← ALL CASE STUDIES MODERNISATION OF THE ENERGY
TEAM EXPERIENCE · INDUSTRIAL AUTOMATION
MODERNISATION OF THE ENERGY
METERING SYSTEM AT AN OIL REFINERY
Detailed design for a unified automated system for technical metering of electricity and steam across the distributed facilities of an oil refinery.
CASE STATUS Team experience
This case reflects the personal practical experience of COVAX experts gained through previous projects. COVAX was not a direct contractor under the relevant contract. All information about the client and the project location is confidential.
01 / CHALLENGE
BRING DISTRIBUTED METERING INTO A SINGLE SYSTEM
Dozens of substations, distribution points and process units operate simultaneously across the industrial site. The project had to combine existing and new metering devices, heterogeneous interfaces and remote facilities within a common information environment.
The system was required to provide operations personnel with reliable electricity and steam consumption data around the clock, generate reports and transfer information to the upper-level monitoring system.
facilities
points
architecture
operation
02 / ARCHITECTURE
THREE-TIER SYSTEM WITH DISTRIBUTED DATA PROCESSING
Field level
PowerLogic PM5000 series electricity meters, vortex and ultrasonic steam flowmeters.
Data acquisition and transmission
Modicon M241 PLCs connected via RS232, RS485 and HART, with industrial metering cabinets.
Information level
Database servers, Power Monitoring Expert, operator workstations and data transfer to the upper-level system.
03 / SOLUTION OBJECTIVES
ENTERPRISE-WIDE VISIBILITY OF ENERGY CONSUMPTION
- Automatically collect, process and store data from every metering point
- Generate a consolidated report for the finance department
- Monitor actual consumption and identify where energy resources are being lost
- Reduce manual operations and the labour required to prepare reports
04 / TECHNICAL BASIS
EQUIPMENT SPECIFIED IN THE DESIGN
BACKBONE NETWORK · 10 GBIT/S
XTran chassis
A modular backbone platform for building a redundant industrial data network.
ACCESS LEVEL · 1 GBIT/S
ETS industrial switches
Managed access switches for connecting remote facilities and operating in a fibre-optic ring network.
ELECTRICITY METERING
PowerLogic PM5000 series
Multifunction meters for technical and commercial metering, with power-quality measurement capabilities.
LOCAL DATA ACQUISITION
Modicon M241
Industrial controllers that poll metering devices and transmit information to the server level.
STEAM METERING
Industrial flowmeters
Vortex and ultrasonic instruments for measuring volumetric and calculated mass flow rates of steam.
05 / IMPLEMENTATION EFFECT
AUTOMATED DATA COLLECTION AND REPORT PREPARATION
Before the system was implemented, some meter readings were collected manually. Collecting, verifying and consolidating the information required significant staff time.
After commissioning, the system began collecting data automatically and consolidating it into a summary report for the finance department. This substantially reduced report preparation time and manual operations, freeing staff to focus on other work.
The experts’ practical contribution included the preparation of design and cost-estimate documentation, equipment supply, installation and commissioning of the communications system.
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