will end function and put any actuators back into program mode. Vessel Loading Automation ========================= General ------- Commanding this function can be done from the operator station in the control room (not from the HMI in the field). 1. The button for dock line approval will be enabled when the function is selected. 2. The transferred quantity is based on the mass in the tank. 3. Selecting the function is done on the function handler of the destination tank. 4. The dock line connected to the tank is selected on the parameter screen. (T1.6 Dock line) 5. The Marine bypass valve (XV08) is used when there are two P01 pumps (Land and Marine). Procedure --------- 1. Before the Tank to Vessel function is selected, pre-load conference needs to be completed so the final nomination can be calculated and agreed upon with the Vessel and Terminal a. Note: Assign the associated dock line for that specific move in the Parameter screen to the proper tank. (T1.6 Dock Line) 2. Once dock hose is connected and pressure tested and line up is confirmed with all manual valves in the correct position, the Control Room Operator can the proceed to initiate the Tank to Vessel function. b. Note: The Control Room Operator is defined as an employee who has been trained and understands the functioning of SCADA. 3. The Control Room Operator will then proceed to go through the steps of setting up the Tank to Vessel function. c. Note: Each step will have an Operator Message explaining what step needs to be done. d. Reference the FDS Section 4.5.3 for start and stop conditions. 4. Control Room Operator will be prompted due perform the line fill function if needed. e. If line fill is required, the Control Room Operator will procced to follow the Operator Messages. Reference FDS Section 3.11 f. The line fill function will follow the same procedures proceeding this step in the process. 5. The Control Room Operator will communicate with the Dock Operator to confirm the correct valve is approved on the HMI in the dock shack. g. Note: Dock line confirmation can only be done on HMI in dock shack h. Note: Control Room Operator must wait for acknowledgement from dock operator before proceeding any activity. I.E. Open/close actuators, start pumps, start functions, etc. 6. Before pressing the "Start" button, look over the data entered to confirm the correct information was entered. i. At this point, the Control Room Operator will communicate with the Dock Operator that they are setup and ready and confirm that the Dock Operator is ready to receive product from the vessel. 7. Control Room Operator will confirm that the correct actuators are opening and confirm product moving into the tank along with the Lead Operator and Dock Operator. j. Reference the FDS Section 4.5.4 for the functionality of the actuator and pump k. Reference the FDS Section 4.5.4 for Stop Conditions 8. Upon completion of movement, the function is ended by the Control Room Operator. l. Follow the Operator Messages to complete the function. i. Note: The function handler will direct the Control Room Operator to perform a Purge to Dock function, but that function is currently unavailable. 9. If the line requires pigging, the Control Room Operator will perform a Purge to Tank function. m. Reference the FDS Section 4.9 for functionality of the actuators and pump 10. The Control Room Operator will communicate with the Dock Operator to confirm the correct valve is approved on the HMI in the dock shack. n. Note: Dock line confirmation can only be done on HMI in dock shack 11. Control Room Operator will communicate with Dock Operator and Lead Operator to which actuators are ready to be open. o. Note: If the Control Room Operator is unable to perform the opening and closing of actuators, the responsibility will be handed over to the Dock Operator. p. The Control Room Operator will communicate with the Dock Operator to resume responsibility of any function and will not proceed control until acknowledgment from Dock Operator is received. q. Note: Terminal is currently operating in a hybrid setup of "Fully Automated", "Semi-Automated", and "Non-Automated" tank systems. See Definitions Section r. All Dock actuators can be controlled in SCADA. This allows the Purging to Tank function to be used for all 3 tank systems. s. Fully Automated tanks with a pig trap that allows the pig to be trapped by a gate valve, the Control Room Operator will communicate with the Lead Operator to open/close actuators when necessary. t. Fully Automated tanks without pig trapping by Gate Valve, the Control Room Operator will put all necessary actuators in Operator Mode. ii. Operator Mode will prevent the Purging to Tank function from shutting down due to the manually opening/closing of the tank actuators. u. Semi-Automated and Non-Automated tanks, the Control Room Operator can perform the Purge to Tank function as these tanks will have manual valves and not cause an alarm shutdown. 12. Upon completion, the Control Room Operator will end function and put any actuators back into program mode. Truck Loading Automation ======================== General ------- 1. Commanding this function can be done from the operator station in the control room or from the HMI in the field. In both cases, the functionality is the same. 2. The transferred weight will be based on the weighbridge. 3. Selecting the function is done on the function handler of the truck loading bay where the truck is located. 4. The Land pump (and its bypass valve, XV08) is used, when there are two P01 pumps (Land and Marine). Procedure --------- 1. Truck Operator will command the function in the field using the HMI on the designated truck rack. 2. Truck Operator will perform truck loading checklist and prepare the truck for loading. 3. Truck Operator will confirm with Lead Operator that the correct line up is ready. 4. Truck Operator will start a Tank to Truck function for designated tank. a. Refer FDS Section 4.1 for functionality. 5. Truck Operator will end the function when batch is reached and begin after loading checklist. 6. The Control Room Operator is allowed to take responsibility in the event the Truck Operator is unable to perform the automated function. b. Control Room Operator will verbally confirm responsibility of the function and must receive acknowledgement from Truck Operator. Truck Un-Loading Automation =========================== General ------- 1. Commanding this function can be done from the operator station in the control room or from the HMI in the field. In both cases, the functionality is the same. 2. The transferred weight will be based on the weighbridge. 3. Selecting the function is done on the function handler of the truck loading bay where the truck is located. 4. The Land Bypass Valve (XV08) is used when there are two P01 pumps (Land and Marine). Procedure --------- 1. Truck Operator will command the function in the field using the HMI on the designated truck rack. 2. Truck Operator will perform truck un-loading checklist and prepare the truck for un-loading. 3. Truck Operator will confirm with Lead Operator that the correct line up is ready. 4. Truck Operator will start a Truck to Tank function for designated tank. a. Refer FDS Section 4.2 for functionality. 5. Truck Operator will end the function when batch is reached, or truck is empty and begin after un-loading checklist. b. Note: Truck Operator will have a choice to unload by batch or emptying. 6. The Control Room Operator is allowed to take responsibility in the event the Truck Operator is unable to perform the automated function. c. Control Room Operator will verbally confirm responsibility of the function and must receive acknowledgement from Truck Operator. Railcar Loading Automation ========================== General ------- 1. Commanding this function can be done from the operator station in the control room or from the HMI in the field. In both cases, the functionality is the same. 2. The transferred quantity is based on mass flowmeter. In case a mass flowmeter is not available, loading can be done based on the mass in the tank (T4.5 choice dosage). When Tank measurement is used, only one rail spot can be used at the same time for the same tank. 3. When the transferred quantity is based on mass flowmeter, the totalized value of the mass flowmeter will be reset to zero on three occasions: » When function is selected, and a valid tank ID has been entered. 4. At initial start of the function. I.e., when you press the START button for the first time during the selection. If the value is not initialized after this reset command, an alarm is generated which will stop the function. If resumed from this totalizer stop condition, then this sequence will repeat itself. Resuming the function after other stop conditions (i.e. not related to the totalizer) will not cause a reset command. 5. When the function has been completed. I.e., when you press the END button. 6. Selecting the function is done on the function handler of the rail spot where the railcar is located. 7. A selection can be made for a Land or a Marine pump (and its bypass valve, XV08), when there are two P01 pumps (Land and Marine). Procedure (Top Loading) ----------------------- 1. Railcar Operator will command the function in the field using the HMI on the designated rail rack. 2. Railcar Operator will perform railcar loading checklist and prepare the railcar for loading. 3. Railcar Operator will confirm with Lead Operator that the correct line up is ready. 4. Railcar Operator will start a Tank to Railcar function for designated tank. a. Refer FDS Section 4.3 for functionality. 5. Railcar Operator will end the function when batch is reached and begin after loading checklist. 6. The Control Room Operator is allowed to take responsibility in the event the Railcar Operator is unable to perform the automated function. b. Control Room Operator will verbally confirm responsibility of the function and must receive acknowledgement from Railcar Operator. Procedure (Bottom Loading) -------------------------- Note: This procedure is for railcars that are using the tank radar to determine the batch amount. 1. Before the Operator will command the function in the field, the Control Room Operator must remove the XV5\* actuator from the designated spot and tank. a. This system will act like there is no actuator installed and will not open the actuator or cause an alarm. b. The system will close the tank actuators and shut down the pump. The Operator must be on standby to close the ball valve as there is no destination actuator available. 2. Railcar Operator will perform railcar loading checklist and prepare the railcar for loading. 3. Railcar Operator will confirm with Lead Operator that the correct line up is ready. 4. Railcar Operator will start a Tank to Railcar function for designated tank. c. Refer FDS Section 4.3 for functionality. 5. Railcar Operator will end the function when batch is reached and begin after loading checklist. 6. The Control Room Operator is allowed to take responsibility in the event the Railcar Operator is unable to perform the automated function. d. Control Room Operator will verbally confirm responsibility of the function and must receive acknowledgement from Railcar Operator. Railcar Un-Loading Automation ============================= General ------- 1. Commanding this function can be done from the operator station in the control room or from the HMI in the field. In both cases, the functionality is the same. 2. The transferred quantity is based on the mass in the tank. 3. Selecting the function is done on the function handler of the rail spot where the railcar is located. 4. The Land bypass valve (XV08) is used, when there are two P01 pumps (Land and Marine). 5. Unloading multiple railcars to the same tank is only possible if all railcars are emptied. There will be no transferred quantity calculated. Procedure (Top Unloading) ------------------------- 1. Railcar Operator will command the function in the field using the HMI on the designated rail rack. 2. Railcar Operator will perform railcar un-loading checklist and prepare the railcar for un-loading. 3. Railcar Operator will confirm with Lead Operator that the correct line up is ready. 4. Railcar Operator will start a Railcar to Tank function for designated tank. a. Refer FDS Section 4.4 for functionality. 5. Railcar Operator will end the function when batch is reached, or railcar is empty and begin after un-loading checklist. b. Note: Railcar Operator will have a choice to unload by batch or emptying. 6. The Control Room Operator is allowed to take responsibility in the event the Railcar Operator is unable to perform the automated function. c. Control Room Operator will verbally confirm responsibility of the function and must receive acknowledgement from Railcar Operator. Procedure (Bottom Loading) -------------------------- Note: This procedure is for railcars that are using the tank radar to determine the batch amount. 1. Before the Operator will command the function in the field, the Control Room Operator must remove the XV5\* actuator from the designated spot and tank. a. This system will act like there is no actuator installed and will not open the actuator or cause an alarm. b. The system will close the tank actuators and shut down the pump. The Operator must be on standby to close the ball valve as there is no destination actuator available. 2. Railcar Operator will command the function in the field using the HMI on the designated rail rack. 3. Railcar Operator will perform railcar un-loading checklist and prepare the railcar for un-loading. 4. Railcar Operator will confirm with Lead Operator that the correct line up is ready. 5. Railcar Operator will start a Railcar to Tank function for designated tank. c. Refer FDS Section 4.4 for functionality. 6. Railcar Operator will end the function when batch is reached, or railcar is empty and begin after un-loading checklist. d. Note: Railcar Operator will have a choice to unload by batch or emptying. 7. The Control Room Operator is allowed to take responsibility in the event the Railcar Operator is unable to perform the automated function. e. Control Room Operator will verbally confirm responsibility of the function and must receive acknowledgement from Railcar Operator. Tank to Tank Automation ======================= General ------- 1. Commanding this function can be done from the operator station in the control room or from the HMI in the field. In both cases, the functionality is the same. 2. The transferred quantity is based on the mass in the tank. 3. Selecting the function is done on the function handler of the source tank. 4. The Marine pump (and its bypass valve, XV08) is used, when there are two P01 pumps (Land and Marine). Procedure --------- 1. Control Room Operator will be responsible for setting up Tank to Tank transfers. a. Tank to tank can be operated with hybrid tanks. b. Source tank will be used for calculations. c. Refer FDS 4.7 for functionality. Circulation Automation ====================== General ------- 1. Commanding this function can be done from the operator station in the control room or from the HMI in the field. In both cases, the functionality is the same. 2. Selecting the function is done on the function handler of the tank. 3. The Land pump (and its bypass valve, XV08) is used, when there are two P01 pumps (Land and Marine). Procedure --------- 1. Control Room Operator will be responsible for setting up Circulation function. a. Circulation function is for Fully Automated Tanks. b. Refer FDS 4.8 for functionality. Purging to Tank =============== General ------- 1. Commanding this function can be done from the operator station in the control room or from the HMI in the field. In both cases, the functionality is the same. 2. The function can be selected from Tank function handler. Procedure --------- 1. Refer FDS 4.9 for functionality. Vessel to Tank/Railcar Automation ================================= General ------- 1. Only for tank B110-01 a concurrent Vessel to Tank/ Railcar function is possible. This function can run Vessel to Tank separately but has the ability to add one or more railcars to the function. The tank functionality is the main function in this matter, this function will be selected first on the tank. When the function starts for the first time, only the Vessel to Tank part can be operational. If the VeTa is started, one or more railcars can be activated. The railcar functionality can be selected at the railcar itself. 2. An alarm or stop command on the tank shuts down the complete functionality while an alarm or a stop command on the railcar functionality will only stop the railcar. 3. The batch of the tank can be completed before the batch of one or more railcars. In this case the function has to stop at the tank and railcars. However, if the railcar functionality hasn't finished this function can be started again. The function at the tank has to stay selected in order to proceed with the railcar function. Procedure --------- 1. Control Room Operator will follow the procedure for Vessel to Tank Function but will Select Vessel to Tank/Railcar function. a. Refer to Vessel to Tank Section of this document. b. This function must be selected and started first before Vessel to Railcar function. 2. Railcar Operator will be responsible for starting the Vessel to Railcar function in the field after the Vessel to Tank/Railcar function has started and the railcar operator receives acknowledgement from the Control Room Operator he/she can proceed. c. Refer FDS 4.16 for functionality of Tank and Single/Multiple Railcars d. Note: The pump will not start for loading railcars. The XV08 actuator will control flow by closing the assigned percentage in the loading diagram. Cleaning ======== General ------- 1. Before Cleaning can be selected on the parameter screen, the tank must first be set to the state "Cleaning" by the Control Room Operator (T1.4 Tank in cleaning). In this state, alarms from the level measurement are being suppressed. 2. Commanding this function can be done from the operator station in control room and from HMIs in the field. a. Supervisor Level of Security is necessary. Procedure --------- 1. Special Services will make the request to the Control Room Operator as to which tank(s) is being cleaned that day and which actuators need to be opened. 2. Control Room Operator will set the tank into cleaning status in the Parameter screen. 3. Control Room Operator can then proceed to start the cleaning function. a. Refer FDS 4.12 for functionality. 4. Control Room Operator will document tank/valve status on the SCADA Equipment Out of Service Checklist. b. Note: At any time, the Control Room Operator is unavailable, permission can be given to the Senior Operator in Special Service to open and close actuators and/or operate pumps as needed from the field HMI's c. The Control Room Operator will communicate with the Senior Operator to resume responsibility of any function and will not proceed control until acknowledgment from Senior Operator is received. 5. Once cleaning is completed, Special Service will hand tank back over to Operations at which point the Control Room Operator will end the cleaning function, document the return status of the tank on the SCADA Equipment Out of Service checklist, and return T1.4 in the Parameter screen to "NO" d. If the tank is to remain out of service, T1.2 should be changed to "NO" to suppress alarms. e. Once the tank becomes back in service, T1.2 can be changed back to "YES." Tank Out of Service =================== General ------- A tank can be taken out of service on the parameter screen (T1.1 Tank in service). When a tank is out of service, alarms of the tank are suppressed, and no function can be started for this tank. Manual commanding of the valves is still possible. Procedure --------- 1. Control Room Operator will set Tank Out of Service: a. Tank's contract is expired or, b. Tank is being taken out for repair/inspection Tank Empty ========== General ------- An empty tank can cause reflection for the radar, resulting in tank level alarms. The tank can be set to "Empty" on the parameter screen (T1.2 Tank empty) to suppress tank level alarms. Procedure --------- 1. This is an automated function that will put the tank into "Tank Empty" when the level of the tank meets a certain threshold.