INDIAN OIL CORPORATION

LIMITED (PANIPAT)

Report on PLC and DCS

Submitted to: Submitted by:

DR. ABHISHEK TOMAR Himanshu Singh
49015
 ACKNOWLEDGEMENT
I am indebted to the IOCL management for providing me an opportunity for industrial
training at their Panipat based refinery.

I express my deep sense of gratitude to Mr. Radhakant Sharma (AM L&D) and Mr
GD Singh (ITM) for providing me the necessary facilities for my summer training.

I also acknowledge my profound gratitude to Mr. Praveen Kumar (ITM), Mr Sudheer Kumar
(ITM), Mr SK Rastogi (ITM), and Training Coordinator for providing me every kind of technical
assistance, valuable counselling, support and co-operation during the entire course of this project.

I would like to express my sincere thanks toward our dissertation professor, Dr Abhishek
Tomar, College of Technology, GBPUAT who ushered us into the discipline of practical
Knowledge.

Thank You!

Himanshu Singh
CONTENTS

1. Introduction

2. 4-20mA Current Loop Primer

3. Industrial Control System

4. Programmable Logic Controller

i) Hardware

ii) System Architecture

iii) Theory of Operation

iv) Main Processor Architecture

v) Digital Input Module

vi) Digital Output Module

vii) Analog Input Module

viii) Analog Output Module

5. Distributed Control System

i) Introduction

ii) Operation of DCS

iii) Parameters related with DCS

iv) Comparison of PLC and DCS

6. Conclusion
 INTRODUCTION
This report is a description of role of Electronic Instruments in a dynamic industry. It says
that Instruments is the nervous system of any process control industry. In an era of intense
competition, wherein every industry strives for best quality with maximum production and
minimum cost, the role of Instruments has increased manifold. From merely pneumatic based
control system, an Instrumentation system has evolved itself into a decision making system
based on complex techniques. Thus, every large scale industry relies heavily on
Instrumentation systems for controlling the plant and also in strategic decision making. To
control the parameters in a process or in a particular system, devices such as microprocessors,
microcontrollers or PLCs are used, but their ultimate aim is to control the parameters of a
system.
During my training, I have tried to understand this complex system and based on
experience of guides and my wisdom, I tried to make a simple & lucid report on this system.
I have learned about all the input devices, how they work, about the controllers.
There are four basic parameters to be measured, monitored and controlled in a process
for quality control of the product. These are:
 Pressure

 Temperature

 Flow

 Level

4-20mA Current Loop Primer :

Why Use a Current Loop?
 The 4-20mA current loop is a common method of transmitting sensor information in
many industrial process-monitoring applications. A sensor is a device used to measure
physical parameters such as temperature, pressure, speed, liquid flow rates, etc.
Transmitting sensor information via transmitter
 Current loop is particularly useful when the information has to be sent to a remote
location over long distances (1000 feet, or more). The loop’s operation is straightforward:
a sensor’s output voltage is first converted to a proportional current, with 4mA normally
representing the sensor’s zero-level output, and 20mA representing the sensor’s full-
scale output. Then, a receiver at the remote end converts the4-20mA current back into a
voltage which in turn can be further processed by a computer or display module.
 However, transmitting a sensor’s output as a voltage over long distances has several
drawbacks. Unless very high input-impedance devices are used, transmitting voltages
over long distances produces correspondingly lower voltages at the receiving end due to
wiring and interconnect resistances. However, high-impedance instruments can be
sensitive to noise pickup since the lengthy signal-carrying wires often run in close
proximity to other electrically- noisy system wiring. Shielded wires can be used to
minimize noise pickup, but their high cost may be prohibitive when long distances are
involved.
 Sending a current over long distances produces voltage losses proportional to the wiring’s
length. However, these voltage losses— also known as “loop drops”—do not reduce
 the 4-20mA current as long as the transmitter and loop supply can compensate for these
drops. The magnitude of the current in the loop is not affected by voltage drops in the
system wiring since all of the current (i.e., electrons) originating at the negative (-
) terminal of the loop power supply has to return back to its positive (+) terminal—
fortunately, electrons cannot easily jump out of wires!

Current Loop Components

A typical 4-20mA current-loop circuit is made up of four individual elements: a
sensor/transducer; a voltage-to-current converter (commonly referred to as a transmitter
and/or signal conditioner); a loop power supply; and a receiver/monitor. In loop powered
applications, all four elements are connected in a closed, series- circuit, loop configuration.
 Sensors provide an output voltage whose value represents the physical parameter being
measured. (For example, a thermocouple is a type of sensor which provides a very low-
level output voltage that is proportional to its ambient temperature.) The transmitter
amplifies and conditions the sensor’s output, and then converts this voltage to a
proportional 4-20mA dc-current that circulates within the closed series-loop. The
receiver/monitor, normally a subsection of a panel meter or data acquisition system,
converts the 4-20mA current back into a voltage which can be further processed and/or
displayed.
 The loop power-supply generally provides all operating power to the transmitter and
receiver, and any other loop components that require awell-regulated dc voltage. In loop-
powered applications, the power supply’s internal elements also furnish a path for closing
the series loop. +24V is still the most widely used power supply voltage in 4-
20mAprocess monitoring applications. This is due to the fact that +24V is also used to
power many other instruments and electro-mechanical components commonly found in
industrial environments. Lower supply voltages, such as +12V, are also popular since they
are used in computer-based systems

General Control loop:

INDUSTRIAL CONTROL SYSTEMS
 Industrial control system (ICS) is a general term that encompasses several types
of control systems used in industrial production, including supervisory control and
data acquisition (SCADA) systems, distributed control systems (DCS), and other
smaller control system configurations such as programmable logic controllers (PLC)
often found in the industrial sectors and critical infrastructures.
 ICSs are typically used in industries such as electrical, water, oil, gas and data. Based
on data received from remote stations, automated or operator-driven supervisory
commands can be pushed to remote station control devices, which are often referred
to as field devices. Field devices control local operations such as opening and closing
valves and breakers, collecting data from sensor systems, and monitoring the local
environment for alarm conditions.

PROGRAMMABLE LOGIC CONTROLLER

Modern industrial processes tend to be technically complex, involve substantial energies, and
have the potential to inflict serious harm to persons or property during a mishappening,
absolute safety can never be achieved; risk can only be reduced to an acceptable level.

Safety methods to mitigate harm and reduce risk include:

• Changing the process or mechanical design, including plant or equipment layout
• Increasing the mechanical integrity of equipment
• Improving the basic process control system (BPCS)
• Developing additional or more detailed training procedures for operations and maintenance
• Increasing the testing frequency of critical components
• Using a safety instrumented system (SIS -)
• Installing mitigating equipment to reduce harmful consequences; for example explosion
walls, foams, impoundments, and pressure relief systems

An Emergency Shutdown Device like Programmable Logic Controller (a Safety

Instrumentation System) ensures the Safe Shutdown and Safe Start-up of a process. During an
abnormal conditions when the plant parameters deviates from their normal values, it is better
to take a safe shutdown than to get the machinery damaged and similarly it is better to ensure
the healthiness of the machine parameters prior to its start-up. A PLC through its interlocks
(or logic) performs the same task.
Triconex , a product of Invensys Group is a Triple Modular Fault Tolerant PLC being widely
used in different units of our plant.
Fault Tolerant Control: A fault-tolerant control system identifies and compensates for failed
control system elements and allows repair while continuing an assigned task without process
interruption.
Tricon Controller
The Tricon is a state-of-the art controller that provides fault tolerance by means of Triple-
Modular Redundant (TMR) architecture. TMR integrates three isolated, parallel control
systems and extensive diagnostics in one control system. The system uses two out- of-three
voting to provide high integrity, error-free, uninterrupted process operation.
The Tricon controller uses three identical channels. Each channel independently executes the
control program in parallel with the other two channels. Specialized hardware/software voting
mechanisms qualify and verify all digital inputs and outputs from the field, while analog
inputs are subject to a mid-value selection process.
Extensive diagnostics on each channel, module, and functional circuit immediately detect and
report operational faults by means of indicators or alarms.

Key Features Of The Tricon

• Ability to operate with three, two, or one Main Processors before shutdown
• Fully implemented and transparent triplication
• Comprehensive system diagnostics
• Complete range of I/O modules
• Dual and single I/O modules for safety-critical points with a limited need for availability
• Remote I/O up to 7.5 miles(12 kilometers) away from the MPs
• Simple, online module repair
• Unsurpassed reliability and availability

Applications:
1.ESD application: Provides safety/ safe shutdown for critical machines/equipments in
Refineries and other industries where deviation in process parameters is hazardous to both
machine and man.
2.Boiler Flame Safety: Normal Startup, Shutdown and protection of boiler from upset
conditions, all can be linked in Tricon system.
3.Turbine Control Systems: Speed Control, Safe startup and safe shutdown are implemented
in Tricon. Unscheduled outages are avoided by Hot Spares which means that in case a
module fails, the redundant one comes in line without manual intervention.

HARDWARE
A. Memory backup battery
B. Connectors for terminations
C. I/O expansion ports
D. Power terminals
E. Key switch
F. Redundant Power Modules
G. Three Main Processors
H. COM slot (empty)
I. Two TCMs (Triconex Communication Module)
J. DI module without spare
K. DO module with hot-spare
L. AI module with hot-spare
M. AO module without spare
SYSTEM ARCHITECTURE

The Tricon controller uses three identical channels. Each channel independently executes the
control program in parallel with the other two channels. Specialized hardware/software voting
mechanisms qualify and verify all digital inputs and outputs from the field, while analog
inputs are subject to a mid-value selection process.
Because each channel is isolated from the others, no single-point failure in any channel can
pass to another. If a hardware failure occurs on one channel, the other channels override it.
Meanwhile, the faulting module can easily be removed and replaced, while the controller is
online, without interrupting the process.
The Front End of the Tricon is just like a single control system. Logics are written by
considering the Tricon as single system and not by considering triplicate system. And hence
only one field termination is required. The voting is internal.
Diagnostics are run on each channel and the functional circuit the report of which is directly
accessible to the operator.
Since there are three main processors (MPs) installed in the main chassis, the Tricon can
work with two (dual mode) or even one processor (Single mode) increasing the reliability and
the availability of the system. Keeping the Single mode for a long duration is however not
recommended for TMR systems (TUV Guidelines).

THEORY OF OPERATION

Each I/O Module hosts circuitry for three independent channels. Each channel communicates
to respective MP (channel A-> MPA, Channel B-MPB, Channel C-MPC) for data processing
which in turn communicate to each other over Tribus.
The Simplified Cycle for Executing the Logic Goes like:
Polling
Input Scan
Input Voting
Logic Execution
Output Voting
Output Scan
 SCAN TIME: Input Scan + Program Scan + Output Scan
 Poll Time: Time taken to read the field inputs and update the Input table for the next
scan.
 Input Scan: Time taken to read all the inputs from the Input table and write it to the
shared memory.
 Program Scan: Time taken to execute the logic.
 Output Scan: Time taken to write the output in memory, the registers called output
Image table. These outputs are send to output cards and then reflected in field.
Clearly the scan time must be greater or equal to the Poll time, otherwise the processor would
process the data with old inputs
Scan Time >= Poll time
 Voting and Cases related to it : The inputs are read and input Voting is carried out
as one input is triplicated to three inputs. If the input is Digital Input, then 2oo3 Voting is
carried out i.e. if two input legs are giving 1 and the third is giving 0, then the voted input is
considered to be 1.
In case one leg fails, the voter will carry 2oo2 voting, the input from the faulty leg (which is
diagnosed by the internal diagnostics) is not taken into consideration. Here if only one
channel is faulty, 2nd is giving 1 and 3rd leg is giving 0, then in this case of discrepancy (1,0),
the input will be considered zero i.e. trip to avoid running machine on faulty parameters.
If two legs are faulty, then only the value from healthy leg is the final voted input. Same is the
case for DO output voting.
If One MP Fails: The System goes into Dual mode and carries out 2002 Voting only.
If Two MPs fail: The System goes into Single Mode and single voting is done. TUV
recommends to shutdown the plant in single mode.
If the input is Analog input, the voted input is calculated through mid value selection
procedure.
 Logic Execution: Now since the MPs have their voted inputs written in the shared
memory (shared by all the three MPs over the Tribus), each 32 bit MP now executes the logic
(written by the user) separately and generates individual output tables.
Using the table of o/p values, the I/O processor generates smaller tables corresponding to
each output module. These tables are further disintegrated into smaller tables corresponding
to each channel of a particular output module over the I/O Bus . Example: MPA transmits the
appropriate table to Channel A of each output module over Bus A i.e. all transmissions from
MPA->Channel A are carried via I/O Bus A
These outputs are then voted in output voter, the voted output is reflected in field.
 Auto Spare: Each I/O Slot can contain 2 identical modules, which means if a fault is
detected in one module, control is automatically switched to the healthy module . A Faulty
module can also be replaced online when only one module is installed in the slot. In this
case, a healthy module is inserted in the spare slot and the control is switched to this module,
this allows the faulty module to be pulled off and sent for repair.

MAIN PROCESSOR ARCHITECTURE

Tricon Main Chassis resides three 32 bit main processors which process the safety interlock
parallel, communicates with each other over tribus, each of them communicates
independently with the I/O modules over their respective I/O Bus.
Each Main Processor contains two processors of its own:
1. I/O & Communication Processor MPC860A : This processor reads Input from I/O
Modules thorugh I/O bus and updates the Input table for the values to be available for the
next scan cycle. Also, it writes the contents of output table in shared mempry after the logic
has been executed.
2. Main Processor MPC860A: Executes the User Provided Logic.
DIGITAL INPUT MODULE
Every Digital Input Module houses the circuitry for three identical channels (A, B, and C).
Although the channels reside on the same module, they are completely isolated from each
other and operate independently. A fault on one channel cannot pass to another. In addition,
each channel contains an 8-bit microprocessor called the I/O communication processor,
which handles communication with its corresponding Main Processor. Each of the three input
channels asynchronously measures the input signals from each point on the input module,
determines the respective states of the input signals, and places the values into input tables A,
B, and C respectively. Each input table is regularly interrogated over the I/O bus by the I/O
Communication Processor i.e. MPA interrogated Input Table A over I/O Bus A.

Detection of Stuck on condition: If the Plant is running in normal conditions, then the DIs
are in healthy (ON) condition (in a de-energize-to-trip model). If for a long time the Inputs
are ON, then during an abnormality, the same input may not change their state. To Detect
this, a switch within the input circuitry is closed to allow OFF to be read, during this period
the last value of the input is frozen. The result of the diagnostics of each channel is reported
to the MPs. Periodic Stuck on test ensures the workability of the DIs in abnormal conditions.

DIGITAL OUTPUT MODULE

Every Digital Output Module houses the circuitry for three identical, isolated channels. Each
channel includes an I/O microprocessor which receives its output table from the I/O
communication processor on its corresponding Main Processor. All of the Digital Output
Modules, except the dual DC modules, use a patented quadruplicated output circuitry,
referred to as Quad Voter, which votes on the individual output signals just before they are
applied to the load.
This voter circuitry is based on parallel series paths which pass power if the drivers for
channels A and B, or channels B and C, or channels A and C command them to close—in
other words, 2-out-of-3 drivers voted On. The quadruplicated voter circuitry provides
multiple redundancy for all critical signal paths, guaranteeing safety and maximum
availability.

Digital Output Module executes a particular Output Voter Diagnostic (OVD) for every point
which is kind of a stuck on condition for the outputs. Loopback on the module allows each
microprocessor to read the output value for the point to determine whether a latent fault exists
within the output circuit. This OVD can be disabled through the Tristation Software by
Enable/Disable OVD Option.

ANALOG INPUT MODULES

On an Analog Input Module, each of the three channels asynchronously measures the input
signals and places the results into a table of values. Each of the three input tables is passed to
its associated Main Processor module using the I/O bus. The input table in each Main
Processor is transferred to its neighbors across the TriBus. The middle value is selected by
each Main Processor, and the input table in each Main Processor is corrected accordingly. In
TMR mode, the mid value data is used by the control program; in duplex mode, the average
is used. Each Analog Input Module is automatically calibrated using multiple reference
voltages read through the multiplexer. These voltages determine the gain and bias that are
required to adjust readings of the analog-to-digital converter (ADC).
Analog Input Modules and termination panels are available to support a wide variety of
analog inputs, in both isolated and non-isolated versions: 0-5 VDC, -5 to +5 VDC, 0-10 VDC,
4-20 mA, thermocouples (types K, J, T, E), and resistive thermal devices (RTDs).

ANALOG OUTPUT MODULE

The Analog Output Module receives three tables of output values, one for each channel from
the corresponding Main Processor. Each channel has its own digital-to-analog converter
(DAC). One of the three channels is selected to drive the analog outputs. The output is
continuously checked for correctness by “loop-back” inputs on each point which are read by
all three microprocessors. If a fault occurs in the driving channel, that channel is declared
faulty and a new channel is selected to drive the field device. The designation of “driving
channel” is rotated among the channels, so that all three channels are tested.

Distributed Control System

The DCS is a control system which collects the data from the field and decides what to do
with them. Data from the field can either be stored for future reference, used for simple
process control, use in conjunction with data from another part of the plant for advanced
control strategies.
What must be in the DCS for it to be able to do so much?
Operator Console
These are like the monitors of our computers. They provide us with the feedback of what
they are doing in the plant as well as the command we issue to the control system. These are
also the places where operators issue commands to the field instruments.
Engineering Station
These are stations for engineers to configure the system and also to implement control
algorithms.
History Module
This is like the hard disk of our PCs. They store the configurations of the DCS as well as the
configurations of all the points in the plant. They also store the graphic files that are shown in
the console and in most systems these days they are able to store some plant operating data.

Data Historian
These are usually extra pieces of software that are dedicated to store process variables, set
points and output values. They are usually of higher scanning rates than that available in the
history module.
Control Modules
These are like the brains of the DCS. Specially customized blocks are found here. These are
customized to do control functions like PID control, ratio control, simple arithmetic and
dynamic compensation. These days, advanced control features can also be found in them.
I/O Modules
These manage the input and output of the DCS. Input and output can be digital or analogues.
Digital I/Os are those like on/off, start/stop signals. Most of the process measurements and
controller outputs are considered analogue. These are the points where the field instruments
are hard-wired to.
All above mentioned elements are connected by using a network, nowadays very often used is
Ethernet.
The practical and technological boundaries between a Distributed Control System DCS,
Programmable Logic Controller PLC and Personal Computer PC control are blurring.
Systems traditionally associated with process control are being used in discrete applications.
Likewise, traditionally discrete solutions are used increasingly in both batch and continuous
process control.
Today's control hardware is constructed from many of the same standard industry
components such as Intel processors. Therefore the only real difference between control
systems is at the software level.

OPERATION OF DCS
Basically DCS works in two loops namely closed loops & open loops which work on four
parameters-Flow, Temp., level, & Pressure. The structure of DCS is shown below:-

Parameters related with DCS:-

(1)AIN-Converts the count coming from analog input to % value (800-4000)
(2)AO-Analog Output
(3)PID Controller-It executes an algorithm so that process value is close to the set value.
(4)Barrier-Informs about the fault in the field to the control room.
(5)Processor-There are basically 2 processors of which one is working & Other is for
backup. This is known as redundancy system.
(6)Comm. Card-This transfers the data between the processor & the analog/ digital card.

Closed Loop
(1)Flow Loop

(2)Level Loop

Level Troll:-

Controller:-
(3)Temperature Loop

Controller:-
(4)Pressure Loop

Controller:-

Compare PLC and DCS: What is the difference?

The programmable logic controller (PLC) is king of machine control while the distributed
control system (DCS) dominates process control.
PLCs still dominate high-speed machine control, and DCSs prevail in complex continuous
processes.
The early DCS looked dramatically different from the early PLC. Initially, the DCS
performed the control functions of the analog panel instruments it replaced, and its interface
mimicked their panel displays. DCSs then gained sequence logic capabilities to control batch
processes as well as continuous ones. DCSs performed hundreds of analog measurements and
controlled dozens of analog outputs, using multi-variable Proportional Integral Derivative
(PID) control. With the same 8-bit microprocessor technology that gave rise to the DCS,
PLCs began replacing conventional relay/solid-state logic in machine control. PLCs dealt
with contact input/output (I/O) and started/stopped motors by performing Boolean logic
calculations.
The big change in DCS over the past 20 years is its move from proprietary hardware to the
personal computer (PC) and standard LAN technologies. With each advance in PC power,
DCSs have moved up in power. PCs gave us speedy, responsive, multi-media, windowed,
operator-process interfaces (OPI). Relational databases and spreadsheet software enhance the
ability of DCSs to store and manipulate data. Artificial intelligence (AI) technology gives us
"smart" alarming.
DCSs allow centralized configuration from the operator or engineering console in the control
room. They allow inter-controller communications & use multi-tasking operating systems.
The typical DCS has integrated diagnostics and standard display templates that automatically
extend/update when your database changes. This database is central to the system-you don't
have different databases sitting in the controllers.
Most DCSs allow graphical configuration, provide online diagnostics, and are self-
documenting. Most provide for user-defined control blocks or customized strategies. The
controllers execute control strategies as independent tasks; thus, making changes to part of
the control logic has no impact on the rest.
PLCs are fast: They run an input-compute-output cycle in milliseconds. On the other hand,
DCSs offer fractional second (1/2 to 1/10) control cycles. However, some DCSs provide
interrupt/event-triggered logic for high-speed applications.
PLCs are simple, rugged computers with minimal peripherals and simple OSs. While
increasing reliability, PLC simplicity is not conducive to redundancy. Thus, fully redundant
("hot," automatic, bumpless) variations of PLCs, with their added hardware and software,
sometimes suffer from a reduction in their reliability-a characteristic PLCs are famous for.
Typical PLC Relay Ladder Logic (RLL) languages include function blocks that can perform
complex control and math functions (e.g., PID algorithms). Complex multi-loop control
functions (e.g., cascade management and loop initialization) are not typical. For functions too
messy to implement in RLL, most PLCs provide a function block that calls a user-written
program (usually in BASIC or C).
PLCs typically operate as "state" machines: They read all inputs, execute through the logic,
and then drive the outputs. The user-written logic is typically one big RLL program, which
means you may have to take the whole PLC off-line to make a change of any size. You also
run into database synchronization problems because of the separation of PLCs and the Man
Machine Interface (MMI) software packages, as opposed to the central databases of DCSs.
A PLC will run in a stand-alone configuration. A DCS controller normally expects an
operator interface and communications, so it can send alarms, messages, trend updates, and
display updates.
Some PLCs use proprietary networks, and others can use LANs. Either way, the
communication functions are the same-fetch and put registers. This can result in
bottlenecking and timing problems if too many PCs try communicating with too many PLCs
over a network.
A PLC may have a third-party package for operator interfaces, LAN interface to PCs and
peripherals, PLC data highway or bus, redundant controllers with local and distributed I/O,
local MMI and local programming capability. The PLC would have redundant media support,
but not the redundant communication hardware or I/O bus hardware you'd find in a DCS. A
PLC would have preprogrammed I/O cards for specific signal types and ranges.
 CONCLUSION
In the training period of 28 days at IOCL, Panipat I have understood a lot more about
Electronic Instruments and their application in the industry.
Measurements of process variables are an integral part of its applications in the industry and
accuracy is imperative. Probably more important that the Instrumentation itself is the
automated control that is used today. DCS, PLC etc are very important in controlling the
working of different units in the plant.
During my training, I have tried to understand this complex system and based on experience
of guides and my wisdom, I tried to make a simple & lucid report on this system.
I have learned about all the input devices, how they work, about the controllers.
There are four basic parameters to be measured, monitored and controlled in a process for
quality control of the product. These are:
 Pressure
 Temperature
 Flow
 Level

This report attempts to shed light on these areas and explain them the way I have understood
in these 28 days.