System Controller
This unit includes a NEMA 4 (weatherproof) enclosure, with a PLC (or interface to the customer's PLC), interface programming, and the other equipment necessary for a fiber optic or copper wire system. The unit can also be configured to include a basic driver to interface with most plant DCS systems (e.g. with Modbus connection). The cost of these control units is about $38,000. This cost does not include the development of any graphic screens for the human-machine-interface (HMI) in your control room. Each control unit can continuously monitor a length of about 350 miles. However, we generally limit control unit spacing to a maximum of 50 miles; this ensures adequate headroom for future splices and other line losses for the life of the pipeline system. The control unit is normally co-located with an existing pipeline PLC (e.g. at an existing remotely operated block valve or pump/compressor station). We normally include all drivers and PLC interfaces with the control unit. The control unit can be housed within an existing PLC enclosure or in a separate enclosure, which is included. The customer simply needs to modify their control room human machine interface (HMI) to show the new alarm and the alarm location.Fiber or Metallic Optic Cable
For most installations, we recommend fiber optic cable systems, instead of a metallic cable system. The fiber optic system provides an alarm when the cable is severed or damaged. The metallic system only alarms when the cable is severed or more severely damaged. Most above grade fiber optic cables cost $0.75 to $1.00 per lineal foot, including your TRIP WIRE® license, plus freight. For longer length systems, with long lead times, the cable costs can be reduced, often significantly. In areas subject to rodent damage, there may be a slightly higher cost for armored cable.
Installation/Commissioning Support
We typically spend a couple of days on-site after the system has been installed by the customer’s construction contractor. During this time, we test the installed cable, complete all fiber optic terminations at the system controller, adjust the field equipment sensitivities to match the field installation, test/modify the PLC and SCADA system interface drivers, and train your personnel to make field cable splices. This work is normally done on a time and material basis at $95.00 per hour, plus travel expenses. If desired, we can also complete any intermediate fiber optic cable splices you may have in your system.
Construction, Direct Burial Versus Duct
Direct burial cable is somewhat less expensive to install than cable inserted into a duct. Contractors have quoted from less than $1.00, to $3.00 per lineal foot to install direct burial cable during pipeline construction. This cost covers the additional pipeline construction costs associated with backfilling the ditch to the appropriate level, stringing the cable, making the splices, and backfilling to the final elevation.
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