The city gas distribution (CGD) industry has adopted advanced technologies to bring down costs and enhance efficiency. Indraprastha Gas Limited (IGL), a leading natural gas distribution company in India, is driving advancements in gas metering and network optimisation through technology, particularly supervisory control and data acquisition (SCADA). This system enables IGL to improve operational efficiency and elevate customer service standards by facilitating remote monitoring and process control from a centralised location.
Leveraging technology in operations
IGL has leveraged SCADA technology for comprehensive monitoring and control across various aspects of its operations, including compressed natural gas (CNG) stations and pipeline segments. Implemented in 2018 at IGL, the SCADA system employs a traditional approach in plants, wherein all field equipment is linked to a remote terminal unit panel, which facilitates the wireless transmission of critical signals to a central control hub. An innovative aspect of this system is the concept of a “data centre in a box”, a standalone device that eliminates the need for separate air conditioning. Through an intuitive web portal, users have seamless access to every aspect of the data centre, allowing them to monitor process parameters and equipment health status.
SCADA significantly enhances monitoring practices at CNG stations, with 10 control rooms overseeing groups of stations for efficient operational management. This system provides a comprehensive view of each compressor, monitoring digital inputs, levels, switches and pressure switches. Critical areas such as gas and flame detector conditions and explosive limit levels inside compressors are closely monitored, ensuring optimal safety and efficiency. Dispenser parameters are presented on an easy-to-understand dashboard, with each dispenser at individual sites clearly marked. Totaliser instances, flow rates and sales data for kilogram-based reconciliation are meticulously captured for each shift. The detailed information and automation ensure accuracy and efficiency in managing CNG operations at IGL.
Furthermore, the SCADA system features a mechanism used to adjust monthly prices based on government rates. It is managed remotely and updated in real time. This streamlined approach to monitoring and control improves overall safety and customer satisfaction. SCADA has also replaced traditional logbook mechanisms, offering remote access to process parameters and digital logbooks for enhanced monitoring. For pipeline segments, SCADA monitors sectionalising walls for pressure values, ensuring optimal efficiency and throughput.
Advanced metering
In addition to SCADA, IGL employs two types of meters – mass based and volume based. At CNG stations, gas metering is exclusively conducted using mass flow meters or core base flow meters, simplifying gas balancing. Daily gas reconciliation, based on the kilograms dispensed from the CNG dispensers, is a standard practice at IGL, ensuring precise tracking of gas flow. The transition to thermal mass meters and mass flow meters in compressor engines represents a shift from volumetric flow meters, aimed at improving accuracy and efficiency in gas metering.
Similarly, smart meters have been pivotal in improving the accuracy of readings, leading to precise billing and better leak detection. Real-time data consumption empowers customers to manage usage effectively, enhancing the overall experience by eliminating manual readings and providing convenient billing.
Pain points
Challenges in implementing smart metering solutions have been significant for IGL, primarily due to the diverse range of meter types used by different manufacturers, complicating data integration efforts. The manual collection of data from meters in remote areas has also posed challenges, leading to increased operational costs. In addition, the reliance on batteries for smart meters has raised concerns about battery life and the need for alternative power sources. Ensuring cybersecurity in wireless communication has added complexity to the implementation process. Despite these challenges, IGL is actively seeking solutions for remote data collection, exploring alternative power sources and ensuring compliance with cybersecurity standards.
One of the key challenges faced during the implementation of the SCADA system was the need to integrate a wide variety of equipment, including legacy systems, which posed difficulties in ensuring compatibility with the SCADA system, especially for equipment like compressors and dispensers. Another challenge was the lack of network connectivity at remote sites, even with the implementation of dual SIM cards. Network outages were observed, with both samples failing cabling at all stations. While cabling a new CNG station was relatively easy, the task became more difficult for existing CNG stations.
Strategic solutions
To effectively address these challenges, IGL has developed a comprehensive roadmap for transitioning to smart metering solutions. It plans to expand the deployment of automated meter reading (AMR) meters, replacing older diaphragm meters with AMR meters in Delhi-NCR to improve efficiency and accuracy. The roll-out of prepaid meters in rural markets, where the risk of defaults is higher, is also part of its strategy. The firm has already initiated this process by ordering 5,000 smart prepaid meters for its subsidiary company. Furthermore, it aims to replace ageing meters with smart or AMR meters in Delhi over the next two years.
In terms of technology, IGL’s IT department is actively developing software to enable two-way communication for remote price updates. It has also implemented a well-defined calibration strategy for its meters, ensuring the accuracy and reliability of its metering infrastructure.
Despite the challenges, SCADA will continue to play a vital role in monitoring and controlling assets, with a master control room in Delhi overseeing individual geographical area assets. In addition, IGL has implemented the quick response (QR)-based piped natural gas (PNG) asset monitoring system, with approximately three CNG regulators and 9,000-10,000 industrial and commercial regulators tagged through QR codes for monitoring and tracking purposes. It has also implemented video analytics at 65 stations on the IGL Connect app, allowing users to check the wait time at CNG stations based on the movement and throughput of vehicles. Further, it has piloted a 100 per cent code automation system, connecting the pause machine with the dispenser SCADA system, allowing users to pay for the billing and receive a receipt for the amount of gas delivered. The company aims to implement a paperless mechanism for converting manual records to a digital mode, which is currently being piloted at an undisclosed CNG station.
In sum
IGL’s strategic implementation of SCADA technology and smart metering solutions has significantly enhanced its operational efficiency and customer service standards. The successful implementation of SCADA has transformed monitoring and control processes, ensuring real-time monitoring of critical parameters such as gas flow, equipment health and safety systems. This has not only improved accuracy and efficiency but has also streamlined operations, reducing manual intervention and operational costs. Furthermore, IGL’s proactive approach to addressing challenges such as data integration, remote data collection and cybersecurity highlights its commitment to innovation and excellence.
The future roadmap, which includes scaling up AMR deployment, rolling out prepaid meters and enhancing SCADA capabilities, demonstrates IGL’s commitment to technology adoption for continuous improvement. As IGL continues to innovate and optimise its network, it is poised to set new benchmarks in the gas industry, ensuring sustainable and efficient gas operations for the future.