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Arcom Control SystemsYear 2000 Readiness Disclosure
APEX Key to Chevron SCADA System via TCP/IP over VSAT

The Problem:
Chevron Pipe Line Company (CPL) initiated a VSAT SCADA project in February 1996 with the purpose of implementing VSAT on their SCADA communications network. CPL has many different communications technologies supporting the centralized pipeline operations in Houston. These technologies include AT&T digital, VSAT, Bell analog, Multi-address radio, and Microwave communications with average network reliability of 95-97%. The majority of this infrastructure is older than ten years, and high levels of maintenance are required to maintain circuit reliability. It has been recommended that CPL build a VSAT communications network for SCADA operations. The project intended to replace 80-90% of the existing infrastructure with VSAT technology. The final solution is required to be compatible with and provide full functionality with the new Host.

Existing SCADA Network Chevron Pipe Line Company operates over 9000 miles of pipeline in the continental U. S. System control for all pipeline systems was moved to two data centers in Houston, Texas in 1995, making network reliability a critical component for successful operations. CPL had over 400 RTU sites connected to the two data centers. The RTU sites are connected to Houston via 54 multi-drop communications channels.
The following SCADA Protocols are used in the SCADA Systems and are supported in the Host:
  • TI Dynamic Protocol
  • Control Applications 3 Byte Meter Protocol
  • Control Applications 4 Byte Meter Protocol
  • Tano Model 5 Protocol
  • Valmet Sentrol SAGE 800 Protocol
  • Brown-Boveri CSI 6-Bit Protocol
  • Brown-Boveri CSI 12-Bit Protocol
  • Modbus Protocol
Challenges
Communicating over a satellite network presents a unique set of challenges. Typical SCADA networks poll in a round robin fashion, but since VSAT charges by the amount of bandwidth is necessary to have controls of the data throughput.

The solution must offer the flexibility to incorporate all existing hardware. One of biggest problems to many of the solutions today is the economic barrier presented by the lack of communication compatibility. This problem is compounded by the vast array of existing equipment that often forces users to decommission and replace perfectly adequate systems and devices prematurely. End solution must create a communication network incorporating many different mediums among products with dissimilar protocols into one common platform eliminating these problems faced today and retaining the capitol investment already in place.

To achieve a protocol neutral homogenous network, conversion of the existing protocols is required at the remote site. Thus, the addition of new equipment or incorporation of old is a download away with a new configuration enabling Chevron to choose and expand equipment based on technical features and cost, not on proprietary concerns with a simple change in the remote configuration.

It is crucial that an IP network is provided, given the capabilities of TCP/IP with multiple logic connections on the same communications port, the end-user can Telnet into a site and diagnose problems without affecting system performance. Real-time data captures of the actual hex values of polls sent to a device with its corresponding response can be analyzed remotely by a dial-up connection or through the local LAN.

The Key to Success
Arcom provided the data controls center at each remote site with an APEX. The APEX has the ability to poll the RTU protocols, provide an IP interface, create a network with multiple logic connectivity, increase diagnostic capabilities with the use of tolls like TELNET and FTP.

APEX Each unit is standard with (6) RS232 communication ports supporting asynchronous polling enabling complete control of the data points. Each port can poll with a separate protocol or be configured to support several protocols on a tail circuit. The APEX also has the capability to have on-board I/O with PLC/RTU programmability for sites that require I/O or is used to replace old or out-dated RTUs and PLCs.
A key advantage to the APEX is controlling the bandwidth of the data stream over the satellite system. Since VSAT networks charge by the amount of data traffic, it is necessary to send only changed data in the field. The APEX has a Report-By-Exception (RBE) technique for individual data point control. The APEX polls for the remote data points and stores into a local virtual database and then checks each point for exceeding their associated dead-band. As the points are exceeded, the APEX formulates a RBE message and sends over the VSAT network back to the HOST. Therefore, it is not necessary to poll over the network and this cuts data traffic from 60-80%.

Once the migration is complete, the APEX leads to a total homogeneous IP network eliminating costly outages and maintenance costs of terrestrial lines. It allows for the migration of new equipment based on the latest technology independent of proprietary protocols.

 

Below, a table describes the costs reasoning behind the decision of VSAT as well. Chevron has projected saving to almost cut in half the current cost of terrestrial lines by the year 2000.
Communication costs VSAT Network will provide
  • 99.6% Reliability
  • Standard Technology across all of CPL
  • Standard Approach to System Maintenance
  • Centralized Network Management
  • Improved Diagnostics
  • Adaptability to Changing CPL Infrastructure

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