科克雷尔牧场油田注水项目是一个耗资巨大旨在提高石油产量的项目, 它坐落于美国德克萨斯州的潘汉德尔。卡努石油公司成功地利用高新技术从一度曾被认为“已被挖空”的油井里重新获得了石油，在开采过程中利用高压水的水流的流动形成的力量推动原油从油井出地面。

位于得克萨斯州的Boss Automation of Spearman公司被邀请到设计和安装卡努石油的分散自动化平台和控制网络以便监视流向油井的高压水的流量与压力。

以他们在自动化方面的经验, 该项目需要对以往传统的SCADA系统进行改进，从而能设计和实施一整套的新型的、具有全自动化自我监测功能的数据采集与监视控制系统的新型SCADA。

这个系统需要去采集、组合、传送那些油井和注射器等现场的数据，最后，再将这些数据传送到主站。 这就使我们可以用互联网来监视和控制那些生产现场的日常操作，同时也可以利用那些采集上来的数据来做出详细的生产模型。

经过全面地分析考量这个项目，得出的结论是：它必须要包含可靠性高、可维护性优良、简单易用，另外，这个系统能否在当地获得支持也很重要。

后来在Rexel的帮助下（Rexel是当地的一家AB的分销商），Boss Automation of Spearman 公司决定用一个由AB的硬件、罗克韦尔自动化的软件、ProSoft无线通信技术组成的解决方案来吸引人们的目光。

Boss Automation of Spearman 公司对这些自动化产品与软件非常熟悉，同时也有以往成功的应用经验，使得他们对这个组合解决方案非常地有信心。

这个SCADA系统由一个在主站上的带着4个ControlLogix子站和超过100个定制的远程终端单元（RTU）组成的，其中每个RTU又由一个罗克韦尔的MicroLogix1100 PLC和一个ProSoft工业热点电台组成。主站和4个子站象征着项目的网络主干路。

同时，4个子站中的每一个子站在它们各自的子网络中都还扮演着“主站”的角色。所有油井、注射器到各个子站以及所有子站到主站的通讯都采用了ProSoft Technology无线解决方案来完成。

保罗.布鲁克斯，罗克韦尔自动化网络系列产品的商务经理这样说道，“为了这个案例应用，ProSoft的无线技术部为该系统集成提供了一个通讯主干网络，它是一个可靠的、工业级别的、透明的网络，从而使卡努石油公司成功地对工艺数据进行远程监控。

在主站上，使用罗克韦尔自动化公司的RSView 32软件，可以将人机界面（HMI）用于主站中的系统。配套的图形界面软件也已经被验证为具有用户友好界面、且具有信息信件使能功能的成功软件，它可以自主随时地通过拨打操作人员手机以语音方式给操作员汇报详细的报警信息。

基于ProSoft技术的RadioLinx OPC服务被用在远程处理计算机上去监视无线网络的通信状态。

一个令人印象深刻的数字是：超过3500个离散型输入/输出型数据和1000个模拟量数据点被打包在一起并通过无线网络以大约11Mbps的速度传送到网络中主要的主站中，在那里数据包组装成数据日志模型，然后这些数据日志模型由卡努石油特有的经过授权的模型软件来解析、存储。

 Rexel为这个项目提供了后勤保障与技术支持，而为了慎重对待这个耗时长、规模大的无线网络的建设，ProSoft Technology公司在整个项目的建设与实施中自始至终提供了成功的工程支持。

帕特里克Haga，ProSoft Technology公司的无线技术工程师这样评论道：“从这个项目的技术层面来讲这是一个成功的项目实施案例，主要的理由就是在实际实施项目之前我们做了大量的规划以及对这个项目的慎重对待。

我和 BossAutomation of Spearman 公司的控制工程师们花了大量的时间去学习怎样利用 ProSoft 公司的 Pathloss 软件，在项目进行安装之前以及整个实施过程中，我们合作地非常紧密，而且合作的领域很广，不光在网络结构的布局上，还包括PLC的报文传送的策略上。

“项目的整个网络覆盖在大约12平方英里的地理范围里其中最长的数据链路大约有2英里。还有就是，大部分的电台都被放在一个大约只有3平方英里的区域里面，这就会引起一个焦虑，那就是“如何在这种规模的大密度的无线网络里，设置 PLC 的信息报文通讯方式将显地特别重要。” 帕特里克Haga这样说道。“如果所有的电台都设法同时去通讯，你就会很快因为射频带宽碰撞和重试从而增加网络带宽的负载压力，最后会使整个网络瘫痪掉。”

帕特里克Haga继续说道，“考虑这一点，利用 ProSoft 电台具有 IGMP 功能的特性，我们建立一个采用令牌类型模式通讯的网络结构而不是所有的电台都试图在同一时间进行通讯。在成功地安装这样规模的无线网络之前需要进行大量的规划设计，最后，ProSoft公司的技术支持小组提供了非常好的规划帮助。

Boss Automation of Spearman 公司的克里斯. 迪肯评价时这样说，“这个处理过程是非常可靠的、持续的，本质上是一个自主管理运行的计算机站点。从主要的 SCADA 监测站里，操作人员能看到油井的虚拟示意图以及油井里面正在执行的操作，此外，还能看到远程终端和控制单元采集与发送的数据。

该项目投入运行于2008年的春天，从那以后到现在接近生产零停机时间。“无线网络无缝地、可靠地工作，因此它实际是透明的对于用户来讲。” 迪肯阐述道。“当所有的规划与计划都完美实现之后，我问那些客户喜不喜欢无线网络时，他们的回答却是：无线网络是什么？”

ARC咨询集团的哈里.福部斯说道，“科克雷尔牧场油田注水项目说明了3个关于工业无线网络的重点：

第一，无线网络对于象科克雷尔牧场油田注水此类的 SCADA 项目来讲是必不可少的。

第二，最终客户需要选择可靠的、工业级别的、经过现场实际验证的产品，来提供一个长期稳定的无线解决方案。

第三，经过精心设计好的无线网络能以高可靠性、高速地在SCADA系统中传送数据。事实上，正是因为这高可靠性、高速性，使得最终客户几乎忘记了无线网络的在。”

ProSoft Technology 上海（美国普索科技有限公司上海代表处）
 上海市徐汇区虹梅路1905号远中科研楼101室
 电话: +86.21. 5187.7337
 http://cn.prosoft-technology.com/

在美国加州中部的圣华金，富饶的土地生产了全美国12%的农作物，但也恰巧是加州最大的产油区。这些地域宽广的不同行业都聚集在Bakersfield以外的南贝尔里奇区域，这里你可以看到油井遍布于农牧场之中。也就是在这里PXP公司将其蒸汽计量和数据采集变成了一个高度复杂的自动过程控制系统，其核心部分是一个庞大的无线HART变送器和工业直扩电台网络.

项目概述

PXP公司的Hopkins 油田就位于南贝尔里奇地区，其在大约2.5平方公里的地域内分布有200个油井。作为一个强化生产项目，连续蒸汽喷射器对于油井的产油量有着至关重要的作用。在每个产油井的周围，蒸汽会被注射到地下的藏油层以促使石油集中流向产油井。

在项目实施初期，每个喷射器都配有一个图表记录仪来计量并记录蒸汽量。为了跟踪采集这些数据，工人们必须每天都要去大概120个喷射器安装点来查看流量情况，实时记录，并手动计算流速。这些数据接下来要记录在一个表格内，被送到Bakersfield办公室，最后输入到数据库内。

碰到的问题

这种流量监测方法是非常耗费人力的。这些记录仪每三个月需要重新校对一次，并且数值读取也无法非常准确。同时，也有人担心在工作交接或手动记录时可能会存在数据不一致的问题。最后，这个过程也耗费了操作员绝大多数的时间，但每天却也只能记录一个数据。如果井头出现了问题，PXP通常响应会很慢，也就拖延了解决问题的时间。

PXP的项目设施工程师把这种低效率操作方式当作了一次改进PXP运行方式的好机会。 在经过对设备的考察，分析以及和操作员的讨论后，他觉得可以做一个新的无线测量及监视系统，使用最新的科技来创造一个实时系统，这样就能给PXP带来很多益处。而无线系统的使用也让项目实施变得迅捷和经济。如果没有无线技术，就需要敷设独立的供电和通讯线缆，那会让这个改造项目变得耗时耗财。同时系统的维护也会因为这先电力和通讯电缆变得繁杂。

成功的解决方案

经过细致的沟通工作，PXP实施了一个非常先进的自动化系统来作为试点项目。他们在4个油井安装了10个Rosemount 3051S 无线HART压力传感器。每口井都安装了两个传送器来测量节流装置前后的上下游压力。对于双流管井，还要安装第三个下游压力传感器，而上游压力传感器可以共享。这些压力传感器通过其自身构建的网络将数据发送到Emerson 无线HART网关。网关将这些过程数据连同过程诊断及仪表诊断数据都转换为Modbus TCP/IP 数据。ProSoft Technology 802.11 工业直扩电台则把这些网关的数据传送到1英里外办公室内的工业计算机。也就是说这些工业电台组成了一个空中无线网络，把现场的数据点都送到了信息系统中。

在这个试点项目中，PXP邀请了一个独立的公司来计量所有的蒸汽流量以获得每个油井蒸汽流量的准确数据。通过对无线传送系统所获得的数据和数据记录仪的数据比较后，PXP发现前者平均比后者精确10倍！

项目设施工程师，Michael Fischback 评价说"我们非常惊讶于新技术带来的精确度能有如此大的提高。"对于油藏工程师来说， 不准确的数据通常意味着昂贵的维修费用。而过多的蒸汽注入量也会带来运营成本的提高。如果蒸汽量不足也意味着我们不能够最大的挤压地下石油。

在试点项目验收合格后，其良好的效果让PXP公司决定立刻在剩余的120个油井上安装类似的系统。最后，现场安装了总计249个 Rosemount 无线HART传感器，4个无线网关，安装了3个ProSoft Technology 工业电台来传送现场数据到办公室。在这里，数据被送往PXP内部网络的两个ProGauge Technologies 定制的网页软件包。其中一个可以让操作员登录并查看油井数据，打印报告，查阅报警。而另一个对历史数据进行统计分析，形成对现场工况的最佳重现。. 其提供了油井现场的视觉实时模拟，能给油藏工程师和操作员提供每个油井的实时数据，或历史数据，计算蒸汽注入量等诸多功能。同时也可以生成一个 .csv 文件并导入到PXP的报告系统中供公司其它部门来共享。

项目实施

整个项目实施的非常平稳，且迅速。

"安装 Emerson 压力传感器也就是把原有的机械压力表拆除换上新装置而已" Fischback如是描述， "而ProSoft 电台安装时也只是将其固定在背板上，整个安装花了不到一天的时间。"

Bob Karschnia, Emerson无线解决方案副总裁评价说 "上游石油公司通常只有非常有限的时间来解决碰到的问题。解决方案也要实施的越快越好。而使用 ProSoft Technology 解决方案和 Emerson 无线方案让项目实施变得异常简单。他们都具有直接的用户界面可以同时设置两个网络，也是高水平工程解决方案的产品，让用户能轻松的接受。"

Jim Weikert, ProSoft Technology无线产品战略市场经理也说, "许多专注企业级通讯的公司在开发产品时都寄希望于使用者都接受了系统的培训。但Emerson和  ProSoft 都有不同的认识。我们认为项目实施的自动化工程师可能应该是更专注于他们自身的领域 - 例如这里的上游油气 - 而他们可能并不是无线系统的专家。这给像Emerson和ProSoft这样的两家公司提供了专注于开发稳定性和操作便捷性产品及解决方案的机会。

这个系统的最大优点是其能让操作员及时发现现场问题并作出最快的反应，从而大大提高了生产效率。

受益 

在强化产油项目中，蒸汽的成本大概能占到总成本的40-65%， 同时也决定着产油量。有了新自动化无线过程和数据采集系统，PXP不仅取得了更高的生产效率，较低了成本，也能够提高产油量。在头几个月内，节约下来的成本已经超过了新系统的造价。之后的几年PXP能够获得更多的利润。而这来源于:

维护成本降低

Rosemount 的无线HART变送器已经在出厂前校对过，而Emerson建议在运行后每5年校对一次。相比较之前图表记录仪每3个月要进行一次校对，维护成本大大降低。

实时数据:改善响应时间，有利于迅速决策

办公室能够得到现场的实时数据，操作员可以监视油井当前的状态，也可以查询其它许多运行状况。实时报警触发系统可以让操作员快速了解油井的运行问题。而数据也被永久保存以方便日后做相应分析及判断。

效率提高

新系统能够让操作员在到达油田现场后的工作更加有针对性，而不像以前那样要跑遍所有120个油井，而无法确定究竟是那个出了问题。这就提高了工作效率。

利润来源于资源的精确布置

现在在Hopkins一年的蒸汽价格超过1千万美元。而有了新系统，PXP可以非常精确的分配蒸汽资源给油井来使用。

未来

Hopkins油田是PXP在中部山谷中一个有重要意义的资产，而他们的长远目标也是要使用类似的解决方案来改进生产环节。PXP也在考虑是否在其其它领域应用类似技术也会带来生产效率的提高。

"我们对现在的结果非常满意," Fischback评价说. "这让我们整个运行小组非常兴奋。使用新技术来提高生产效率确实是一个正确的方向。"

经过这次成功的试点项目，PXP将会在Hopkins油田的25个新油井中使用无线数据传输。

而对于Emerson 和 ProSoft Technology来说，这已经不是他们第一次在类似项目中的成功合作了。在新加坡也有相同的项目成功实施。

中国电台项目列表

1. 上海临江水厂。             RLX-FHS.              3个点的串口无线网络。中心是滤池车间内的MicroLogix 1500，远程两个点是在沉淀池上的两个刮泥机的MicroLogix 1000.电台网络为透明网络，内走DF1协议。
2. 上海吴淞水厂。             RLX-IH。              4个节点，主要是连接各个车间的本地以太网到办公室。
3. 苏州新宁水厂管网SCADA系统。         RLX-FHS。          超过10个节点的无线网络，距离最远到8公里。无线网络用来将分布于各处的供水管网的测压点压力数据通过Modbus协议上传给水厂控制中心。网络使用了一个10层楼高的中继站来提高覆盖范围
4. 梅钢1号焦炉系统。    RLX-IH.                 12个电台。用于将焦炉四大车的数据上传到办公室。这个项目的特殊处在于中心站电台是由冗余的双电台组成。而每个双冗余中心电台分别连接两个远程站电台，来平衡网络负担。当某个中心站出问题时，远程站可以实现通讯切换。这个项目的背景是Datalinc电台不能满足EPC的要求。
5. 建阳电网保护系统。   RLX-FHS。          6个电台的网络。于S&C合作，将其自动电网断路装置无线连接到电力局控制中心实现远程控制。通讯协议为DNP。
6. 南通川崎船厂龙门吊控制通讯。          6104/6105 无线ProLinx。           和ABB合作（ABB提供龙门吊的所有控制系统）。一套无线DP的ProLinx6000产品把两个龙门吊的控制系统相连来交换数据。通讯的主要目的是当两个龙门吊联动时，交换控制和信息数据。
7. 南通川崎船厂龙门吊信息通讯。          RLX-IH。              4个电台的网络。一个中心站，一个中继站，和两个龙门吊上的两个电台。龙门吊电台通过中继电台将其数据发送给中心站（办公室）供公司内部网络使用。由于龙门吊在长约1公里的轨道上移动，处于远端的龙门吊可以在中继站或另个龙门吊上来漫游通讯。

Learn more about ProSoft Technology’s Wireless Solutions  here. 

Once named the oil capital of the world, Tulsa, Oklahoma rests near the foothills of the Southern Ozark Mountains.

Winding among these wooded hills and across the open wheatlands is a liquefied petroleum gas (LPG) pipeline belonging to a midstream oil company.

Nationwide, pipeline operational data is monitored in real time from the company's office control center in Texas. For security, safety, and real-time accessibility, all critical data is transmitted via satellite to the SCADA control center.

To improve line integrity, the engineering team responsible for this 100-mile LPG pipeline wanted to increase monitoring for some non-critical data points at 12 PLCs along the length of the pipeline. The crux: how to do so when their standardized satellite solution would be cost-prohibitive for these non-critical, low-data-transfer locations. Without additional monitoring points, they were left with visibility at only three points on the pipeline. In the event of a leak, discovery requires an operator to physically drive the entire length of the pipeline between point A and point B to locate the leak, which in this case could be anywhere along a 20-, 30- or 40-mile stretch of pipeline. From a line integrity standpoint, having nothing in between these points meant less resolution as to what was happening on the pipeline, and though leaks are rare, when they occur it’s essential to find and isolate them quickly for the safety of personnel, collateral, and the environment.
  
With the plethora of wireless products now available, the engineering team began investigating alternatives to satellite for these non-critical locations.

"When I was first approached about this opportunity, I immediately thought of ProSoft," said Brian White from Rexel. "With its extensive line of products and services and history of assistance to Rexel in Oklahoma, I felt confident they could provide a viable option for this application."

Originally, 900 MHz industrial radios were considered for these stations, because of their long-range capabilities and ability to penetrate foliage. Because of the dramatically different landscape, however, a site survey concluded that of these twelve locations, three lacked the required line-of-sight. To bring these sites onto the network, towers would have to be built, which would have brought the cost of implementation close to $100,000, rendering yet another solution infeasible.
  
Luckily, every site had cell service.
  
"Cellular technology is fantastic for real-time network access to industrial devices around the world," said the Wireless Product Marketing Manager at ProSoft Technology. "This application highlights the ease with which devices in remote areas can be made accessible at an affordable price."

Within three weeks from the time the order was placed, the radios were onsite. Installation was a challenge for the company only in that they had never worked with cellular. ProSoft Technology’s technician engineer walked them through the setup process, and with 15 minutes of setup per device, had the radios talking.

Results

The cellular radios are scattered along that length of the pipeline, monitoring line pressure and valve statuses along the way. Each radio is wired to a PLC via serial Modbus®, gathering information from their remote locations. A thirteenth cellular radio is connected to the satellite network, relaying data from all twelve points back to the control center in Texas.
  
By adding these data points to the network, the company was able to minimize risk while keeping the application safe and operational. In fact, using cellular has enabled them to pinpoint line pressures to 5-mile intervals versus 40, so should pressure drop off between two of these points, they can quickly isolate leaks with as little impact as possible. 

For more information about ProSoft Technology’s Wireless Solutions, click here.

A while back, a major oil company took a good look at their legacy system and didn’t like what it saw.

The centralized control system, which had been installed in 1978, used multi-drop, leased telephone lines. Four operators at consoles in Houston, Texas, controlled the pipelines for 12 hours a day. This left large stretches of its pipeline unmanned, with no support. The system was already operating at maximum capacity and had many technical risks. They were concerned about the availability of replacement parts for the old RTUs, loop controllers, and alarm annunciators. They needed to know the exact contents of a pipeline, wherever it was, instead of the meter-in/meter-out leak detection they had. Their data entry system was cumbersome, in some cases requiring that data be entered two or three times.

“We reviewed our control system strategy and concluded that we had a unique and hard-to-maintain system. It consisted of dedicated, custom-built and programmed RTUs, along with a lot of odds and ends,” said the company’s lead project engineer.

In short, the company needed to improve its pipeline reporting system by adopting a platform that would let it automate the manual activities to improve efficiency in its small-diameter, high-pressure pipelines running throughout the United States.

First, the company abandoned its old leased telephone lines and went to a VSAT satellite system. The VSAT Ku Band Network system supports 170 sites where the company has 200 PLCs and RTU addresses handling about 20,000 I/O points.

In addition to the VSAT, the company installed a dial backup using analog lines and communicating via the Modbus® protocol to 140 critical sites.

 “When the company installed the new equipment, the old equipment couldn’t communicate with it,” said Ken Hopwood, Software Engineering Manager at ProSoft Technology. “So, they used a ProSoft Modbus module as an interface.”

“When the company approached us, they needed to eliminate the need for continuous polling that was necessary on their old system,” Mr. Hopwood said. “It created communication delays when using the satellite which were expensive. The module we created for them is basically a Modbus Slave but with a few modifications. One, it has Report by Exception, giving it the ability to send timed, unsolicited data reports to the Master Station in Houston. This eliminated the need for continuous polling. The CMS module also contains some specialized data that is unique to the company.”

“In the past, many communication systems were closed,” said the ProSoft Regional Sales Manager who helped the company. “Since the Modbus protocol is open, it has become a de facto industry standard for many industrial devices today, especially in the oil and gas industry. The popularity of our Modbus module doesn’t really surprise me. I see instances like this company’s on a weekly basis. Using the Modbus module to communicate from old equipment to new equipment is simply the most cost-effective way (and in some cases, the only way) to accomplish their goals.”

Learn more about ProSoft Technology’s solutions for the Oil and Gas industry here.

Venezuela is home to the Western Hemisphere’s largest oil reserves, and its economy is extremely oil-dependent. A major oil company in the country is constantly striving to remain competitive and profitable in the world energy scene.

Initial Requirements

 A while back, the company conducted an analysis of their technology requirements for their oil production fields in Eastern Venezuela. The requirements identified included:

• Control system with strong third-party vendor developers and integrators
• Direct plug-in communications modules
• Use of intelligent devices (instrumentation, electrical, and mechanical)
• Open system and standard protocols on plant floor

Because of its internationally recognized brand name, the availability of future product support and its strong third party vendor/partners, Rockwell Automation was chosen to replace the end user’s legacy control system with their 1771 PLC processors. This allowed the end user to incorporate technology from some of Rockwell Automation’s Encompass™ partners, including ProSoft Technology.

In Eastern Venezuela, the end user needed to add new tank farms, pipelines, pump and valve stations, and a SCADA system for control. Simply stated, petroleum produced at a well contains a mixture of oil, gas and water. This mixture is pumped from the pumping stations to the tank farms via a complex network of pipelines. It then undergoes field processing to separate the salable oil from the gas and water. Once the field processing is complete, 1.2 million barrels per day of crude oil are pumped through the end user’s pipeline from the actuator network to the coast for shipment to refining facilities in the United States.

Tank Gauging, Electric Actuator, and Motor Protection Relays

The SCADA system used by the end user communicates to many of its end devices via the Modbus® protocol.

The tank gauging systems monitor tank level. This data is transmitted to the Rockwell Automation processor, which automatically opens and closes valves to and from the tank. The electric actuator network controls the influx of oil from the pumping stations to the main trunk line. The end user installed medium-voltage soft starters for their control valves in order to reduce mechanical stress, starting current, and hammering.

ProSoft Technology’s single-slot Modbus interface module was used in Rockwell Automation’s 1771 PLC processors to communicate with the tank gauging systems, the electric actuator, two-wire control systems, and the motor protection relays. 

A few years later, the end user used the Modbus interface in a SCADA system that was installed to control the movement of heavy crude oil from 1,500 wells in Eastern Venezuela to the coast for shipment to the U.S. for refining.

HART Multidrop module to the rescue

A few years after the SCADA system project, ProSoft was contacted by Perez-Compac in Argentina and Rockwell Automation in Venezuela, requesting their help in communicating between Rockwell Automation’s ControlLogix PLC using DF1 and numerous Rosemount end devices using the HART protocol. Representatives from three companies, including the original end user, worked together to test ProSoft’s HART gateway. Approximately 15 HART Multidrop modules underwent extensive factory acceptance testing for control of the original end user’s crude oil production units in eastern Venezuela.

“The HART Multidrop module provides maximum efficiency for HART networks,” said the ProSoft Regional Sales Manager who worked on the application.

Learn more about ProSoft Technology’s solutions for Oil and Gas applications here.

Making its way along Peru’s Lower Urabamba River, a jaguar’s whispery black shape easily tangles with the darkness of nearby vegetation. Below the tree canopy, two parallel curves of the dual pipelines shoot into the surrounding Amazon, making their way through the jungle, far past where the big cat will wander and perhaps find its prey. Along the tree canopy, equipment dangles from tethered lines. All of the equipment needed for this massive project is flown in and lowered from the sky onto hilltop clearings.

From underground reserves more than a mile deep, natural gas and natural gas liquid will flow through the pipelines under the control of an integrated solution, a flow computer that will use the jungle’s underground resources so that much-needed natural gas can properly make its journey to Peru’s coast. For the Peruvians, the pipelines’ path to the sea will eventually see natural gas and natural gas liquid processed and sold to help create an increased standard of living.

 Facing one of the greatest pipeline challenges in Peruvian history, ISI Solutions, the system integrator for the project, knew the application needed to rely on a cost-effective automation solution that combined the power of control and flow computers to integrate, operate, and maintain pipeline control. The pipeline company needed an internationally recognized name-brand solution with local distribution. They needed a product line that would enable complex control over a Peruvian pipeline where failure to provide much needed natural gas and natural gas liquid could mean dire consequences for the Peruvian economy.

The answer came when ISI discovered a simple solution: ProSoft Technology had a Flow Computer that was compatible with Rockwell Automation’s ControlLogix® platform. As an in-rack solution, it could easily plug into the Rockwell Automation® backplane.

An electrical engineer for ISI Solutions tested the ControlLogix platform with ProSoft Technology’s in-rack flow computer communicating with the backplane. He found such integration and compatibility a huge plus versus utilizing a stand-alone flow computer that might have provided a similar service.

Since ISI Solutions is a system integration company that provides consulting, integration, and management solutions for a multitude of pipeline-related projects, finding an automation solution meant choosing a product line that they knew was going to work.

“We recommended the use of a Rockwell platform early on as we wanted to add a highly functional backplane and flow computer,” said ISI Solutions’ electrical engineer. “The challenges were significant. The customer’s pipelines needed flow management control with a solution that could fit the Allen-Bradley® backplane. What really made the Rockwell platform functional for the end user was ProSoft Technology’s involvement in solving their flow computer needs with their in-rack flow computer module.

“Implementation of products such as these are just part of standard development,” the engineer explained. “We design pipelines, then program, then test; then we start up. This is just the way we do things. If you want professional quality on a pipeline such as this one, then you really have to make sure the technology fits the needs of the project.”

Such challenges also included converting the Rockwell Automation protocol to Modbus® TCP/IP.

“For that situation, we found ProSoft’s Modbus TCP/IP Client/Server module very reliable and efficient,” the engineer said.

How the application is set up

The company’s natural gas liquid (NGL) pipeline has one scraper launcher, one pumping station with a mass metering system, three pumping stations without a metering system, two pressure reduction stations, one receiving station, three scraping stations, and 19 block valve sites. The natural gas (NG) pipeline has one pressure control station, five scraping stations, one receiving and measuring station, four fuel gas modules, and 22 block valve sites. Since fuel gas will be supplied to power the NGL pumps, a metering system was installed to provide the final mass balance along the NG line. In addition, a liquid mass metering system was supplied for each pumping station in order to cross-check the leak detection system.

The pipeline SCADA system has two control centers in local cities. One will be used in case of a major problem at the MCC location, or interruption of communications to the MCC.

Local control systems will control both pipelines and bring information to the SCADA Host system at the control centers to supervise those pipelines and their associated facilities: receiving, pumping, scraping, and block valve stations.

Since both pipelines run parallel and close to each other for 550 km, in many instances they will share a common local control system (i.e.: A common RTU or PLC). Local control systems will be implemented with PACs from Rockwell Automation.

The ISI Solutions engineer emphasized the importance of working with one vendor and one technology in an in-rack project of such a complex magnitude.

To begin with, ProSoft’s flow computer module makes for a single point of communication with tight programmable controller and flow computer integration on a compatible backplane. That translated into an easier learning curve for the system integrator and end user. Other benefits include:

• An easy-to-use software utility, which takes a lot of the complexity out of the set-up that stand-alone flow computers require
• Password security prevents potential pipeline disaster by eliminating non-user ability to change calculations and variables

When asked how ProSoft Technology might bring further solutions to such pipeline construction and development in the near future, the engineer said he was looking at ProSoft’s wireless radios as a cost-efficient, wireless solution for bridging data between pipeline block stations across South American rivers and gorges. He felt wireless technology could help deter costs in constructing cables between hazardous points as well as running costly cable between pumping stations that may only be 10 kilometers apart, well within the range of ProSoft’s wireless capabilities.

“A lot of projects are depending on this pipeline,” he said while simulating pipeline measurement stations with the AFC module at ProSoft Technology’s headquarters in Bakersfield, California. “With such professional quality in a job, we had to ensure the technology fit the needs of the overall project.”

Learn more about ProSoft Technology’s Integrated Oil and Gas solutions here.

No matter which direction you look in Gainesville, Texas, you see the same thing: rolling hills, grassy prairie dotted with cattle, and oil wells. The city is located in Cooke County, just 70 miles north of Dallas, where 82 percent of the county’s income comes from cattle. This makes it an environmentally sensitive area for oil companies.

A while back, an oil field there began experiencing interference in its 150 MHz licensed-frequency radio network. The end user contacted Jeff Walters of Automation Alternatives in Weatherford, Texas, to see if he could diagnose the problem. Using a spectrum analyzer, Walters quickly found that the radios were experiencing elevated noise zones from power-grid interference, which caused the system to overload and shut down spontaneously.

“The radios were simply unable to differentiate between their own network traffic and the interfering radio signals around it,” Walters said.

There were other concerns facing Walters in his search for an upgraded system. Since the field was located in an environmentally sensitive area, it needed to be monitored 24 hours a day. Should there be an alarm condition, the SCADA system needed the capability to automatically shut down all or parts of the field.

Walters’ solution incorporated an interesting and effective blend of technology. Both Schneider Electric® and Rockwell Automation® PLCs receive analog and discrete data from the field. The data is then transmitted wirelessly using 22 ProSoft Technology serial radios. Since the radio network is inherently able to accommodate multiple protocols simultaneously, transmitting both Modbus and DF1 protocols presents no problem.

National Instruments Lookout was chosen as the SCADA system, allowing facilities to be polled every five minutes. Tank levels, line pressures, LACT readings, and a variety of discrete alarms trigger call-outs 24 hours a day. Because much of the oil field has trees and deep creek beds, chloride sensors are also monitored for possible spills.

“The new wireless system has eliminated a number of expenses for the end user,” said the ProSoft Regional Sales Manager who worked on the application. “Our radios are 2.4 GHz license-free, which saves the expense associated with licensed radios. The wireless system also allows an operator to monitor the field 24 hours a day from a central location, saving on employee overtime.”

ProSoft Technology’s 2.4 GHz radios experience no interference or downtime, making this wireless solution very reliable. As the oil field’s radio network grows, more radios can easily be added to the network and can continue to accommodate multiple protocols. 

Learn more about ProSoft Technology’s Wireless Solutions here. 

The largest offshore oil field in Malaysia, Angsi in the South China Sea, requires the fastest level of data communication so it can continue to produce 40,000 barrels of oil a day quickly, smoothly, and efficiently.

The Angsi Field consists of one central processing platform and 5 drilling platforms. It will provide fully integrated support for drilling up to 52 wells, with facilities including two gas compression trains, gas lift and dehydration, power generation, water injection, and a 16MW power generation plant.

So when the Angsi Field’s legacy GE Fanuc PLC system started showing its age, upgrading to a new Rockwell Automation® ControlLogix® EtherNet/IP™ system was a no-brainer. Forty thousand barrels of oil a day cannot be taken lightly.

INEAX (Integrated Network Electrical Automation Expertise) is an expert at oil control systems, and was approached about the application.

"The response from the GE Fanuc PLC was getting slower with intermittent faults, so it was decided that replacing the entire system would be the best solution," said Wee Keat Ng, INEAX’s Managing Director.

Everything but the protection relays would be upgraded, and it had to be done with minimal downtime.

The Problem
The protection relays ran on Modbus®, a non-native Rockwell Automation® protocol. Protection relays are used for protection of electrical load of motors, pumps and other devices, from overcorrect and overvoltage.

The Solution
ProSoft Technology's modules made it possible for the ControlLogix system to communicate to the protection relays as seamlessly as if they were both on the same identical network.

"Our system leverages the ProSoft Modbus module’s unique features to speed up overall communication between the protection relays and the ControlLogix system," Ng said, and specifically pointed out the module’s data prioritization features.

"This is done by splitting the polled data into critical data with continuous updates and non-critical data with on-demand updates," said Mr. KL Yew, INEAX Technical Director. “We would not have been able to do this without the features included in ProSoft Technology’s Modbus module.”

Ng added that INEAX is impressed with the level of features available in the ProSoft modules. “These features aren’t normally seen in other third-party solutions.”

With the ProSoft Technology Modbus module, INEAX was able to provide a better and faster solution for the Angsi platform.

"The decision to use ProSoft Technology modules was an easy one as we have worked with ProSoft modules for close to 15 years,” Ng said.

Because INEAX has upgraded similar solutions before, it was able to upgrade the Angsi system in record time within a tight downtime window.

Learn more about ProSoft Technology’s Modbus solutions here.

By Lauren Robeson

ARC Resources is a major oil and gas company centered on four areas across Western Canada. In such a large operation, efficiency is key.

The company was looking to minimize cabinet space and streamline its operations. On a multi-well pad site in Dawson Creek, British Columbia, they had a Rockwell Automation® ControlLogix® system with standalone flow computers that were used to meter natural gas. The flow computers were only able to handle 8 meter runs apiece, however, which wasn’t optimal for such a large operation that had its sights on future expansion. The company also found it was difficult to get meter data from the standalone units into their ControlLogix system. For real-time information and control of their equipment, that integration needed to be seamless.

In ProSoft Technology’s Enhanced Flow Computer, ARC Resources found a solution that would allow the company to minimize space and left room for expansion in the future.

By the end of the project, the company saw a variety of benefits, including:

• Reduced wiring
• Data integration
• Fewer flow computers
• No licensing fees
• Smaller cabinet

ProSoft’s team and Rockwell Automation’s Calgary sales group, working with Rexel Westburne (the local distributor), helped the company see the benefits of this simplified setup.

 “ProSoft’s in-chassis flow computers fit right into their controller, which has helped streamline data integration and reduced their wiring,” said Scott Monton, Regional Sales Manager at ProSoft.

This streamlined setup has also enabled the company to make better use of its cabinet space.

And those limited meter runs? No longer an issue.

“With this solution, we’re now able to do 16 meter runs per flow computer, limiting the number of units we need,” said Charlie Kettner, Programming Specialist at ARC Resources. “We also like that the system can be expanded later if we need more meter runs.”

With the decreased number of units and their placement in the PAC, the company has been able to reduce wiring and labor costs, and use a smaller cabinet – all of which has helped ARC Resources lower its overall system cost, which was a major goal. Licensing costs have also been eliminated with the addition of ProSoft’s solution, since they will no longer need separate licenses for gas and liquid metering.

With this streamlined setup, ARC Resources is able to optimize their space and resources, and receive important data even more quickly.

Find out more about ProSoft Technology’s solutions for the Oil and Gas industry here.

A while back, a manufacturer of color picture tubes (CPTs) installed a new barcode tracking system in its India facility.

Using Rockwell Automation’s ControlLogix® platform and ProSoft Technology’s interface modules, the new tracking system allows better monitoring of the entire manufacturing process.

The company’s facility has a production capacity for manufacturing 3.2 million CPTs per year. Line one in the facility manufactures 21” and 20” CPTs. Line two is dedicated to manufacturing 14” CPTs.

In order to raise their market share to 50% in the next three years, the CEO wanted the company to have “more efficient capacity utilization and greater manufacturing efficiencies. Our mantra for success is to stay ahead of the competition using differentiation in products and services...We have taken many technological initiatives in order to improve our CPT market share.”

One of the ways the company found to help them improve their market share and increase the quality of their products was the implementation of a barcode tracking system in their facility.

The plant was already equipped with the Rockwell Automation® ControlLogix platform containing a 1756-ADN card. The company installed over 100 barcode scanners communicating via the RS-485 network. ProSoft Technology’s ASCII communication modules were added to connect the ControlLogix system to the barcode scanners.

“Since the barcode scanners are ASCII devices, an interface was needed to allow the data collected by the scanners to be transmitted over an RS-485 network to the ControlLogix system,” said the ProSoft Regional Sales Manager who worked on the application. “The ProSoft modules were installed (a maximum of 15 scanners per module), allowing the scanners to communicate over the backplane to the DeviceNet Adapter.”

“A ‘C’ application in the ProSoft module polls all of the scanners, reads the barcode ID and, using direct I/O instructions, writes to the ControlLogix PLC,” said the application’s Project Implementation Manager. “The data collected via the barcode IDs is presented as Crystal reports to the Main Server using an Oracle database. This information has helped the company achieve better monitoring of the manufacturing process, which translates into better-quality products.”

Learn more about ProSoft Technology’s Modbus solutions here.