PSIG 2319

Simulating SCADA Systems in Synergi: An Application for Pipeline Controller

Training
Amy Eisenbeisz1

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1
Southern California Gas Company

INTRODUCTION AND BACKGROUND

© Copyright 2023, PSIG, Inc.

This paper was prepared for presentation at the PSIG Annual Meeting held in San Antonio,
Texas, 16 May – 19 May 2023.

This paper was selected for presentation by the PSIG Board of Directors following review of Effective training is critical to the safe operation of natural
information contained in an abstract submitted by the author(s). The material, as presented,
does not necessarily reflect any position of the Pipeline Simulation Interest Group, its officers, gas pipelines. If these systems are not monitored and managed
or members. Papers presented at PSIG meetings are subject to publication review by Editorial
Committees of the Pipeline Simulation Interest Group. Electronic reproduction, distribution, or
effectively the consequences could be disastrous. New
storage of any part of this paper for commercial purposes without the written consent of PSIG is measures are being taken at a United States federal level to
prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300
words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment ensure pipeline control room response to emergencies is swift
of where and by whom the paper was presented. Write Librarian, Pipeline Simulation Interest
Group, 945 McKinney, Suite #106, Houston, TX 77002, USA – [email protected].
and impacts are reduced. On October 5th, 2022, the Pipeline and
Hazardous Materials Safety Administration (PHMSA) made
effective a new rule regarding the minimum rupture detection
standards for natural gas transmission pipelines. The new rule
ABSTRACT requires operators to respond to potential pipeline ruptures
within 30 minutes if remote control valves and automatic
Pipeline controller training conducted with hydraulic shutoff valves are not available.1 The 30-minute time frame
modelling software introduces the possibility for adaptive introduces the necessity for quick and decisive action in the
training scenarios that explore direct consequences of controller control room, making the need for training and drills ever more
inputs. Additionally, uncommon scenarios can be practiced in a important.
virtual environment without affecting real operations. There are instances beyond emergency response that
Applications include responding to line breaks, practicing necessitate specific, customizable training. For example, in
operational configurations and strategies, and responding to Southern California Gas Company’s (SoCalGas) transmission
high demand situations. system, the Southern System subsystem usually transports gas
An issue with using hydraulic modeling software for this west toward the Los Angeles Basin. When supply is insufficient
purpose, however, is that pipeline controllers are not acquainted to meet local demand, it is necessary to reverse flow direction
with the software and its visual display or how to interact with in this subsystem to the east to support the San Diego system.
it. Control rooms commonly use Supervisory Control and Data This practice was uncommon in recent years but is becoming
Acquisition (SCADA) software to monitor pressures, flowrates, more useful, such that training in the specific operations to
and alarm signals at points throughout a pipeline network. The achieve “east flow” is desirable. This is just one example, but a
visual displays of SCADA and the selected modelling software, customizable training platform offers a plethora of operational
DNV Synergi Gas, are not similar. Training that uses the scenarios that can be drilled.
modeling software display while controllers normally work
with SCADA displays could lead to confusion, delayed
response times, and additional training to learn the unfamiliar
EXISTING SYSTEMS
interface. The effectiveness of the training simulation would
thereby be limited. Supervisory Control and Data Acquisition (SCADA)
Features available in the selected modeling software can be software is commonly used in pipeline control rooms to
leveraged to overcome the visual inconsistency. Through a remotely monitor points throughout a pipeline network.
novel application of Synergi software features, SCADA screens SCADA "tags” in the field relay information about key
can be simulated in the modeling software interface to deliver locations to the control room regarding pressure, flowrate,
adaptable pipeline controller training sessions that include temperature, and other variables. Alarms are configured for
hydraulic considerations in a familiar visual environment. each tag that will warn controllers of an abnormal variable, such
as high pressure or a quick drop in pressure. Display screens are
customizable and, for SoCalGas, are arranged in a functional
layout. An example of a SCADA screen is shown in Figure 1.
2 Amy Eisenbeisz PSIG 2319

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Figure 1 – Example SCADA Screen

Tags reading flowrates through and upstream pressures for

“city gate” valve stations are arranged together on the left side,
even though the stations are geographically distant. Arranging
information this way simplifies complex systems in a way that
facilitates monitoring a large system.
SCADA systems are primarily used for remote monitoring
and control of live networks2, and generally lack the ability to
simulate hypothetical situations. Operational training can still
be delivered with SCADA systems, but this method will not
include accurate and dynamic hydraulic consequences to
controller inputs.
Many natural gas delivery companies, including SoCalGas,
use DNV Synergi Gas, referred to as the hydraulic modeling
software (HMS) in this paper, to model pipelines. The HMS
display is usually that of a map, with the pipelines arranged
according to their geographic location. Models consist of
facilities (pipes, valves, compressors, regulators, etc.) and
nodes, defined as the point where the system structure changes,
such as where two facilities connect, where gas supply enters or
leaves the system, or where an elevational change occurs.
Pressure and flowrates are either specified or solved at every
node for each time step in a transient analysis. Figure 2 shows
the HMS display of the same area depicted in Figure 1. The two
displays are very different, such that controller training
conducted with HMS alone would not be favorable for
controllers who use SCADA. Training on the HMS platform
would require additional training to learn the interface.
Additionally, the training would not be as effective if
controllers practice with one format but use another in their
daily activities. Manipulating the HMS display to resemble
SCADA as closely as possible would yield a superior and more Figure 2 – Example HMS Map
effective training session. Display
PSIG 2319 Simulating SCADA Systems in Synergi: An Application for Pipeline Controller Training 3

DEVELOPING SCADA DISPLAY IN created with notepad, included three pairs of numbers that
specified scale, rotation, and location of the imported image for
SYNERGI the x- and y- axes. Scale and rotation were both 1 and the
location was the x- and y-coordinates in the HMS map display.
Several features of the selected HMS were leveraged to The specified coordinates corresponded to where in the map
simulate a SCADA interface: basemaps, labels, and operating display the upper left corner of the image appeared.
scripts. The basemap feature imports a static image into the Labels were added on top of each empty SCADA tag
background of the map display as a separate layer that can be box, the area that would normally read live data in the SCADA

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toggled on and off. The intended use is to layer a map showing system. The labels were linked to the facilities in the hydraulic
streets, landmarks, and other reference points behind the model, so that as a simulation progressed the tags would update
modeled pipes in order to aid in navigation and geographical on the SCADA image. Labels were made for tags reading
relation. 3 Labels allow the user to link facility or node attributes pressure, flowrate, compression ratio, and linepack. In many
(pressure, flowrate, etc.) to a text box that will display the cases the labels were linked to user-defined variables, which
desired data. The scripting feature offers a multitude of calculate desired information based on facility attributes. For
possibilities for automation, if-then commands, and output example, total linepack for a particular subsystem was created
messages among other applications. The scripting language is by defining a variable as the sum of all pipe linepack in the
unique to Synergi and consists of variable declaration, variable subsystem. Figure 3 shows a SCADA image with labels added.
definition, and facility setup before the operating code. These Valve and regulator symbols can change color between
three features were leveraged to simulate SCADA screens green when open to red when closed in real SCADA systems.
within the HMS interface. Since the SCADA screenshot in the HMS is a static image,
The first step in bringing the SCADA display into the HMS color changes in the basemap are not possible. To work around
was manipulating the basemap feature. A screenshot was taken this issue, HMS valve facilities were added on top of the
of the SCADA display, the tag values were removed, and the basemap image overlaying the SCADA valve icon. This new
image was imported as a basemap layer. The image was valve was then linked with an operating script to the real
imported spatially away from the hydraulic model, allowing the counterpart in the hydraulic model; the value of the basemap
individual screens to be seen by themselves. The screenshot valve (mirror valve) was set to equal the valve in the hydraulic
was saved as a .bmp file and an accompanying world file with model (true valve). Similarly, the open/close position of
a .bpw file extension was created. Information in the world file, regulators in the model were simulated with mirrored valves.
Figure 4 shows the SCADA image with mirror valves added for

Figure 3 – SCADA Screen in HMS with Labels

4 Amy Eisenbeisz PSIG 2319

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Figure 4 – Complete Simulated SCADA Screen

color changing facilities. other conditions such as line breaks or valve closures. For the
The final visual to complete the SCADA replication within pipeline rupture example mentioned previously, a script was
HMS was the alarm message section. In SCADA, when an written to simulate a pipeline rupture. When the transient
alarm is received a message appears at the bottom of the screen simulation reached a predetermined time, a valve connecting a
with several customizable details, including time, type of alarm, pipeline to atmospheric pressure was opened to simulate the
alarm limit, location, severity, etc. An operating script was used rupture. From this point, the controllers had 30 minutes to
to output a custom message when certain criteria were met. For identify and close the appropriate valves to isolate the break.
pressure alarms, such as pressure falling below a threshold The simulation progress was matched to real time as closely as
value at specific locations, a message would appear in the log. possible, which required moving the simulation forward a time
For rate of change alarms, when a derivative pressure variable step every so often.
fell below 10 psig/min a message would appear in the log. In the “east flow” scenario, a script was not needed. Setting
These log messages were customized to read the same detail as the gas supply receipt points at suitable flowrates and increasing
the SCADA screen. The operating script defined the message demand in the San Diego system was enough to necessitate
as a text string with references to model values, like facility “east flow” operations. In this case, controllers had to recognize
name and pressure. that “east flow” was required based on tag readings and make
The HMS also allows multiple windows to be open the appropriate adjustments to the system to facilitate it.
simultaneously, which allows a SCADA screen to be shown on In order to conduct the training sessions in this manner, an
the map and the message log with alarm messages at the bottom. engineer familiar with the HMS must pilot the model alongside
Figure 4 shows the complete simulated SCADA screen, with the controllers. The developed display looks like SCADA but
alarm messages in the lower pane. still behaves like an HMS. Controllers indicate what change
they would make (open valves, close valves, change pressure
set points, etc.) and the engineer must make the change in the
DEVELOPING AND CONDUCTING hydraulic model. This can be performed using the side panel
TRAINING SCENARIOS shown in Figure 5, so that the SCADA display is never
interrupted.
Specific training modules can be created for specific
supply and demand scenarios, different system initial
conditions, and can use different operating scripts to automate
PSIG 2319 Simulating SCADA Systems in Synergi: An Application for Pipeline Controller Training 5

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Figure 5 – Simulated SCADA Screen with Side Control Panel

The automation from the operating script is important for flow” configuration.
this type of training, so the engineer does not need to manually
cause a change on the system that the controller would see. The
automation allows the model to continue the simulation with no LIMITATIONS
indication to the operator that there is a problem on the system
and where it occurred. Scripting also allows the engineer to There are several limitations of simulating SCADA in the
create several different scenarios easily, so each controller has HMS in this manner. First, there is limitation in the accuracy of
a unique training experience. the training inherent to the use of a hydraulic model; the model
is merely a tool mimicking the real world. Another limitation of
the system is the tedium in converting an existing model into a
RESULTS SCADA-simulating version. Script writing can be automated
but placing and linking individual labels cannot. In addition,
The final simulation with SCADA screens replicated when changes to the system and model are made, all links and
within the HMS resulted in a familiar visual environment for references to the altered segment must be updated. The system
the pipieline controllers, which provided a more streamlined also requires a training administrator knowledgeable in HMS
basis for training. When the controller closed a valve, the color navigation to convert the action controllers want to take to an
was reflected in the familiar SCADA screen and the pressure action that will change the true hydraulic model and not just the
tags responded in a manner similar to the real world. When a mirror facilities. Despite this, the combination of SCADA and
pre-programmed pipeline rupture occurred, alarms for low the HMS offers a new way to explore cause and effect relations
pressure and high rate-of-change were generated in a familiar between closing valves (and other operations) and how the
style using the message log. system reacts.
Controllers who participated in the training were able to
recognize that a rupture had occurred and responded by closing
nearby valves within the 30-minute timeframe. In the “east CONCLUSION
flow” training scenario, controllers were able to practice
manipulating the system to provide sufficient supplies to the The visual format of SCADA and the hydraulic
San Diego system. Trainees and control room supervisors alike consequences of Synergi were combined to deliver training
gained more confidence in their ability to successfully meet the conducive to pipeline controller development. The basemap,
new PHMSA requirement and to prepare the system for “east label, and scripting features were manipulated to create the faux
6 Amy Eisenbeisz PSIG 2319

SCADA display. Scripts were also employed to automate

scenarios, such as a pipeline rupture. Despite the labor-inensive
AUTHOR BIOGRAPHY
process of adapting an existing HMS model to the familiar
SCADA interface, the combination offers a novel training Amy Eisenbeisz is a Senior Engineer in the Distribution
format that promotes controller competency and safe operation Engineering Department at Southern California Gas Company
of natural gas pielines. She previously held a position within the company’s Gas
Transmission Planning section of the Gas Control and System
Planning Department as Engineer I. She has experience in
REFERENCES

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designing and modeling transmission and distribution systems
with DNV Synergi Gas, making use of both steady-state and
1. 49 C.F.R § 192.745 (2023) transient modules. Amy holds a Bachelor of Science in
2. “Learn All about SCADA Systems: What Is SCADA?: Chemical Engineering from California State Polytechnic
Scadapedia.” SCADA International, 27 Feb. 2023, University, Pomona.
https://scada-international.com/what-is-scada/.
3. Synergi Gas 4.9.4 User Guide (2022)