SEMINAR ONI.O.C.L. COMPLEX REFINERY

PANIPAT,(HARYANA)

Submitted to- Submitted by-Submitted to- Submitted by- Mr. K.S. NAGALA GEETANJALI SINGH Mr. K.S. NAGALA GEETANJALI SINGH

I.C.E ENG.I.C.E ENG.

IV YEAR IV YEAR

PANIPAT REFINERYPANIPAT REFINERY

Barauni

Haldia Mathura

Digboi

Guwahati Gujarat

Panipat

ABOUT I.O.C.L. ABOUT I.O.C.L.

IOCL is the India’s flagship national oil company.IOCL is the India’s flagship national oil company.

IOCL is the 18IOCL is the 18thth largest co. in the world & the no. largest co. in the world & the no. 1 Petroleum trading co. in Asia Pacific Region. 1 Petroleum trading co. in Asia Pacific Region.

IOCL is the top ranked co. among both private & IOCL is the top ranked co. among both private & public sectors at 116public sectors at 116thth position in the worldwide position in the worldwide list.list.

..

FLOW DIAGRAM OF PANIPAT REFINARYFLOW DIAGRAM OF PANIPAT REFINARY

ABOUTABOUT INSTRUMENTATIONINSTRUMENTATION Instrumentation is used in almost every industrial process andInstrumentation is used in almost every industrial process andsystem, where system, where consistent consistent and and reliable reliable operations are required.operations are required.

Instrumentation provides the means of monitoring, recording and Instrumentation provides the means of monitoring, recording and controlling a process to maintain it at a desired state. controlling a process to maintain it at a desired state.

A typical industrial plant such as an electric generating station (figure-Electrical Generating System) yield many

process variables that have to be measured

MAIN CONTROL SYSTEMMAIN CONTROL SYSTEM

IN THIS SYSTEM MAN POWER IS USED.IN THIS SYSTEM MAN POWER IS USED.THE OPERATORS IN THE CONTROL ROOM THE OPERATORS IN THE CONTROL ROOM

KEEP EYE ON THE PLANT AND IF ANY ALARM KEEP EYE ON THE PLANT AND IF ANY ALARM OCCURS THEY ORDER THE FIELD WORKERS OCCURS THEY ORDER THE FIELD WORKERS

TO TAKE ACTION.TO TAKE ACTION.

Temperature Temperature Measurement ScalesMeasurement Scales

(°F) = 9/5*(°C) +32(°F) = 9/5*(°C) +32

(°C) = 5/9*[(°F) –32](°C) = 5/9*[(°F) –32]

(°F) = (°R) – 459.67(°F) = (°R) – 459.67

(°C) = (K) – 273.15(°C) = (K) – 273.15

Methods of Temperature Methods of Temperature MeasurementMeasurement

1.1.ThermocouplesThermocouples

2.2.ThermistorsThermistors

3.3.Electrical resistance change (RTD)Electrical resistance change (RTD)

4.4.PyrometersPyrometers

THERMOCOUPLETHERMOCOUPLE

When 2 dissimilar metals are joined together to form When 2 dissimilar metals are joined together to form a junction, an a junction, an emfemf is produced which is is produced which is proportional to the temperature being sensed.proportional to the temperature being sensed.

The magnitude of The magnitude of emfemf depends on the junction depends on the junction temperature.temperature.

Simplified Thermocouple Simplified Thermocouple Temperature Transmitter Temperature Transmitter

CircuitCircuit

Circuit emf = Measurement emf - Reference emf

THERMISTORTHERMISTOR The resistance of thermistors decrease with

increases in temperature.

The operating range can be -200°C to + 1000°C

The thermistors can be in the shape of a rod, bead

or disc.

Resistance Temperature Detector- Resistance Temperature Detector- RTDRTD

RTD (Resistance Temperature Detector) is a

temperature sensitive resistor.

It is a positive temperature coefficient device, which

means that the resistance increases with

temperature.

The resistive property of the metal is called its

resistivity.

PLATINUM WIRE RTD

linear temperature sensors

Resistance vs temperature characteristics are stable and reproducible

Platinum Scale ( 0 to 100 °C )

Wheatstone Bridge Temperature Detector for an RTD

RELATION GRAPH BETWEEN RELATION GRAPH BETWEEN THERMISTOR,RTD,THERMOCOUPLTHERMISTOR,RTD,THERMOCOUPL

EE

PYROMETERPYROMETER Pyrometry is a technique for measuring temperature without physical contact An apparatus for measuring high temperatures that uses the radiation emitted by a hot body as a basis for measurement.

Radiation pyrometers Optical Pyrometers

OPTICAL PYROMETER

basic principle of using the human

eye to match the brightness of the hot

object to the brightness of a

calibrated lamp filament inside the

instrument

Radiation pyrometersRadiation pyrometers

Level MeasurementLevel Measurement

IntroductionIntroduction

There are multiple technologies There are multiple technologies available in the market to measure available in the market to measure level. Each and every technology level. Each and every technology

works, when applied appropriatelyworks, when applied appropriately

Different types of Level Different types of Level Measurement TechniquesMeasurement TechniquesDifferential Pressure type Differential Pressure type Capacitance Capacitance Displacers / Floats Displacers / Floats BubblerBubbler

Differential pressure type - A DP is used to transmit the head pressure that the diaphragm senses due to the height of the material in the vessel multiplied by a density variable. Advantage:- the most frequently used device for the measurement of levelis a differential pressure transmitter. Using DP for level is really an inferential measurement.

DIFFERENTIAL PRESSURE

Open Tank Level Measurement

Closed Tank Level Measurement

 Capacitance - A capacitance transmitter which converts capacitance signals input to a standard 4-20 mA output. Together with a capacitance probe, the tx is used to measure a continuous level or interface of liquids

Advantage:-Accurate level measurement independent of sticky or crystalline cotaing or varying moisture content of granulars.

Capacitance Type Capacitance Type Level measurementLevel measurement

Displacers/Floats-Displacers/Floats- when a body is immersed in a fluid it loses when a body is immersed in a fluid it loses weight equal to that of the fluid displaced. By detection of the weight equal to that of the fluid displaced. By detection of the apparent weight of the immersed displacer, a level measurement apparent weight of the immersed displacer, a level measurement can be inferred. When the cross can be inferred. When the cross

sectional area of the displacersectional area of the displacer

and the density of the liquidand the density of the liquid

is constant, then a unit changeis constant, then a unit change

in level will result in a reproduciblein level will result in a reproducible

unit change in displacer weight.unit change in displacer weight.

DISPLACER/FLOAT

BUBBLER LEVEL MEASUREMENT BUBBLER LEVEL MEASUREMENT SYSTEMSYSTEM

If the process liquid contains suspended solids, or is chemically If the process liquid contains suspended solids, or is chemically

corrosive orcorrosive or radioactive, it is desirable to radioactive, it is desirable to prevent prevent that fluid that fluid

from coming into from coming into direct contactdirect contact with the level transmitter.with the level transmitter.

In these cases, a In these cases, a bubbler level measurement system bubbler level measurement system can be can be

used.used.

Bubbler Level Measurement System

Pressure MeasurementPressure MeasurementPressure:-means force per unit area exerted by Pressure:-means force per unit area exerted by

a fluid on the surface of the container.a fluid on the surface of the container.

Absolute pressure:- means fluid pressure above Absolute pressure:- means fluid pressure above the reference value of a perfect vacuum or the the reference value of a perfect vacuum or the

absolute zero pressure.absolute zero pressure.

Gage pressure:- represent the value of pressure Gage pressure:- represent the value of pressure above the reference value of atmospheric above the reference value of atmospheric pressure. It is the difference between the pressure. It is the difference between the

absolute and local atmospheric pressure. The absolute and local atmospheric pressure. The atmospheric pressure at sea level is nearly 14.7 atmospheric pressure at sea level is nearly 14.7 lb./in square (PSI) or 1.013 X 100000 N/M square lb./in square (PSI) or 1.013 X 100000 N/M square

(Pa) or 760 mmHg.(Pa) or 760 mmHg.

we have the pressure and level dependency of:we have the pressure and level dependency of:

P = S P = S . . HH

wherewhere

P = Pressure (Pa)P = Pressure (Pa)

S = Weight density of the liquid (N/m3)S = Weight density of the liquid (N/m3)

H = Height of liquid column (m)H = Height of liquid column (m)

The The level level of liquid inside a tank can be determined of liquid inside a tank can be determined from the from the pressure pressure readingreading

at the base of the tank, if the specific gravity of the at the base of the tank, if the specific gravity of the liquid is constant.liquid is constant.

Types of measurementTypes of measurementManometersManometers:- The difference in levels h :- The difference in levels h

between the two limbs is an indicator of the between the two limbs is an indicator of the pressure difference (P1-P2) between the two pressure difference (P1-P2) between the two

limbs. If one of the pressures, say that applied to limbs. If one of the pressures, say that applied to limb2, is atmospheric, the difference gives the limb2, is atmospheric, the difference gives the

gage pressure applied to limb1.gage pressure applied to limb1. h = (P1-P2)/ph = (P1-P2)/p p being the mass density of the p being the mass density of the

liquid.liquid.

Bourdon TubeBourdon Tube:- The cross-section of the tube, :- The cross-section of the tube, due to pressure, tends to round out. The tube due to pressure, tends to round out. The tube uncoils since the inner and outer arc lengths uncoils since the inner and outer arc lengths

remain almost equal to their original lengths. The remain almost equal to their original lengths. The motion of the end of the tube amplified & motion of the end of the tube amplified &

indicated by a pointer moving on calibrated scale.indicated by a pointer moving on calibrated scale.

Diaphragm ElementsDiaphragm Elements:-:-

Elastic diaphragm converts pressure Elastic diaphragm converts pressure input into deflection or displacement.input into deflection or displacement.

Flow Measurement Flow Measurement Orifice meterOrifice meter VenturimeterVenturimeter Flow nozzleFlow nozzle Orifice meterOrifice meter--Based on Based on Bernoulli's Bernoulli's

principle.principle. Orifice plate- inserted to pipe to create a partial Orifice plate- inserted to pipe to create a partial

restriction to flow.restriction to flow. Pressure before orifice plate rises and pressure Pressure before orifice plate rises and pressure

after it reduces but velocity increases.after it reduces but velocity increases.

Types of orifice plateTypes of orifice plateConcentric : The concentric orifice plate is used for ideal liquid as well as gases and steam

Eccentric : used for measuring fluid containing solids, oil containing water and wet steam

Segmented : used for colloidal and slurry flow measurement

venturimeteventurimeterr

- -

Throat to diameter ratio 0.25 to 0.75Made of cast iron, gun metal, stainless steelMay be circular, square or rectangular

where high permanent pressure loss is not where high permanent pressure loss is not tolerable, a venturi tube (Figure 7) can be used. tolerable, a venturi tube (Figure 7) can be used. Because of its gradually curved inlet and outlet Because of its gradually curved inlet and outlet cones, almost no permanent pressure drop occurs.cones, almost no permanent pressure drop occurs.This design also minimizes wear and plugging by This design also minimizes wear and plugging by allowing the fluid flow to sweep suspended solids allowing the fluid flow to sweep suspended solids through without obstruction.through without obstruction.

FLOW NOZZLEFLOW NOZZLE A flow nozzle is also called a half A flow nozzle is also called a half

venturi with flow characteristics venturi with flow characteristics between an orifice plate and a between an orifice plate and a venturi tube. Figure 8 shows a typical venturi tube. Figure 8 shows a typical flow nozzle installation.flow nozzle installation.

nozzles are widely used for flow nozzles are widely used for flow measurements at measurements at high velocitieshigh velocities

PLC(programming logic PLC(programming logic control)control)

Programmable logic controllers are the most Programmable logic controllers are the most widely used electronic devices in the control of widely used electronic devices in the control of production and assembly process in most production and assembly process in most automated factories due to its simplicity and automated factories due to its simplicity and versatilityversatility..

Initially designed to replace relay logic boardsInitially designed to replace relay logic boards Sequence device actuationSequence device actuation Coordinate activitiesCoordinate activities

Accepts input from a series of switchesAccepts input from a series of switches Sends output to devices or relaysSends output to devices or relays

INTRODUCTION PLCINTRODUCTION PLC

PLC ARCHITECTUREPLC ARCHITECTURE

ProcessorPowerSupply

Data Highway

PLC Cabinet

ProgrammingInterface

I/O Modules

InputDevices

OutputDevices

ComponentsComponents Central Processing Unit (CPU)- Central Processing Unit (CPU)- It is a micro-controller based circuitry. The CPU consists of following blocks :It is a micro-controller based circuitry. The CPU consists of following blocks :

Arithmetic Logic Unit (ALU), Program memoryArithmetic Logic Unit (ALU), Program memory

Process image memory (Internal memory of CPU)Process image memory (Internal memory of CPU)

Internal timers and countersInternal timers and counters

Flags Flags CPU performs the task necessary to fulfill the PLC functions. These tasks include Scanning, I/O bus traffic control, Program execution, Peripheral and External device CPU performs the task necessary to fulfill the PLC functions. These tasks include Scanning, I/O bus traffic control, Program execution, Peripheral and External device

communication, special functions or data handling execution and self diagnostics.communication, special functions or data handling execution and self diagnostics.

Input Output Modules-Input Output Modules-These modules act as interface between real-time status of process variable and the CPU.These modules act as interface between real-time status of process variable and the CPU. Analog input module : Typical input to these modules is Analog input module : Typical input to these modules is

4-20 mA, 0-10 V4-20 mA, 0-10 V

Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple (mV) Ex : Pressure, Flow, Level Tx, RTD (Ohm), Thermocouple (mV)

Digital input module : Typical input to these modules is 24 V DC, 115 V AC, 230 V AC Ex. : Switches, Pushbuttons, Relays, pump valve on off status Digital input module : Typical input to these modules is 24 V DC, 115 V AC, 230 V AC Ex. : Switches, Pushbuttons, Relays, pump valve on off status

These modules act as link between the CPU and the output These modules act as link between the CPU and the output devices in the field.devices in the field. Analog output module : Typical output from these modules is Analog output module : Typical output from these modules is 4-20 mA, 0-10 V4-20 mA, 0-10 V Ex : Control Valve, Speed, Vibration Ex : Control Valve, Speed, Vibration Digital output module : Typical output from these modules is Digital output module : Typical output from these modules is 24 V DC, 115 V AC, 230 V AC 24 V DC, 115 V AC, 230 V AC Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump Ex. : Solenoid Valves, lamps, Actuators, dampers, Pump valve on off control valve on off control

Power Power SupplySupply-The power supply gives the -The power supply gives the voltage required for electronics module (I/O Logic voltage required for electronics module (I/O Logic signals, CPU, memory unit and peripheral signals, CPU, memory unit and peripheral devices) of the PLC from the line supply.devices) of the PLC from the line supply.

Bus systemBus system--IT ISIT IS path for the transmission of path for the transmission of the signal . Bu system is responsible for the signal the signal . Bu system is responsible for the signal exchange between processor and I/O modulesexchange between processor and I/O modules

DCS( distributed Control DCS( distributed Control System)System)

Multiple microcomputers connected Multiple microcomputers connected together to share and distribute the together to share and distribute the process control workloadprocess control workload

Features:Features: Multiple process control stations to Multiple process control stations to

control individual loops and devicescontrol individual loops and devices Central control room where supervisory Central control room where supervisory

control is accomplishedcontrol is accomplished Local operator stations for redundancyLocal operator stations for redundancy Communications network (data highway)Communications network (data highway)

Can be installed in a very basic configuration, Can be installed in a very basic configuration, then expanded and enhanced as needed in the then expanded and enhanced as needed in the futurefuture

Multiple computers facilitate parallel multitaskingMultiple computers facilitate parallel multitasking Redundancy due to multiple computersRedundancy due to multiple computers Control cabling is reduced compared to central Control cabling is reduced compared to central

controller configurationcontroller configuration

THANKS…..THANKS…..