Telefónica DATA Processing Center

The project consisted of automating and controlling the Gas Oil supply needs of 25 Emergency Power Generator Units from two main tanks, one for each line, and a reserve tank for the daily service tanks of each power generator unit.
The project had to be done in compliance with the indications of Uptime Institute, the certification body, to obtain a Tier IV score in project and installation with the goal of becoming the first Data Processing Center (DPC) in Europe to obtain that certificate in both fields: project and installation.
One of the condition was having two independent gas oil supply lines (A and B) to provide 100% of power at each side.
The required amount of gas oil had to allow operation for 12 hours at maximum load.
The power increase expectations of the installation posed the challenge of performing calculations on the dimensions of the pipes and achieving proper operation at all power levels. As well as designing the pumping and control units taking into account a gradual increase up to the maximum power level of the project, without hindering normal operation.
The increased environmental requirements posed another challenge regarding management of possible spills. The first solution presented in the project suggested using meters at the point of use and propulsion meters. To make this solution feasible, all meters -and therefore their deviation- had to be adjusted to the outlet meter, which would waste a lot of time at commissioning and could compromise long-term reliability. After scratching this solution, a leak detector spill protocol is implemented.

Solution adopted by INPRO

Tanks

Two 80 m3 oil storage tanks were planned and installed, buried inside a concrete bund in the area stated in the installation plans with easy access for filling the bund.
A 30 m3 gas oil storage tank was planned, meant to provide a reserve tank to supply the others.

Pipe Network

The gas oil distribution pipe lines were installed with double plastic skin and rigid and flexible couplings. The pipe was buried in a single, independent trench for side A and B. They were installed with inclines leading to the planned leak drain basins. The basins included a gas oil leak detector that would notify the central control system and close and isolate the different areas required via the relevant panels.
Pipes were selected according to the criteria of standard DIN 4755 indicating that gas oil speed in propulsion pipes must be between 1 and 1.5 m/s and in suction pipes between 0.2 and 0.5m/s.

Anti-spill Systems

The adopted solution neutralizes the pressure in the line when the system is idle. Operation without pressure limits the possibility of spills, so a leak detection, containment and management system was installed in the entire facility, which allowed communication with the management system and a verification option.
In the pump rooms, the collector trays of the pump systems are controlled with infrared sensors.
Both the pump room and the perimeter of the pipe have basins that can contain both water and gas oil, so detectors for both types of fluids are installed in order to prevent false alarms.
Any spillage in valve connections or supply filters of the generators would go to the collector trays, which would include a leak detector connected to the leak detection system and the DPC control.
Due to the presence of multiple points to control, a spillage control central was installed, capable of handling up to 5 spillage probes with independent relays and locating the specific location of the leak.

Main tank interstitial chamber detection

Double-skin detection can be done in several ways: with pressure, vacuum, fluid…, with automatic regeneration or without it…
We opted to place vacuum detectors with regenerative pump in the supply tank as well as in the main tanks, thus preventing false alarms. Controlling and installing a vacuum system is more effective than installing a pressure or fluid system. In conclusion, we chose to install a DDP-25 double-skinned detector according to standard EN 13160-1, Class 1.

Control of main tanks

The purpose is knowing the amount of gas oil in these tanks at all times, opening the solenoid valves meant for suction protocols ad well as low-level and high-level alarms.
Thus, EDM-40 continuous analog gauging probes will be placed to control the tank levels, which serves to obtain their measurements. As a redundant safety measure, SMMR2 probes were installed with 2 digital contacts: a high-level and a low-level one. Local reading of tank capacity was done with EDM-40 digital displays, as well as alarm systems to prevent overfilling upon unloading the tanker; the alarms will trigger due to the high levels of each tank.

Pump Systems

Given that the simultaneity coefficient required by the consumption needs of the system is extremely variable, pump systems were provided with speed adjustment control according to demand. These units must be able to pump 4000 L/h to 12/13 points of use and adjust to provide flow for a single point of use.
With this in mind, two pump systems were designed to supply sides A and B independently, consisting of: Two 4000 L/f self-priming motor pumps, each with flow adjustment, double-filtering collector, safety valves, retention valves, pressure transducer and spillage collector tray with infrared detector. To verify the defined operation and safety protocols, they have a self-checking system consisting of recirculation lines located on the main tank and controlled by solenoid valves and meters that can simulate the demand of several tanks and the generated flow and thus check the actual input of each flow under certain circumstances. All the aforementioned elements were mounted on a steel frame, producing a modular system that were integrated in the installation after undergoing all adequate operation tests in the testing bench in our facilities.

An additional pump system was placed between the main tanks and the reserve supply tank meant to increase the operation time of the installation via this pump system. Consisting of: Two 10,000 L/h motor pumps with independent filtering, safety and retention valves and controlled by the suction panel.
The design of the systems included the dimensions and additional connections to fulfill the real-time growth needs required in the project.
Solenoid N.C. valves were placed in the suction points of the pump units to automate the suction protocol of the tank to suction.
All pump systems were controlled by the control panels with a programmable automaton.

Control Panels

To control the pump systems and collecting all the signals required to know the status of the installation and possible alarms, control panels with touch screen automatons were installed in each main pump room and each generator room, as well as a general control panel for the main tanks and the pump system of the reserve supply tank. The main problem occurred when collecting all the signals from each area and centralizing them in one point to make appropriate system operation decisions and manage possible protocol and spillage alarms.
Communications work via a Mod-bus RTU. This protocol was selected due to the problem posed by the distance among the different panels, which exceeds 1,000 meters in some cases. Communication with the main management system was established with this same protocol.
The design of the systems conditioned their dimensions and included additional components to comply with the real-time growth needs of the project.

Daily service tank filling

The primary issue when filling was providing service with an appropriate level of safety. This is always a conflictive issue: an increase in safety against spilling decreases the certainty of adequate fuel supply, and vice-versa. Before installing the daily service tanks, N.O. solenoid valves were installed in each basin, so if spilling or excessive tank levels were detected in them, these solenoid valves and the previous ones would close, being able to supply the rest of the installation even after closing this area.
Daily service tank filling is conducted via the control and safety systems (filter, N.C. solenoid valve, flow container, N.O. solenoid valve, filling safety control). Solenoid valves are managed with the control and management panel, which receives the corresponding tank status signals from the level probes, one for operation and one for safety, as well as an overfilling safety flow switch in the vents.

IMAGES OF THE PROJECTS

INSTALLATION ELEMENTS SUPPLIED BY INPRO

PROBE EDM40

Continuous level display and control unit completely adapted to the needs of the installation. Displays the level at all times, expressed as a percentage. All required operations can be done via the relay module and the analog communication output. Customized manufacture makes this unit perfect for all kinds of tanks and a wide array of fluids.
•    Standard operating temperature: 40ºC that can be adapted to reach up to 125ºC.
•    Control unit in standardized module (DIN 43700) 96 x 43 x 100, can be mounted with panels.
•    Flexible probe with sealed head, can be fastened with 2’’, 11/2’’ or 1’’ nuts. Mounted with aluminum or standardized flange.
•    Overfilling warning alarm triggering with 95 dB acoustic signal, automatic shut-off and reset push button with IP-55 protection. It complies with the requirements of the standard MI-IP03 on “Oil Installations for own consumption”.

INTERSTITIAL CHAMBER DETECTOR DDP-25

Vacuum leak detector for interstitial chamber in double-skinned tanks according to EN 13160-1, Class 1.
•    Has a regenerative pump controlled with an adjustable vacustat. Thus keeping a -400 mBar pressure between the inner and outer skins of the double-skinned tank. When dropping below 380 mBar, the pump regenerates the vacuum; if there are any holes, the negative pressure does not regenerate; the alarm triggers upon reaching 340 mBar.
•    These units are perfect for tanks of up to 3 m of diameter.

OIL PUMP SYSTEM “INPRO” ATAM-GE

Oil pump systems ATAM-GET are synonyms for adaptation. They are designed to fulfill pumping and redundancy needs and to comply with the safety protocols of installations controlled by centralized control panels, with touch screen automatons and Mod-bus communication. A perfect combo for every installation. Control panels for filling motor pumps, overflow, solenoid valves, alarms, etc., as well as possible operating management inputs.
•    Compact units with all the elements required for gas oil pumping, joined in an aluminum collector on a furnace-painted plate bench.
•    Flows of up to 70 Liters/hour, with the possibility of on-demand pumping via speed variation.
•    With a flow meter to instantly check the operating conditions.

COLLECTOR TRAY WITH SPILLAGE DETECTOR

Placing collector trays under certain elements of the installation is recommended. Particularly, equipment that could leak due to its characteristics or during maintenance tasks. Placing a spillage detector for the tray gives the possibility of creating protocols.
•    Furnace-painted plate tray with the appropriate size for each circumstance.
•    Spillage detector in the control panel and detection probe. Infrared optical sensor for oil and water, conductivity sensor for water or both, mounted on the same probe.
•    Standard 1.5 m probe.
•    The control unit of the detector is mounted in a box with impact-resistant plastic cover. The control unit contains two voltage free relays, one for commuting and the other one usually open.

SOLENOID VALVES

Set of solenoid valves to control the filling process and safety against spillage due to excessive levels.
•    Chrome plated brass Y-shaped filter, with stainless steel 0.05 mm mesh PN16.
•    Gas oil N.C. solenoid valve to control the filling process.
•    A regulated and sealed container (flow limiter) adapted to the desired flow, consisting of a chrome plated brass valve and nylon seals.
•    Gas oil N.O. solenoid valve to control the filling process.

LEVEL SWITCH

SMMR level switches perform the operations required for the filling process and the tank overfilling alarms and protocols. Custom manufacture based on actual needs.
•    Probes manufactured from different materials to work with fluids such as gas oil, oil, water, milk, etc.
•    Probe with sealed head, can be fastened with 2’’, 11/2’’ or 1’’ nuts, mounted with aluminum or standardized flange.
•    For controlling pumps, solenoid valves, alarms, etc…
•    Control box with relays and power supply.

METER

Meters for gas oil, fuel, kerosene, gasoline and lubricants
•    Flow meter for hydrocarbons and co-generation in burners, ships, vehicles and fixed facilities.
•    Metrological certificates and calibrations available based on regulatory needs.
•    The whole model range provides the best solutions to measure fuel consumption.
•     State-of-the-art designs in electronic meters, with analog and digital outputs with parametrizable values.
•    Propulsion or suction assembly.
•    Independent from viscosity and temperature.
•    System monitoring and control simplifies the configuration of the burner and the optimization of consumption.
•    Maximum safety in shipbuilding and automotive industry.

PUMP WITH RETENTION VALVE

Eccentric motor pump with self-adjusting blades for oil transfer with an approximate flow of 50 liters per minute IRON-50 with retention valve for maintenance of
•    With re-circulation by-pass valve and pre-filter.
•    Free outlet flow: 50 L/min
•    Consumption: 1.2-2 A
•    Motor: 0.25 kW 230 VCA 50/60 Hz mono-phase, self-ventilated with thermal protection
•    Continuous operation S1
•    IP55 Protection

 

 

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