Background

The customer required customized Compressed Natural Gas (CNG) supply-chain solutions, including the continuous 24/7 supply of CNG, as well as the design and manufacture of pressure reduction and meter skids. To ensure the proper operation of the gas skids supplied and installed at various customer locations in Karachi, a robust remote monitoring solution was needed.

System Description

FAIZAL Case Study | System Architecture:

Gas skids were supplied to various end customers at different locations throughout Karachi. Each skid was automated with various makes and models of Programmable Logic Controllers (PLCs) and Human-Machine Interfaces (HMIs). FAIZAL provided a Data Acquisition System (DAS) capable of communicating with the existing PLCs to acquire necessary data from the system.

Connectivity:

The DAS connects to the Internet using either Wide Area Network (WAN), Wi-Fi, or Global System for Mobile Communications (GSM). Remote stations communicate with a central station via the Internet over a secure Virtual Private Network (VPN).

Central Station:

• Equipped with a VPN server capable of handling up to 200 remote connections.
• Features Data Visualization Software for monitoring real-time and historical data from all remote stations.

Software Capabilities:

• Real-Time Monitoring: The software visualizes the real-time status, alarms, and operations of all remote sites.
• Data Archiving: It archives data to a Structured Query Language (SQL) database.
• Historical Data Analysis: Enables analysis of historical data through trend analysis.

Benefits:

Through this project, the customer could ensure the proper operation of gas skids at remote locations and efficiently schedule gas deliveries by analyzing consumption data from the central station.

Detailed Benefits

1. Enhanced Operational Efficiency:
   • Real-time monitoring allows for immediate detection and resolution of issues, minimizing downtime.
   • Centralized control and monitoring reduce the need for on-site inspections, saving time and resources.
2. Improved Data Management:
   • The SQL database securely stores historical data, facilitating long-term analysis and reporting.
   • Trend analysis tools help identify patterns and predict future consumption, enabling better planning and resource allocation.
3. Increased Security and Reliability:
   • The VPN ensures secure communication between remote stations and the central station, protecting data integrity.
   • Redundancy features in the VPN server and DAS enhance system reliability.
4. Cost Savings:
   • Remote monitoring reduces the need for physical visits, lowering operational costs.
   • Energy and resource optimization based on data analysis leads to cost-effective operations.
5. Scalability:
   • The system is designed to handle up to 200 remote connections, allowing for future expansion as the customer’s operations grow.
   • The modular design of the DAS enables easy integration with additional PLCs and HMIs as needed.

Conclusion:

By implementing FAIZAL’s advanced remote Data Acquisition System, the customer achieved seamless and efficient monitoring of gas skids across multiple locations in Karachi. This solution not only ensured the proper operation of the gas skids but also optimized the scheduling and delivery of gas, reinforcing the customer’s commitment to providing reliable and efficient CNG supply-chain solutions.