RCC INSTITUTE OF INFORMATION TECHNOLOGY,

DEPARTMENT OF APPLIED ELECTRONICS & INSTRUMENTATION ENGINEERING

STUDENT WORKSHOP 4tH DAY

Topic :- Introduction of Industrial Automation DCS/PLC and its application

Presented By:
Arindam Mahanti,
Manager Instrumentation ,
IOCL Paradip Refinery, Odisha.

Date: 27.09.2020
 TOPIC OF DISCUSSION:

1) Understanding the role of Instrumentation in Industry

2) Basics of Project Implementation and Instrumentation role.
3) Glimpse of Field instruments , PLC /DCS/ESD/Fire Control and its
understandings.
4) Sharing Paradip Refinery Project executions experience.
5) Understanding the future needs of Industry ..Industry4.O Revolutions.
6) Discussion on various Career Prospects and innovations.
 Role of Instrumentation In Industry

1. Design of Piping and Instrumentation Diagram- P&ID

2. Selection of Suitable Instruments required for the Plant.
3. Selection of suitable Automation System to run the process.
4. Selection of Emergency shut down system and other safety
systems.
5. Project Engineering , detailed design, procurement.
6. Project Management and project execution. Commissioning of
project.
7. Maintenance jobs.
PROCESS FLOW DIAGRAM ( PFD )- Role of Chemical Engineering
P&ID ( Involvement of all discipline )
3D Modelling of Plant
Flow Instruments
Pressure Measurements:
Level Measurements
Temperature Measurements:
Control Valves & On-OFF Valves
Field Control Panels;
 Refinery Instrumentation
• 1. Distributed Control Systems/DCS
• 2. Emergency shutdown systems/ESD
• 3. Fire & Gas Detection Alarm system/FDA
• 4. Disaster Control & Mitigation System : Automated Fire Mitigation
Control Room
DCS Controllers
 WHAT IS INTERLOCK

EACH EQUIPMENT HAS GOT A SET OF PROCEDURE

FOR ITS SAFE OPERATION.

IF THE SPECIFIED CONDITIONS ARE NOT MET,

MACHNINE OR EQUIPMENT SHALL BE SHUTDOWN.
 INTERLOCK types
1.RELAY LOGIC

2.SOLID STATE LOGIC

3.PROGRAMMABLE LOGIC
 RELAY LOGIC
SW STOP START
R3
LO PSL CW LS
SUPPLY
R1 R4
R2
R1 R2 R3
R4

SW : Double pole switch

LO PSL: Lube oil pr.low
CW : Cooling water flow low
LS : Knock out drum level high
 RELAY LOGIC

M.C.C

BREAKER R5
AUX.CNT.
R4
R5 LAMP
RELAY LOGIC EXAMPLE
 SOLID STATE RELAY LOGIC

ELECTRONIC DEVICES LIKE DIODES, TRANSISTORS AND

ICs ARE USED INSTEAD OF ELECTROMAGNETIC RELAYS.

THESE DISCRETE COMPONENTS MOUNTED ON A PRINTED

CIRCUIT BOARD TO MAKE A LOGIC SYSTEM.
 ADVANTAGE OF SOLID STATE RELAY LOGIC

• HIGH CURRENT SWITCHING CAPABILITY WITH NO

CONTACT BOUNCE
• NOISE FREE OPERATION
• IMMUNE TO SHOCK AND VIBRATION
• ABILITY TO PERFORM A LARGE NUMBER OF REPETITIVE
OPERATIONS.
 DISADVANTAGE OF SOLID STATE RELAY
LOGIC

• PRINTED CIRCUIT BOARDS DESIGNED FOR A PARTICULAR

LOGIC HENCE IT CAN ‘T BE MODIFIED
• NO REDUNDANCY
• SINCE MANY DISCRERTE DEVICES ARE USED, FAILURE
RATE IS HIGH
• EXPANSION OF LOGIC CIRCUIT IS DIFFICULT
• EVENT PRINTING IS NOT POSSIBLE.
 Under standing of interlocks
PSLL
LSHH
K
O
Filter Pr. Reg. D
Suction

LO Pr. LOW
C Motor G
W B
Compressor

Discharge
Lube Oil
Tank
 COMPRESSORS
INTERLOCK IS BUILT FOR THE FOLLOWING CONDITIONS

• LUBE OIL PRESSURE LOW

• KNOCK OUT DRUM LEVEL HIGH
• LOW SUCTION PRESSURE
• HIGH DISCHARGE PRESSURE.
• HIGH DISCHARGE TEMPERATURE.
• COOLING WATER FLOW LOW
• HIGH BEARING TEMPERATURE
• EMERGENCY SHUTDOWN.
 FURNACE INTERLOCK

Damper
Feed In
PT

F.O. Return

Feed Out

F.O. Supply
HEAT
EXCHANGER

Fuel Gas

FD Fan
ID Fan
 What is ‘PLC’
PROGRAMMABLE LOGIC CONTROLER Is a control system
that is programmed to perform Logic Control to increase the safety
and efficiency of manufacturing operations.
PLC development began in 1968 in response to a request from an US
car manufacturer (GE). The first PLCs were installed in industry in
1969.
 DIGITAL ELECTRONOIS
THL ELEMENTS FOR A LOGIC FAMILY ARE CALLED “GATES”

OR GATE OR GATE AND GATE

A
B
A B Output Output
1 0 1 0
A AND GATE
0 1 1 0
B 1 1 1 1
0 0 0 0
NOT GATE
A A Output
1 0
0 1
DIGITAL ELECTRONOIS
‘SR’ FLIP FLOP

S Q
S R Q n+1

R Q 0 0
0
0 1 0
1 0 1
CLK 1 1 X
PULSE
 STRUCTURED TEXT-ST
Ladder Diagram-LD

FLD-FUNTIONAL LOGIC DIAGRAM

 Functional Safety
&

Emergency Shutdown Systems

Refinery Control & Safety Systems
COMMUNITY EMERGENCY RESPONSE
Emergency broadcasting Mechanical Safety Action (if available)
PLANT EMERGENCY RESPONSE
Evacuation procedures
Plant Shut-down
MITIGATION
Mechanical mitigation systems Safety Instrumented ESD controlled
Safety instrumented control systems System Functionality Trip level
Operator supervision
PREVENTION
Mechanical protection system Wild Process
Process alarms with operator corrective action parameter
Safety instrumented control systems
Safety instrumented prevention systems
If Operator takes action
CONTROL and MONITORING High Alarm level
Basic process control systems
Monitoring systems (process alarms)
Operator supervision DCS
High Control level
Functionality
PROCESS
Normal behavior
Certain Process
parameter value Low Control level

Time
Have You Been Asked This?

“How can you demonstrate that you are safe?”

 Hazard Identification and Risk Analysis

A typical Methodology for Hazard Identification and Risk Analysis

(by the end user)

• Hazard studies and HAZOPs

• Evaluate possible consequences
• Establish tolerable frequencies vs ALARP
• Build event chain
• Estimate demand rates
• Define protection required
• Specify required SIL
 Safety Integrity Level SIL

LOW DEMAND MODE CONTINUOUS/HIGH

OF OPERATION
SAFETY (Probability of failure
INTEGRITY to perform its
LEVEL designed function on
(SIL) demand)
4 >= 10-5 up to < 10-4
3 >= 10-4 up to < 10-3
2 >= 10-3 up to < 10-2
1 >= 10-2 up to < 10-1
DEMAND MODE OF
OPERATION
(Probability of one
dangerous failure per
hour)
>= 10-9 up to < 10-8 h-1
>= 10-8 up to < 10-7 h-1
>= 10-7 up to < 10-6 h-1
>= 10-6 up to < 10-5 h-1

PFD PFH
Probability of Failure on Probability of Failure per
Demand Hour
 Risk and Determination of Safety Integrity Levels

Basic
Design
Unacceptable

Increasing
Severity
No
Protection
Increasing
likelihood
Reliability, Failure Rate and Availability at each level

Reliability Probability of Trip Unavailable

failure on (per year)
SIL 1 demand
90% - 99% 0.1 to 0.01 876 to 87.6hrs

SIL 2 99% - 99.9% 0.01 to 0.001 87.6 to 8.76hrs

SIL 3 99.9% - 0.001 to 0.0001 8.76hrs to 52.6

99.99% mins

99.99% - 0.0001 to 0.00001 52.6 mins to 5.3

SIL 4 99.999 mins
%
 Protective System Technology

Standard components, single channel or twin non-

SIL 1 diverse channels

Standard components, 1 out of 2 or 2 out of 3,

SIL 2 possible need for some diversity. Allowance for
common-cause failures needed

Multiple channel with diversity on sensing and

SIL 3 actuation. Common-cause failures a major
consideration. Should rarely be required in
Process Industry

Specialist design. Should never be required in

SIL 4 the Process Industry
 Paradip Refinery: The journey towards Energy
Gateway of India

Sunrise Project for Sunshine India

49
Virgin Land before Start of the Project
PARADIP REFINERY LAND SCAPE
2010

51
Piling
• During super cyclone (1999) wind velocity of 65 m / sec (235
km/hr) witnessed
• In view of above, Structural design was made very heavy can
withstand 235 Km/Hr Wind Speed
• All foundations made on piles. About 1 lakh piles done
• Concreting (RCC & PCC) : 11.6 Lakh M3.(3 times volume of Burj
Khalifa, Dubai)
 Concrete and structural steel
• Concreting (RCC & PCC) : 11.6 Lakh M3
(3 times volume of Burj Khalifa, Dubai)

• Structural Steel (incl.

Tor Steel): 2.8 Lac MT
(Equivalent to 30 Eiffel
Towers or about 350
Rajdhani Trains)

Eiffel Tower, Paris : 9,441 MT

Concrete: 3.3 Lac M3
Piping

• Pipes Consumed: 2,400 KM

(almost the length of Ganges, 2,525 KM)
- Piping Fabrication 60.0 Lac Inch Dia
- Piping Erection 112 Lac Inch Metre
Largest Dia Pipe: 104” (8.7’)
(Mercedes-Benz “S’” can pass through )

Largest Diameter Pipe

 Tanks, Mounded Bullets, Cables

• Tanks & Mounded Bullets:

111 Nos.

• Cables: 20,000 km (about

1.8 times Dia of
Earth:12,756 KM)

Largest Bullet (L-99.4m, D-6.4m)

 Vacuum Distillation Column (M/s L&T,

Equipments ( Static & Rotary)

Wt.: 1208 MT, Ht.: 57 M, Dia.: 14 M )
- on Self-Propelled Barge - Aug’11

Equipment (Static & Rotary): 3,300 Nos.

32 heavy equipment (weighing >300 MT)

Transported via sea route from vendors shop

on self propelled/ pulled barges up to Paradip
Port

Erection by M/s Mammoet using 4 Heavy Duty

Cranes of capacity – 2000 MT, 1600 MT, 1200
MT & 600 MT (brought from Singapore/
Netherland/ Middle East etc)

Erection of VDU
Column – Nov’ 11
PARADIP REFINERY LAND SCAPE
2011

57
PARADIP REFINERY LAND SCAPE
2012

58
PARADIP REFINERY LAND SCAPE
2013

59
PARADIP REFINERY LAND SCAPE
2014

60
INDMAX 2015

61
CAPTIVE POWER PLANT-CPP Designer : BHEL
(366MW)
ATMOSPHERIC VACCUM DISTILLATION (AVU) UNIT: 15 MMTPA
Product : LPG, Naphtha, Kerosene, Untreated Designer : Foster Wheeler
Diesel, VGO(INDMAX Feed), VR (Coker Feed)
 DIESEL HYDROTREATER (DHDT) UNIT : 5.2 MMTPA
Product : TREATED DIESEL(BS-IV ) Licenser : Shell Global
 DELAYED COKER UNIT (DCU) : 4.4 MMTPA
Product : LPG, NAPHTHA, DIESEL Licenser : Foster Wheeler
COMPONENT,
PET COKE
CONTINUOUS CATALYTIC REFORMER (CCR)UNIT: 2.98
MMTPA
Product :MS(PETROL) Licenser : UOP
 SULPHUR RECOVERY UNIT (SRU) : 2 X 525 TPD
Product : SULPHUR Licenser : Black &
Veatch
FLARE Designer : Foster Wheeler
IOC OWN TECHNOLOGY INDMAX PILOT
PLANT AT R&D
FIRST INDMAX UNIT AT GUWAHATI REFINERY
(0.1 MMTPA)
 OUR OWN TECHNOLOGY
INDMAX UNIT AT PARADIP CAPACITY 4.17 MMTPA
Product : LPG, PROPYLENE, MS & Licenser : IOC-
DIESEL COMPONENT R&D
7th Feb2016 Paradip Refinery Dedicated to nation

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 Industry 4.0 - Evolution
1st Revolution 2nd Revolution 3rd Revolution 4th Revolution

73
Internet of Things - Evolution
 IOT: People connecting with Things

ECG sensor

Internet

Motion sensor

Motion sensor
Motion sensor
IoT: Things connecting with Things

- Complex and heterogeneous

resources and networks
INDUSTRIAL INTERNET OF
THINGS

77
 IT/OT & IOT

Machines Manager Reliability Manager HSSE

Business Network (Health, Security,
Safety, Environmental)

DCS Operator Console

Cloud
Network LAN Process Engineer
Server

Controller

Wireless Gateway

Real Time Data

Analytics

Analog Input Wireless Input

Digital Input / Output
Analog Output
IT/OT & IOT
How IOT is Different from IT/OT
IoT: 4 layer Model
Integrated Application Smart Grid Green Building Smart Transport Env. Monitor

Information Processing Data Center Search Engine Smart Decision Info. Security Data Mining

WWAN WMAN

Network Construction
Internet
WPAN WLAN

Sensing & Identification

GPS Smart Device RFID Sensor Sensor

 Main Components of Industrial IoT
• Intelligent Assets, Devices, Products or Machines
Technology-enhanced assets with sensors, processors, memory,
communications Digital Twin
Self Powered
Potentially self-aware and autonomous

• Data Communications & Infrastructure

Cloud-based Distributed
Computing
Massive Parallel computing and In Memory

• Analytics and Software

Asset Optimization and System Optimization Descriptive,
Predictive, and Prescriptive Analytics “Intelligent
Information” when and where people need it

• People, Processes, and Systems

Empowered and Engaged, connected in context.

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IoT: Reference Model

4
IoT Technologies
IOT IN IOCL
85
 IIOT in Control valve & Shutdown valve in PDR

• This real - time visibility into operational

performance as well as predictive analytical
capabilities allows plant managers to access
relevant data and make critical decisions
about asset health and energy usage, thereby
avoiding equipment failures and costly
downtime while improving profitability.

• The ability to track asset health and be

proactive in scheduling repairs and
preventing unplanned downtime

Example
Real time Pollution Monitoring by CPCB
Drone for Stack checking
 Career Prospects
1. Project Design & Engineering
2. Project Management & Execution.
3. Technical Consultancy.
4. Maintenance & Operation
5. Automation – DCS/PLC/ESD/FDA
6. Analytical Instrumentations- Analysers
7. Data Scientists
8. IIOT / Networking and Cyber Security Specialist
9. Industry4.0/IOT/AR-VR/Robotics/Machine Learning/Cloud Computing /
3d Printing.
10.R&D and Academia
11.Entrepreneurships
Question and Answers
 Contact Details

Arindam Mahanti

Mobile: 9937477878
Whatsapp no – 9937477878
Mail: arindam.mahanti@gmail.com
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