SYNOPSIS

PROJECT TITLE

PROGRAMMABLE LOGIC CONTROLLER (PLC) & ITS

SIGNIFICANCE

IN

HYDROCRACKER UNIT

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 SYNOPSIS OF THE PROJECT

1. TITLE OF THE PROJECT

Detailed study of PROGRAMMABLE LOGIC CONTROLLER (PLC)

and its significance

2. OBJECTIVE

To study the Operation and functionality of Programmable Logic

Controller (PLC) at Hydrocracker Unit of Mathura Refinery and also to
study how Analog and Digital Input / Output signals are received and
transmitted to analyse the Furnace logic that is controlled by PLC.

3. RATIONALE FOR THE STUDY

Mathura Refinery, the sixth refinery of Indian Oil was commissioned
in 1982. With the commissioning of “Once through Hydrocracker Unit”
(licensed from Chevron, USA) in July 2000, capacity of Mathura
Refinery was increased to 8.0 MMTPA.

Multiple types of PLC (Programming Logic Controller) and DCS

(Distributed Control System) are used in Refinery, where DCS used to
automatic control of hundreds of process parameter, and PLC used to
monitor critical plant safety interlocks and take action automatically if
any interlock violates its limits.

To understand the structure and functions of the PLC system

thoroughly, a case study is helpful in getting knowledge about the
systems and operation of the safety PLC

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 4. DETAILED METHODOLOGY TO BE USED FOR
CARRING OUT THE STUDY
 Study about history of PLC.
 Study of Hardware, Parts & function of each part.
 Study about structure and external communication of PLC.
 Study about how large number of Input/output signal gathered at PLC
unit from intrinsic safe environment.
 Study about Uses of PLC.
 Study of different logic system like relay logic, ladder logic Functional
Block Diagram (FBD) etc. its advantages and disadvantages.
 Study about maintenance procedure of PLC.

5. THE EXPECTED CONTRIBUTION FROM THE

STUDY
 Developing an understanding of different PLC systems used in
industry

 Achieving knowledge of industry standard for IS (intrinsic safe) and

gain experience through installing cabling connector & other
hardware component.

 Learning the basics of PLC as well as the parts and device used to
set up functional control system, such as Microprocessor , Power
supply, I/O cards, isolators and its configuration

 Learning the maintenance of the PLC system and how to use

isolators to save PLC from external interference

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 6. LIST OF ACTIVITIES TO BE CARRIED OUT TO
COMPLETE THE PROJECT

SL. TIME
NO. TASK (ACTIVITY) SCHEDULE
IN DAYS

1 Discussion and allotment of the project. 2 days

2 Preparation of the synopsis. 3 days
3 Detailed study of Programmable logic controller 11 days
and its features.
4 Collection of data. 4 days
5 Meeting to the seniors and project guide. 3 days
6 Write-up of the project. 8 days
7 Final submission of the project. 4 days
Total time to complete the project 35 days

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 BAR CHART FOR ACTIVITYTO BE CARRIED OUT TO
COMPLETE THE PROJECT

DAYS
12

10

6
days

0
Activity 1 Activity 2 Activity 3 Activity 4 Activity 5 Activity 6 Activity 7

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 7. PLACES / LABS / EQUIPMENT AND TOOLS
REQUIRED & PLANNING OF ARRANGMENTS

During the project work a detailed study will be carried out by visiting
the Oil Refinery control room, by interacting with Instrumentation Engineer
of the Hydrocracker Unit. Planning for the study of PLC has been done to
understand operations and maintenance issues. Learning PLC connection
on the Marshalling rack room and using isolator/barrier and other
equipments to connect field I/O to device. Multimeter, loop calibrator, screw
drivers were used during PLC maintenance.

8. PROBLEM ENVISAGED IN CARRYING OUT THE

PROJECT ,IF ANY

The following problem may occur in PLC.

1. Power supply failure

2. Slow Response

3. Cards Malfunctioning

4. Voltage drop in input output terminal

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