A TRAINING REPORT ON INSTRUMENTATION AND CONTROL ENGG. AT INDIAN OIL CORPORATION LIMITED MATHURA REFINERY, MATHURA.

National Institute Of Technology, Jamshedpur

Supervisor:Submitted by:V. NAGARAJAN ACHARYA Chief Instrumentation B.Tech(E.C.E) Manager

PARUL

ACKNOWLEDGEMENT

I am happy on the completion of the Vocational Training at Indian Oil Corporation Ltd., Mathura, for which I would like to thank Mr. V. NAGARAJAN, CITM under whose visionary enlightenment I was able to complete this report. I would also like to acknowledge the help and support by Mr.A.S.Verma, ITE,Mr. S.K. Maity,ITE and Mr.N.Rajesh,ITM who spared their precious time for the sake of this report. They helped me at times when I required help.

Parul Acharya

B.Tech(E.C.E)

CONTENTS
TOPIC PAGE NO.
(1)INTRODUCTION. ..04

(2) INSTRUMENTATION.0 9

(3) PIPELINES...................................................................34
3

(a)MJPL .35 (b)SMPL 36

(4)CONCLUSION 39

INDIAN OIL CORPORATION LIMITED

Indian Oil Corporation, or IndianOil, is an Indian public-sector oil and gas company. It is Indias largest commercial enterprise, ranking 105th on the Fortune Global 500 list in 2009. IndianOil and its subsidiaries account for a 47% share in the petroleum products market, 40% share in refining capacity and 67% downstream sector pipelines capacity in India. The Indian Oil Group of Companies owns and operates 10 of India's 19 refineries with a combined refining capacity of 60.2 million metric tons per year. IndianOil operates the largest and the widest network of fuel stations in the country, numbering about 17606 (15557 regular ROs & 2049 Kissan Sewa Kendra). It has also started Auto LPG Dispensing Stations (ALDS). It supplies Indane cooking gas to over 47.5 million households through a network of 4,990 Indian distributors. In addition, IndianOil's Research and Development Center (R&D) at Faridabad supports, develops and provides the necessary technology solutions to the operating divisions of the corporation and its customers within the country and abroad. Subsequently, IndianOil Technologies Limited - a wholly owned subsidiary, was set up in 2003, with a vision to market the technologies developed at IndianOil's Research and Development Center. It has been modeled on the R&D marketing arms of Royal Dutch Shell and British Petroleum.

Products:
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IndianOil's product range covers petrol,diesel LPG, auto LPG, aviation turbine fuel, lubricants, naptha, bitumen,paraffin,kerosene etc. Xtra Premium petrol, Xtra Mile diesel, Servo lubricants, Indane LPG, Autogas LPG, Indian Oil Aviation are some of its prominent brands. Recently Indian Oil has also introduced a new business line of supplying LNG (liquefied natural gas) by cryogenic transportation. This is called "LNG at Doorstep". LNG headquarters are located at the Scope Complex, Lodhi Road,Delhi.

Refineries:

Digboi Refinery, in Upper Assam, is India's oldest refinery and was commissioned in 1901. Originally a part of Assam Oil Company, it became part of IndianOil in 1981. Its original refining capacity had been 0.5 MMTPA since 1901. Modernisation project of this refinery has been completed and the refinery now has an increased capacity of 0.65 MMTPA.

Guwahati Refinery, the first public sector refinery of the country, was built with Romanian collaboration and was inaugurated by Late Pt. Jawaharlal Nehru, the first Prime Minister of India, on 1 January 1962. Barauni Refinery, in Bihar, was built in collaboration with Russia and Romania. It was
commissioned in 1964 with a capacity of 1 MMTPA. Its capacity today is 6 MMTPA. Gujarat Refinery, at Koyali in Gujarat in Western India, is IndianOils largest refinery. The refinery was commissioned in 1965. It also houses the first hydrocracking unit of the country. Its present capacity is 13.70 MMTPA. Haldia Refinery is the only coastal refinery of the Corporation, situated 136 km downstream of Kolkata in the Purba Medinipur (East Midnapore) district. It was commissioned in 1975 with a capacity of 2.5 MMTPA, which has since been increased to 5.8 MMTPA Mathura Refinery was commissioned in 1982 as the sixth refinery in the fold of IndianOil and with an original capacity of 6.0 MMTPA. Located strategically between the historic cities of Delhi and Agra, the capacity of Mathura refinery was increased to 8 MMTPA. Panipat Refinery is the seventh refinery of IndianOil. The original refinery with 6 MMTPA capacity was built and commissioned in 1998. Panipat Refinery has doubled its refining capacity from 6 MMT/yr to 12 MMTPA with the commissioning of its Expansion Project.

INDIAN OIL CORPORATION LIMITED, MATHURA

Mathura Refinery, commissioned in 1982, presently operates @ 8.0 MMTPA crude processing level and is meeting the product demand of North-West region of the country including the National Capital Delhi.The Refinery processes low sulphur crudes from Bombay High, Nigeria, and high sulphur crudes from Middle East Countries. The process configuration of the Refinery employs the state-of-the-art technologies with minimal impact on the environment. Various steps have been taken by Mathura Refinery to monitor and control the emission of Sulphur Dioxide. Mathura Refinery is the only refinery in the country to have set up the concern of community and archeological sites. These Ambient Air Monitoring Stations were commissioned before commissioning of the Refinery in 1981 and being continuously operated thereafter.

IOCL,MATHURA
Mathura Refinery has taken many initiatives to produce more and more clean fuels in stages in the interest of environment, public health and preservation of national monuments around. Its noteworthy efforts are stage-wise implementation of various projects like Catalytic Reforming Unit, Diesel Hydrodesphurisation Unit and Hydrocracker for quality upgradation of automobile fuels. The Refinery has full-fledged ETP comprising of physical, chemical and biological treatment facilities. The treated effluent from the Refinery fully meets the MINAS(Minimal National Standards), the prescribes effluent discharge standards. For the protection of the land environment, Mathura Refinery has initiated biodegradation of oily sludge through "Oilivorous-S", an oily sludge degrading bacterial consortium developed by IOC(R&D) in collaboration with Tata Energy Research Institute.

Products from this refinery are dispatched through rail, road and Mathura-Delhi-Ambala-Jalandhar pipeline & Mathura-Tundla pipeline. This contribution of Mathura Refinery is meeting the petroleum product demand of northwest India which is about 68%. The LPG bottling plant situated within Mathura Refinery premises bottles nearly 7 million cylinders per annum for catering domestic market. Major fertilizer industries at Kanpur, Panipat, Nangal, Bhatinda & Kota are supplied with Naphtha or Furnace oil / Heavy petroleum stock as fertilizer feed stocks from Mathura Refinery. Also thermal power plants of Nangal, Obra and Badarpur get fuel oil supply from this refinery. Apart from this Mathura Refinery is privileged to provide the necessary energy to the pulsating capital New Delhi and also boost the standards of the farmers belonging to the crop rich lands of Punjab & Haryana.

The other important product, Bitumen has paved the transportation sector in the region of roadworthiness. To keep the environment clean and green, Mathura Refinery recovers nearly 15000 kgs of sulphur everyday as a by-product from crude oil.

The various products of Mathura Refinery are:-

> > > > > > > > > > >

Liquid Petroleum Gas for domestic use. Naphtha for fertilizer as feed. Aviation Turbine Fuel for civil and defense aviation purposes. Superior Kerosene oil for domestic use. High speed diesel oil for transportation. Furnace oil & heavy petroleum stock as fuel for industries. Petrol (Motor Spirit unleaded) for transportation. Light diesel oil for agro equipments. Bitumen for road paving. Propylene for high polymers. Sulphur for chemical industries.

A beautiful ecological park has been developed in an area of 4.45 acres. During the recent survey, the experts from the BNHS (Bombay Natural History Society) have identified 96 species of birds of which 30 migratory ones in the park giving a testimony of richness of life in the ecosystem. Mathura Refinery has done extensive tree plantation in and around Refinery. The Refinery ahs also taken extra-ordinary initiatives to provide green cover to the archeological heritage sites especially the Taj Mahal by planting 1,15,000 trees in the Taj region.

Major Highlights > Mathura Refinery was the first in Asia and third in the world in refining sector for being certified

for coveted ISO-14001 for its excellent Environment Management System (EMS ) in 1996 . > Quality system of support services of Personal & Administration purposes& Medical Dept of Mathura Refinery certified confirming to Quality basis standard ISO-9002, 1994. > Golden Peacock National Quality Award 1996 Mathura refinery is the first refinery in India to this distinction. > Bagged first prize in National Energy Conservation Award 1996 in refinery sector from Ministry of Power. > Jawaharlal Nehru Centenary Award for achieving best improved method of Energy conservation compared to its past best performance of 1994-96.

Eco Friendly Move Refinerys Concern For Environment

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> BS 7750/ISO 14001certified refinery Mathura Refinery is the first refinery in Asia and third in

world to achieve this distinction. > ISO 9002 certified company. > SO2 emissions well within the prescribed limit by Ministry of Environment & Forest. > Mathura Refinery compares well with international standard of air pollution i.e. WHO standards, Californian standards, Italian standards etc. > Mathura Refinery is the first refinery in India to supply lead free petrol to the country as per Euro III standards. > Mathura Refinery is the first refinery in India to supply Ultra Low Diesel to the country as per Euro III standards. > An area of 18000 sq mtrs pasture of lush greenery inside the refinery (ecological park). > Five ponds for polishing treated effluent water make a cluster of Bird Sanctuary. > Effluent water increases the yield of certain crops by 14% to 18% when used for agriculture established through experimental farming by the Aligarh Muslim University. > Over the years about 1,15,000 trees have been planted in Taj Trapezium Zone & about 18,000 trees at Mathura Region. > Extensive plantations have been done at Mathura Refinery site & Refinery Township.

INSTRUMENTATION
Control engineering has evolved over time. In the past humans were the main method for controlling a system. But today most of the industries are working on the principles of DCS and PLC.

DISTRIBUTED CONTROL SYSTEM

Collection of hardware and instrumentation necessary for implementing control systems. Provide the infrastructure (platform) for implementing advanced control algorithms.

DCS :

It stands for Distributed Control System. In any system, it is very difficult to perform the whole the task by a single unit, so the system is divided into different sections to perform different functions which altogether perform the task. Such a system is known as distributed system. Different sections communicate each other by setting nodes which are connected in a ring fashion. A distributed control system (DCS) refers to a control system usually of a manufacturing system, process or any kind of dynamic system, in which the controller elements are not central in location (like the brain) but are distributed throughout the system with each 9

component sub-system controlled by one or more controllers. The entire system of controllers is connected by networks for communication and monitoring. DCS is a very broad term used in a variety of industries, to monitor and control distributed equipment. A DCS typically uses custom designed processors as controllers and uses both proprietary interconnections and communications protocol for communication. Input and output modules form component parts of the DCS. The processor receives information from input modules and sends information to output modules. The input modules receive information from input instruments in the process (a.k.a. field) and transmit instructions to the output instruments in the field. Computer buses or electrical buses connect the processor and modules through multiplexer or demultiplexers. Buses also connect the distributed controllers with the central controller and finally to the Human-Machine Interface (HMI).

DCS used in Indian Oil Corporation Limited:

ABB August ALLEN BRADLEY

History of Control Hardware: Pneumatic Implementation:

Transmission: the signals transmitted pneumatically are slow responding and susceptible to interference. Calculation: Mechanical computation devices must be relatively simple and tend to wear out quickly.

Electron analog implementation:

Transmission: analog signals are susceptible to noise, and signal quality degrades over long transmission line. Calculation: the type of computations possible with electronic analog devices is still limited.

Digital Implementation:
Transmission: Digital signals are far less sensitive to noise. Calculation: The computational devices are digital computers. 10

General Structure of DCS DCS Element-1

Local Control Unit: This unit can handle 8 to 16 individual PID loops. Data Acquisition Unit: Digital (discrete) and analog I/O can be handle. Batch Sequencing Unit: This unit controls a timing counters, arbitrary function generators, and internal logic. Local Display: This device provides analog display stations, and video display for readout. Bulk Memory Unit: This unit is used to store and recall process.

Supervisory (host) Computer

Operator Control Panel

Main Control Computer

Operator Control Panel

Archival Data Storage

To other Processes

Data highway

To other Processes

Local data acquisition and control computers

Local Computer

Local Computer
Local Display

Local Computer
Local Display

PROCESS

Fig1.General Structure of DCS

DCS Element-2

General Purpose Computer : This unit is programmed by a customer or third party to perform optimization, advance control, expert system, etc 11

Central Operator Display: This unit typically contain several consoles for operator communication with the system, and multiple video color graphics display units Data Highway : A serial digital data transmission link connecting all other components in the system. It allow for redundant data highway to reduce the risk of data loss Local area Network (LAN) .

Advantages of DCS Access a large amount of current information from the data highway. Monitoring trends of past process conditions. Readily install new on-line measurements together with local computers. Alternate quickly among standard control strategies and readjust controller parameters in software. A sight full engineer can use the flexibility of the framework to implement his latest controller design ideas on the host computer. Digital DCS systems are more flexible. Control algorithms can be changed and control configuration can be modified without having rewiring the system.

Categories of process information Type 1. Digital Example

Relay, Switch Solenoid valve Motor drive Alphanumerical displays Turbine flow meter Stepping motor Thermocouple or strain gauge (mill volt) Process instrumentation (4-20 ma) Other sensors (0-5 Volt)

2.Generalized digital 3. Pulse 4. Analog

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Interface between digital computer and analog instruments (A/D) Transducers convert analog signals to digital signals. (Sensor => Computer). Valve).

(D/A) Transducers convert digital signals to analog signals. (Computer =>

Applications Of DCS
Distributed Control Systems (DCSs) are dedicated systems used to control manufacturing processes that are continuous or batch-oriented, such as oil refining, petrochemicals, central station power generation, pharmaceuticals, food & beverage manufacturing, cement production, steelmaking, and papermaking. DCSs are connected to sensors and actuators and use setpoint control to control the flow of material through the plant. The most common example is a setpoint control loop consisting of a pressure sensor, controller, and control valve. Pressure or flow measurements are transmitted to the controller, usually through the aid of a signal conditioning Input/Output (I/O) device. When the measured variable reaches a certain point, the controller instructs a valve or actuation device to open or close until the fluidic flow process reaches the desired setpoint. Large oil refineries have many thousands of I/O points and employ very large DCSs.

PROGRAMMABLE LOGIC CONTROL

A PLC (Programmable Logic Controllers) is an industrial computer used to monitor inputs, and depending upon their state make decisions based on its program or logic, to control (turn on/off) its outputs to automate a machine or a process. It can also be defined as a digitally operating electronic apparatus which uses a programmable memory for the internal storage of instructions by implementing specific functions such as logic sequencing, timing, counting, and arithmetic to control, through digital or analog input/output modules, various types of machines or processes.

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Traditional PLC Applications

In automated system, PLC controller is usually the central part of a process control system. To run more complex processes it is possible to connect more PLC controllers to a central computer. It is mainly used for safety purpose.

Fig2. Control panel with PLC (grey elements in the center). The unit consists of separate elements, from left to right; power supply, controller, relay units for in- and output

Programming:

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Fig3.Ladder Logic

PLC programs are typically written in a special application on a personal computer, then downloaded by a direct-connection cable or over a network to the PLC. The program is stored in the PLC either in batterybacked-up RAM or some other non-volatile flash memory. Often, a single PLC can be programmed to replace thousands of relays. Currently five programming languages are defined for programmable control systems: FBD (Function block diagram), LD (Ladder diagram), ST (Structured text, similar to the Pascal programming language), IL (Instruction list, similar to assembly language) and SFC (Sequential function chart). These techniques emphasize logical organization of operations.

It stands for Programmable Logic Controller. It works together with the DCS but it is mainly used for the safety purpose. PLCs have been gaining popularity on the factory floor and will probably remain predominant for some time to come .

PLC:

Different programming Language of PLC includes

Ladder Logic FBD =Punctional Block Diagram. STL- Statement Logic

PLC used in Indian Oil Corporation Limited:

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ABB August ALLEN BRADLEY

Ladder logic is the main programming method used for PLCs. Ladder logic has been developed to mimic relay logic. The decision to use the relay logic diagrams was a strategic one. By selecting ladder logic as the main programming method, the amount of retraining needed for engineers and tradespeople was greatly reduced. The inputs are activating 24V DC in the PLC which is generated by the sensors and transducers for measuring 4 parameters. Level Pressure Temperature Flow

The above mentioned parameters are measured with the help of Various Instruments which will be discussed later and these are converted into Electrical quantities with the help of transducers and sensors which are then fed to the PLC at the Input. In actual PLCs outputs are often relays which gives the signal to the solenoid valve. The ladder logic in the PLC is actually a computer program that the user can enter and change. It has been developed mainly for the Relay.

OUTPUT INSTRUMENT
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RELAY:

A relay is a remote switch controlled by current, magnetism, or temperature. It is activated when a current is applied to it. Relay was invented in 1835 by Joseph Henry (1979-1878), an American scientist. Relays are a common component in many devices, and there are many different types of relays.

Fig4.Relay

TYPES OF RELAY:

The two main types of relay are electromechanical and solid-state. Electromechanical relays have a moving plate with contacts on it, while solid-state relays work similar to transistors and have no moving parts.

A.) Electromechanical Relays

General Purpose Relay: The general-purpose relay is rated by the amount of current its switch contacts can handle. Most versions of the general-purpose relay have one to eight poles and can be single or double throw. These are found in computers, copy machines, and other consumer electronic equipment and appliances.

Power Relay: The power relay is capable of handling larger power loads 10-50 amperes or more. They are usually single-pole or double-pole units. Contactor: A special type of high power relay, its used mainly to control high voltages and currents in industrial electrical applications. Because of these high power requirements, contactors always have double-make contacts. Time-Delay Relay: The contacts might not open or close until some time interval after the coil has been energized. This is called delay-on-operate. Delay-on-release means that the contacts will remain in their actuated position until some interval after the power has been removed from the coil. A third delay is called interval timing. Contacts revert to their alternate position at a specific interval of time after the coil 17

has been energized. The timing of these actions may be a fixed parameter of the relay, or adjusted by a knob on the relay itself, or remotely adjusted through an external circuit..

B.) Solid State Relays

These active semiconductor devices use light instead of magnetism to actuate a switch. The light comes from an LED, or light emitting diode. When control power is applied to the devices output, the light General Purpose Relay is turned on and shines across an open space. On the load side of this space, a part of the device senses the presence of the light, and triggers a solid state switch that either opens or closes the circuit under control. Often, solid state relays are used where the circuit under control must be protected from the introduction of electrical noise.

Fig7.Circuit Diagram of Solid State Relay

Advantages of Electromechanical relays:

lower cost. no heat sink is required multiple poles are available They can switch AC or DC with equal ease.

Advantages of Solid State Relays:

low EMI/RFI long life no moving parts no contact bounce fast response.

The drawback to using a solid state relay is that it can only accomplish single pole switching.

RELAY SYMBOLS:
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Fig8.Symbols of Relay

RELAY APPLICATION:

Relays are used to control the flow of large currents using a small current. In the past, they were widely used in telephone exchanges to switch calls, but have been largely replaced by digital equipment. They are used to switch motors on and off, and to protect them from overheating. Thermostats use an overload relay to shut off the current when the temperature rises above the required setting.

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Fig9.Relays

INPUT INSTRUMENT
LEVEL MEASUREMENT
A pressure transmitter can be used to determine the liquid level in a tank, well, river or other body of liquid. The pressure at the bottom of a liquid filled container is directly related to the height of the liquid. The transmitter measures this hydrostatic head pressure and gives the resulting liquid level. To get an accurate reading, the measurement device needs to be located at the lowest point you want to measure; typically mounted or laying on the bottom of the container.

Open Tanks:
This is the simplest case to consider in level measurement. Vented/open tanks include elevated, above ground and inground tanks that have open vents or expose the media to local atmospheric pressure.

Sealed / Pressurized Tanks:

A sealed tank often has a higher than atmospheric pressure gas blanket on top of the liquid. There is an additive effect of the hydrostatic head pressure (pressure exerted by the liquid level) and the pressure of the gas blanket on top. The hydrostatic pressure and gas pressure together give a total pressure exerted at the bottom of the tank and on the level instrument. INSTRUMENTS:

Differential pressure transducer (DP)

One method and the most accurate, is to utilize a differential pressure transducer (DP). This device will accurately measure the liquid level while negating the gas blanket pressure effect. A DP with the high side (leg) running to the base of the tank and the low side plumbed to the top of the tank above the liquid will measure the difference between the gas pressure and the combined gas and liquid level pressure. This leaves the liquid level measurement only.

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Fig10.Open tank

Fig11. Closed tank

Capacitance Level Sensor:

Since capacitance level sensors are electronic devices, phase modulation and the use of higher frequencies makes the sensor suitable for applications in which dielectric constants are similar. The sensor contains no moving parts, is rugged, simple to use, easy to clean, and can be designed for high temperature and pressure applications.

A danger exists from build up and discharge of a high-voltage static charge that results from the rubbing and movement of low dielectric materials, but this danger can be eliminated with proper design and grounding.

Fig12.Capacitance Level Sensor

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Ultrasonic

Ultrasonic level sensors are used for non-contact level sensing of highly viscous liquids, as well as bulk solids. The sensors emit high frequency (20 kHz to 200 kHz) acoustic waves that are reflected back to and detected by the emitting transducer. Ultrasonic level sensors are also affected by the changing speed of sound due to moisture, temperature, and pressures. Correction factors can be applied to the level measurement to improve the accuracy of measurement. Application: Measuring liquid levels in a container or pipe using a noninvasive method (direct level measurement) or detecting the presence or absence of liquid in a sealed container (presence/absence test).

Fig13. Ultrasonic level sensor

Air bubbler
An air bubbler system uses a tube with an opening below the surface of the liquid level. A fixed flow of air is passed through the tube. Pressure in the tube is proportional to the depth (and density) of the liquid over the outlet of the tube. Air bubbler systems contain no moving parts, making them suitable for measuring the level of sewage, drainage water, sewage sludge, night soil, or water with large quantities of suspended solids. The only part of the sensor that contacts the liquid is a bubble tube which is chemically compatible with the material whose level is to be measured. Since the point of measurement has no electrical components, the technique is a good choice for classified Hazardous Areas. The control portion of the system can be located safely away, with the pneumatic plumbing isolating the hazardous from the safe area. Air bubbler systems are a good choice for open tanks at atmospheric pressure and can be built so that high-pressure air is routed through a bypass valve to dislodge solids that may clog the bubble tube. The technique is inherently self-cleaning.

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Pressure measurement :

Many techniques have been developed for the measurement of pressure and vacuum. Instruments used to measure pressure are called pressure gauges or vacuum gauges. A manometer could also be referring to a pressure measuring instrument, usually limited to measuring pressures near to atmospheric. The term manometer is often used to refer specifically to liquid column hydrostatic instruments.
Fig14.Bourdon tube

A vacuum gauge is used to measure the pressure in a vacuum --- which is further divided into two subcategories: high and low vacuum (and sometimes ultra-high vacuum). The applicable pressure range of many of the techniques used to measure vacuums have an overlap. Hence, by combining several different types of gauge, it is possible to measure system pressure continuously from 10 mbar down to 1011 mbar.

Although pressure is an absolute quantity, everyday pressure measurements, such as for tire pressure, are usually made relative to ambient air pressure. In other cases measurements are made relative to a vacuum or to some other ad hoc reference. When distinguishing between these zero references, the following terms are used: Absolute pressure is zero referenced against a perfect vacuum, so it is equal to gauge pressure plus atmospheric pressure. Gauge pressure is zero referenced against ambient air pressure, so it is equal to absolute pressure minus atmospheric pressure. Negative signs are usually omitted. Differential pressure is the difference in pressure between two points.

STATIC PRESSURE AND DYNAMIC PRESSURE

Static pressure is uniform in all directions, so pressure measurements are independent of direction in an immovable (static) fluid. Flow, however, applies additional pressure on surfaces perpendicular to the flow direction, while having little impact on surfaces parallel to the flow direction. This directional component of pressure in a moving (dynamic) fluid is called dynamic pressure. An instrument facing the flow direction measures the sum of the static and dynamic pressures; this measurement is called the total pressure or stagnation pressure . Since dynamic pressure is referenced to static pressure, it is neither gauge nor absolute; it is a differential pressure. While static gauge pressure is of primary importance to determining net loads on pipe walls, dynamic pressure is used to measure flow rates and airspeed. Dynamic pressure can be measured by taking the differential pressure between instruments parallel and perpendicular to the flow. 23

Instruments
Hydrostatic
Hydrostatic gauges (such as the mercury column manometer) compare pressure to the hydrostatic force per unit area at the base of a column of fluid. Hydrostatic gauge measurements are independent of the type of gas being measured, and can be designed to have a very linear calibration. They have poor dynamic response.

Liquid column:

The difference in fluid height in a liquid column manometer is proportional to the pressure difference.

Liquid column gauges consist of a vertical column of liquid in a tube whose ends are exposed to different pressures. The column will rise or fall until its weight is in equilibrium with the pressure differential between the two ends of the tube. A very simple version is a U-shaped tube half-full of liquid, one side of which is connected to the region of interest while the reference pressure (which might be the atmospheric pressure or a vacuum) is applied to the other. The difference in liquid level represents the applied pressure. The pressure exerted by a column of fluid of height h and density is given by the hydrostatic pressure equation, P = hg. Therefore the pressure difference between the applied pressure Pa and the reference pressure P0 in a U-tube manometer can be found by solving Pa P0 = hg. If the fluid being measured is significantly dense, hydrostatic corrections may have to be made for the height between the moving surface of the manometer working fluid and the location where the pressure measurement is desired.

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Bourdon
A Bourdon gauge uses a coiled tube, which, as it expands due to pressure increase causes a rotation of an arm connected to the tube. In 1849 the Bourdon tube pressure gauge was patented in France by Eugene Bourdon. The pressure sensing element is a closed coiled tube connected to the chamber or pipe in which pressure is to be sensed. As the gauge pressure increases the tube will tend to uncoil, while a reduced gauge pressure will cause the tube to coil more tightly. This motion is transferred through a linkage to a gear train connected to an indicating needle. The needle is presented in front of a card face inscribed with the pressure indications associated with particular needle deflections. In a barometer, the Bourdon tube is sealed at both ends and the absolute pressure of the ambient atmosphere is sensed. Differential Bourdon gauges use two Bourdon tubes and a mechanical linkage that compares the readings.

In the illustrations the transparent cover face of the pictured combination pressure and vacuum gauge has been removed and the mechanism removed from the case. This particular gauge is a combination vacuum and pressure gauge used for automotive diagnosis:

the left side of the face, used for measuring manifold vacuum, is calibrated in centimetres of mercury on its inner scale and inches of mercury on its outer scale. the right portion of the face is used to measure fuel pump pressure and is calibrated in fractions of 1 kgf/cm on its inner scale and pounds per square inch on its outer scale.

TEMPERATURE MEASUREMENT:
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Many methods have been developed for measuring temperature. Most of these rely on measuring some physical property of a working material that varies with temperature. One of the most common devices for measuring temperature is the glass thermometer. This consists of a glass tube filled with mercury or some other liquid, which acts as the working fluid. Temperature increases cause the fluid to expand, so the temperature can be determined by measuring the volume of the fluid. Such thermometers are usually calibrated so that one can read the temperature simply by observing the level of the fluid in the thermometer. Other important devices for measuring temperature include:

Thermocouple Thermistors Resistance Temperature Detector (RTD) Pyrometers

Fig18.Thermometer

Thermocouple and RTD which are generally used in the refinery are discussed shortly.

Thermocouple

A thermocouple is a junction between two different metals that produces a voltage related to a temperature difference. Thermocouples are a widely used type of temperature sensor for measurement and control and can also be used to convert heat into electric power. They are inexpensive and interchangeable, are supplied fitted with standard connectors, and can measure a wide range of temperatures.

Fig19.Thermocouple

Limitation: accuracy: system errors of less than one degree Celsius (C) can be difficult to achieve.

Principle of operation
26

In 1821, the GermanEstonian physicist Thomas Johann Seebeck discovered that when any conductor is subjected to a thermal gradient, it will generate a voltage. This is now known as the thermoelectric effect or Seebeck effect. Any attempt to measure this voltage necessarily involves connecting another conductor to the "hot" end. This additional conductor will then also experience the temperature gradient, and develop a voltage of its own which will oppose the original.

Resistance thermometer
Resistance thermometers, also called resistance temperature detectors or resistive thermal devices (RTDs), are temperature sensors that exploit the predictable change in electrical resistance of some materials with changing temperature. As they are almost invariably made of platinum, they are often called platinum resistance thermometers (PRTs). They are slowly replacing the use of thermocouples in many industrial applications below 600 C, due to higher accuracy and repeatability
Fig20.RTD

Principle of operation
It works on the principle of Ohms Law i.e. resistance ideally varies linearly with temperature

Advantages and limitations

Advantages of platinum resistance thermometers:

High accuracy Low drift Wide operating range Suitability for precision applications

Limitations:

RTDs in industrial applications are rarely used above 660 C. At temperatures above 660 C it becomes increasingly difficult to prevent the platinum from becoming contaminated by impurities 27

from the metal sheath of the thermometer. This is why laboratory standard thermometers replace the metal sheath with a glass construction. At very low temperatures, say below -270 C (or 3 K), due to the fact that there are very few phonons, the resistance of an RTD is mainly determined by impurities and boundary scattering and thus basically independent of temperature. As a result, the sensitivity of the RTD is essentially zero and therefore not useful.

Compared to thermistors, platinum RTDs are less sensitive to small temperature changes and have a slower response time. However, thermistors have a smaller temperature range and stability.

When to use RTDs or thermocouples

Temperature requirements: If process temperatures fall from -200 to 500 C (-328 to 932 F), then an industrial RTD is the preferred option. Thermocouples have a range of -180 to 2,320 C (292 to 4,208 F),[1] so for extremely high temperatures they are the only contact temperature measurement choice. Time-response requirements: If the process requires a very fast response to temperature changes fractions of a second as opposed to seconds (i.e. 2.5 to 10 s)then a thermocouple is the best choice. Keep in mind that time response is measured by immersing the sensor in water moving at 1 m/s (3 ft/s) with a 63.2% step change. Size requirement: A standard RTD sheath is 3.175 to 6.35 mm (0.1250 to 0.250 in) in diameter, while sheath diameters for thermocouples can be less than 1.6 mm (0.063 in). Overall requirements for accuracy: If the process only requires a tolerance of 2 C or greater, then a thermocouple is appropriate. If the process needs less than 2 C tolerance, then an RTD is sometimes the only choice. Keep in mind, unlike RTDs that can maintain stability for many years, thermocouples can drift within the first few hours of use.

Flow measurement

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Flow measurement is the quantification of bulk fluid movement. It can be measured in a variety of ways. In the refinery the two main instruments used are as follows:

Fig21.Flow meter

INSTRUMENT

Venturi meter
A Venturi meter constricts the flow in some fashion, and pressure sensors measure the differential pressure before and within the constriction. This method is widely used to measure flow rate in the transmission of gas through pipelines.The coefficient of discharge of Venturi meter ranges from 0.93 to 0.97. Orifice plate An orifice plate is a plate with a hole through it, placed in the flow; it constricts the flow, and measuring the pressure differential across the constriction gives the flow rate. It is basically a crude form of Venturi meter, but with higher energy losses. There are three type of orifice: concentric, eccentric, and segmental. Disadvantages of PLC control
-Too much work required in connecting wires. -Difficulty with changes or replacements. -Difficulty in finding errors; requiring skillful work force. -When a problem occurs, hold-up time is indefinite, usually long.

Advantages of PLC control

*Rugged and designed to withstand vibrations, temperature, humidity, and noise. *Have interfacing for inputs and outputs already inside the controller. *Easily programmed and have an easily understood programming language.

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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. If you manufacture plastic widgets, you speak PLC. If you produce chemicals, you speak DCS.

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Today, the two technologies share kingdoms as the functional lines between them continue to blur. We now use each where the other used to rule. However, 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 multivariable 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. Today's DCS architecturally looks much like the DCS of 20 years ago, but tomorrow's DCS may control through networked "smart" deviceswith no I/O hardware of its own.

Most DCSs offer redundant controllers, networks, and I/Os. Most give you "built-in" redundancy and diagnostic features, with no need for user-written logic.

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 31

strategies as independent tasks; thus, making changes to part of the control logic has no impact on the rest.

An important difference between DCSs and PLCs is how vendors market them. DCS vendors typically sell a complete, working, integrated, and tested system; offering full application implementation. They offer many services: training, installation, field service, and integration with your Information Technology (IT) systems. A DCS vendor provides a server with a relational database, a LAN with PCs for office automation, networking support and integration of third-party applications and systems. The DCS vendor tries to be your "one-stop shop." The PLC is more of a "do-it-yourself" device, which is sometimes simpler to execute.

Programmable Logic Controllers. When PLCs were solely replacements for hard-wired relays, they had only digital I/O, with no operator interface or communications. Simple operator interfaces appeared, then evolved into increasingly complex interfaces as PLCs worked with increasingly complex automation problems. We went from a panel of buttons and I/O-driven lamps to PLC full-color customized graphic displays that run on SCADA software over a network.

PLCs now have many DCS-like control functions (e.g., PID algorithms) and analog I/O. They've moved past their birthplace: the digital world (switch and binary sensor inputs and output contacts to run motors and trigger solenoids).

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.

Data exchange typically requires you to preassign data registers and hard code their addresses into the logic. If you add registers or need to reassign data, you typically have to deal manually with the Domino Effect. 32

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.

Many PLC installations use interface software from third-party vendors for improved graphics and various levels of alarming, trending, and reporting. The PLC and MMI software normally interact by sitting on the network and using the register exchange mechanism to get data from and to the various PLCs. This type of communication presumes you have preassigned data registers and can fetch data on an absolute address basis. This can lead to data processing errors (e.g., from the wrong input) you won't encounter with the central database of a DCS.

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.

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PIPELINES
IOCL operates the largest network of crude oil and petroleum products pipelines in India. Started with the construction of the 435 Km. long guwahati siliguri pipeline in early sixties, the pipeline of IOCL today transport petroleum products to the various major demand centres of this geographically vast country and feed crude oil to four major inland refineries. Indian oil is one of the leaders in providing engineering, construction and consultancy services to the pipeline industry.

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TYPES OF PIPELINES IN MATHURA REFINERY

Crude pipeline(SMPL) Products pipeline(MJPL)

PURPOSE OF THESE PIPELINES

These pipelines used for direct supply of crude oil from port to mathura refinery and to send refined petroleum products to other terminals for marketing, this decrease the transportation cost of oil. SMPL used to used to take crude oil from Salaya to Mathura to Jalandhar and MJPL is used to transfer refined oil to Tundla terminal.

MJPL PIPELINE SYSTEM

The pipeline starts at Mathura Refinery & follows an upward gradient up to Delhi installation (i.e. 174.889 meters level at Mathura to 229.105 meters level at Delhi). Further follows upward gradient up to Ambala (i.e. 274.4 meters level at Ambala)& follows downward gradient to Jalandhar (i.e. 236.74 meters levels at Jalandher). This pipeline covers a distance of 526. I Km from Mathura to jalandher, 69.940 km Sonepat T- point meerut Terminal & 57.435 km from Mathura to Tundla.

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The following is the length of the pipeline in section.

S.No. 01. 02. 03. 04. 05.

Section Mathura Delhi Delhi Panipat-Ambala Ambala- Jalandhar Sonepat-Meerut Mathura Tundla PPL

Length in km 146.600 214.5 km 165.000 km 69.940 km 57.435 km

SMPL
SMPL is used to transfer crude oil from Salaya to Mathura. It is the most important part of Mathura refinery and it cannot be operate without this unit. Due to this route it is known as SALAYA_MATHURA PIPELINE. 36

This crude oil fulfills the requirement of three refineries: Panipat Refinery Mathura Refinery Gujrat Refinery

Different sections of SMPL are:

Section Salaya-Viramgam Viramgam-Koyali Viramgam-Caksu Chaksu-Mathura Chaksu-Panipat Length(Km.) 274.40 141.80 605.80 197.20 649.10 Line Size(Dia.) 28 18 24 24 24 Repeater Station 2 3 13 4 6

INSTRUMENTATION AND CONTROL IN SMPL

For any process world wide instrumentation and control system play a key role by sensing, monitoring, controlling & recording complex processes that combines together, provides the desired o/p on which an organization survives and grows likewise in pipeline to sophisticated instrumentation and control systems along high tech ups system are installed for monitoring, controlling and safety of pipeline operations and for achieving throughout goals in most economical manner. 37

All station equipments MOVs and piping are provided with pneumatic/electronic instruments of analog/digital type with associated controls for fail-safe operation of equipments and pipeline as a whole. The instrumentation is broadly classified as under: 1. Main line pumping unit/monitoring control instrumentation 2. Station monitoring & control instrumentation 3. Station auto control instrumentation 4. Instrumentation for auxiliary system

MAIN LINE PUMPING UNIT/MONITORING & CONTROL INSTRUMENTATION

Since the area of operation is hazardous, the instrumentation system comprising engine, gear-box pump mounted sensor and logic elements used and control and mostly of pneumatic type, the operation of engine is controlled locally from unit control panel/interface panel & remotely from the station control panel.

UNIT CONTROL PANEL

The unit control panel consists of diff. pneumatic elements like multi port valves, indicating relays, pilot relays, pneumatic timers, logic gates etc. To achieve the operation in a given sequence as per requirements various monitoring instrumentation such as pressure gauges, temp. Gauges, pyrometer, speed indication are mounted on the UCP. The sensors are mounted on the engine vents the air supply when the sensed parameters falls below or exceed the set pt. as the case may be and actuates the pneumatic indicating relay in the healthy conditions when the sensed parameters meets the operational requirements air venting will not occur. The pneumatic indicating relays has two positions corresponding to healthy/alarm conditions for the display of alarm status(red for alarm & green for healthy). It also provides pneumatic o/p corresponding to actuate other logic elements in order to perform the desired logic function i.e. given alarm, tripping the engine etc. as per the logic design. Apart from this OIL MIST DETECTOR system is also incorporated to OIL MIST exceed a present value. For monitoring engine speed magnetic pick-up is used as a sensor and no. of pulses induced in the pickup due to cutting of magnetic field by a gear connected to the engine crank shaft is proceed in interface panel & signal is obtained for speed indication on UCP as well as SCP.

STATION OPERATION FROM CONTROL PANEL

MAIN LINE PUMPING UNIT
Control and sequence are incorporated in station control panel(SCP) through electronic h/w and in PLC system through ladder logic software for starting/stopping of the main line pumping units and opening/closing of suction/discharge MOVs. 38

The interface panel b/w SCP and UCP converts the electrical to pneumatic signals and vice versa. When engine is given starting command, the logic is arranged in such a way that first opening of pump suction valves takes place after the valves opened fully, engine start and after engine pick-up certain speed, the discharge valves open.

CONCLUSION

INDIAN OIL CORPORATION LIMITED is the first Indian company which comes under FORTUNE 500 companies. At present there are 4 Indian companies-IOCL, BP, HP and Reliance. It also finds a place of pride among the world biggest enterprises in Forbes 2000 list. The IOCL unit of Mathura is one of the largest petroleum units in Asia. It refined crude oil coming from Salaya offshore in Gujarat (where crude oil comes from Bombay high and Gulf countries by ships and pipelines) by pipeline. It produces almost all petroleum products like petrol, diesel, high speed diesel, naphtha, kerosene, ATF (Aviation Turbine Fuel), different gases(LPG etc.), glycerin, bitumen, propylene, sulphur etc.

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Mathura refinery has maximum no. of plants(Crude Distillation Unit, Vis-Breaking Unit, Bitumen Blowing Unit, Diesel Hydro Desulphurization Unit, Once Through Hydro cracking Unit, Vacuum Distillation Unit, Fluidized Catalytic Cracking Unit, Continuous Catalytic Reforming Unit, Hydrogen Generation Unit, Sulphur Recovery Unit) as compare to other Indian Refineries. I have done Vocational Training in IOCL Mathura mainly in two sections: 1) Instrumentation 2) Pipelines(MJPL & SMPL)

REFERENCES
[1] Electrical and electronic Instrumentation by A.K.Shawney. [2] Automating Manufacturing Systems with PLCs by Hugh Jack..

[3] http://en.wikipedia.org/w/index.php?title=Level_sensor&amp.

[4] http://www.pc-control.co.uk/index.htm.

[5] http://en.wikipedia.org/w/index.php?title=Orifice_plate&amp.

[6] http://en.wikipedia.org/w/index.php?title=Pressure_measurement&amp.

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