AN INTERNSHIP REPORT

ON

“POWER AND UTILITIES OF

CHENNAI PETROLEUM CORPORTION LIMITED”

BY

J
SHAKTHIPRI
YA 42130440

PROFESSIONAL TRAINING (S13APT)

DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINEERING

SCHOOL OF ELECTRICAL AND ELECTRONICS

SATHYABAMA
INSTITUTE OF SCIENCE AND TECHNOLOGY
(DEEMED TO BE UNIVERSITY)
Accredited with Grade “A++” by NAAC
JEPPIAAR NAGAR, RAJIV GANDHI SALAI
CHENNAI - 600 119

1
 DEPARTMENT OF ELECTRONICS AND COMMUNICATION ENGINNERING

BONAFIDE CERTIFICATE

This is to certify that “Internship Report” is submitted by, J.Shakthipriya-

42130440, is the work done by her and submitted during semester V. A
report submitted in partial fulfillment of the requirements for the award of
Degree of BACHELOR OF ENGINEERING in ELECTRONICS AND
COMMUNICATION ENGINEERING at
Name of the company.

Internal Guide

Head of the Department

Dr. T. RAVI , M.E .,

Ph.D.,

Submitted for Viva voce Examination held on

Internal Examiner External Examiner

2
 TABLE OF CONTENTS

CHAPTER TOPIC PAGE NO.

NO.

1 INTRODUCTION
6
1.1 ORGANISATION PROFILE

1.2 PLANTS DESCRIPTION 7

1.2.1 MAJOR PRODUCTS 10

2 CPCL REFINERY I 13

3 INTRODUCTION TO CONTROL SYSTEM 15

4 HISTORY OF DCS 17

4.1 INTRODUCTION TO DISTRIBUTED 19

CONTROL SYSTEM (DCS)

5 PLC BASICS

26
5.1 INTRODUCTION

27
5.2 HISTORY

5.3 FUNCTIONALITY 30

5.4 FEATURES 30

5.5 LADDER LOGIC

31

6 REFERENCE 32

3
4
 ABSTRACT

The Power and Utility internship program at Chennai Petroleum Corporation Limited
(CPCL) provides a unique opportunity for aspiring engineers to gain hands-on
experience in the operation and maintenance of critical utilities that support
refinery processes. This internship focuses on key areas such as power generation,
distribution, steam production, water treatment, and compressed air systems,
which are essential for the smooth functioning of the refinery.

Interns will work closely with experienced engineers and technicians, learning about
the practical aspects of power plant operation, energy efficiency optimization, and
utility management. They will be exposed to the latest technologies in power
generation, including gas turbines, boilers, and renewable energy integration, while
gaining insight into environmental management systems and regulatory
compliance.

The program emphasizes safety, sustainability, and operational efficiency,

equipping interns with the technical knowledge and problem-solving skills
necessary to address real-world challenges in the energy and utility sectors.
Through this internship, participants will develop a solid foundation in power
systems engineering, preparing them for future roles in the oil and gas industry and
beyond.

This abstract outlines the comprehensive learning experience offered by CPCL’s

Power and Utility department, designed to shape the next generation of engineers
in the energy sector.

5
 CHAPTER 1
1. INTRODUCTION

1.1 ORGANISATIONS PROFILE

Chennai Petroleum Corporation Limited (CPCL), one of the leading

group companies of IndianOil’s, was conceived in 1960s as a 2.5
million metric tonnes per annum (MMTPA) refinery designed to
produce fuels and lubes base stock. At CPCL, the past five decades have
an eventful, growth-oriented phase as the CPCL family built the
organisation to reach the present stature of 10.5 MMTPA capacity.

Today, CPCL stands tall among the public-sector refining companies

in India, with one of the most complex refineries of its kind in the
country, producing an array of value-added petroleum products. It
also pioneered key initiatives in several areas such as process
optimisation, technology absorption, energy conservation, waste
land reclamation and environment management.

Chennai Petroleum Corporation Limited (CPCL) formerly known as

Madras Refineries Limited (MRL). CPCL is one of the largest oil
refining companies in South India with a total refining capacity of
10.5 million metric tons per annum (mmtpa). The company
operates two refineries located in Tamil Nadu – the first refinery at
Manali with a capacity of 9.5 mmtpa, the second one located at
Cauvery Basin near Nagapattinam with a capacity of 1.0 mmtpa.
CPCL is a group company of Indian Oil Corporation Limited, which
6
holds 51.89% and National Iranian Oil Company (NIOC) holds
15.40%. The company isheadquartered at Chennai in Tamil Nadu,
India.

7
The Manali Refinery has a capacity of 9.5 MMTPA and is one of the
most complex refineries in India with Fuel, Lube, Wax and
Petrochemical feed stocks production facilities. CPCL's second
refinery is located at Cauvery Basin at Nagapattinam. This unit was
set up in Nagapattinam with a capacity of 0.5 MMTPA in 1993 and
later enhanced to 1.0 MMTPA.

The main products of the company are LPG, Motor Spirit, Superior
Kerosene, Aviation Turbine Fuel, High Speed Diesel, Naphtha,
Bitumen, Lube Base Stocks, Paraffin Wax, Fuel Oil, Hexane and
Petrochemical feed stocks.Which is designed to produce paraffin
wax for manufacture of candle wax, waterproof formulations and
match wax. A Propylene Plant with a capacity of 17,000 tonnes per
annum was commissioned in 1988 to supply petrochemical
feedstock to neighbouring downstream industries. The unit was
revamped to enhance the propylene production capacity to 30,000
tonnes per annum in 2004.

1.2 PLANTS DESCRIPTION

Chennai Petroleum Corporation Limited has process units

distributed in three Refinery complexes.An oil refinery or petroleum
refinery is an industrial process plant where petroleum (crude oil) is
transformed and refined into products such as gasoline (petrol),
diesel fuel, asphalt base, fuel oils, heatingoil, kerosene, liquefied
petroleum gas and petroleum naphtha.
8
Petrochemical feedstock like ethylene and propylene can also be
produced directly by cracking crude oil without the need of using
refined products of crude oil such as naphtha.

9
The crude oil feedstock has typically been processed by an oil
production plant. There is usually an oil depot at or near an oil
refinery for the storage of incoming crude oil feedstock as well as
bulk liquid products. In 2020, the total capacity of global refineries
for crude oil was about 101.2 million barrels per day.

Oil refineries are typically large, sprawling industrial complexes

with extensive piping running throughout, carrying streams of fluids
between largechemical processing units, such as distillation
columns. In many ways, oil refineries use many different
technologies and can be thought of as types of chemical plants. Oil
refineries are an essential part of the petroleum industry's
downstream sector.
Raw or unprocessed crude oil is not generally useful in
industrialapplications, although "light, sweet" (low viscosity, low
sulfur) crude oil has been used directly as a burner fuel to produce
steam for the propulsion of seagoing vessels. The lighter elements,
however, form explosive vapors in the fuel tanks and are therefore
hazardous, especially in warships.
Instead, the hundreds of different hydrocarbon molecules in crude
oil are separated in a refinery into components that can be used as
fuels, lubricants, and feedstocks in petrochemical processes that
manufacture such products as plastics, detergents, solvents,
elastomers, and fibers such as nylon and polyesters.

Petroleum fossil fuels are burned in internal combustion engines

to provide power for ships, automobiles, aircraft engines, lawn
10
mowers, dirt bikes, and other machines

11
Different boiling points allow the hydrocarbons to be separated by
distillation. Since the lighter liquid products are in great demand for
use in internal combustion engines, a modern refinery will convert
heavy hydrocarbons and lighter gaseous elements into
thesehigher-value products.
The oil refinery in Haifa, Israel, is capable of processing about 9
million tons (66 million barrels) of crude oil a year. Its two cooling
towers are landmarks of the city's skyline.

Oil can be used in a variety of ways because it contains

hydrocarbons of varying molecular masses, forms and lengths such
as paraffins, aromatics, naphthenes (or cycloalkanes), alkenes,
dienes, and alkynes.[29] While the molecules in crude oil include
different atoms such as sulfur and nitrogen, the hydrocarbons are
the most common form of molecules, which are molecules of
varying lengths and complexity made of hydrogen and carbon
atoms, and a small number of oxygen atoms. The differences in the
structure of these molecules account for their varying physical and
chemical properties, and itis this variety that makes crude oil useful
in a broad range of several applications.

Once separated and purified of any contaminants and impurities,

the fuel or lubricant can be sold without further processing. Smaller
molecules such as isobutane and propylene or butylenes can be
recombined to meet specific octane requirements by processes
such as alkylation, or more commonly, dimerization. The octane
grade of gasoline can also be improved by catalytic reforming,
12
which involves removing hydrogen from hydrocarbons producing
compounds with higher octane ratings such as aromatics.

13
Intermediate products such as gasoils can even be reprocessed to
break a heavy, long-chained oil into a lighter short-chained one, by
various forms of cracking such as fluid catalytic cracking, thermal
cracking, and hydrocracking. The final step in gasoline production
is the blending of fuels with different octane ratings, vapor
pressures, and other properties to meet product specifications.
Another method for reprocessing and upgrading these
intermediate products (residual oils) uses a devolatilization
process to separate usable oil from the waste asphaltene material.

Oil refineries are large-scale plants, processing about a hundred

thousand to several hundred thousand barrels of crude oil a day.
Because of the high capacity, many of the units operate
continuously, as opposed to processing in batches, at steady state
or nearly steady state for months to years. The high capacity also
makes process optimization and advanced process control very
desirable.

1.2.1 Major products

Crude oil is separated into fractions by fractional distillation. The

fractions at the top of the fractionating column have lower boiling
points than the fractions at the bottom. The heavy bottom fractions
are often cracked into lighter, more useful products. All of the
fractions are processed further in other refining units. Petroleum
products are materials derived from crude oil (petroleum) as it is
processed in oil refineries. The majority of petroleum is converted
14
to petroleum products, which includes several classes of fuels.

15
Oil refineries also produce various intermediate products such as
hydrogen, light hydrocarbons, reformate and pyrolysis gasoline.
These are not usually transported but instead are blended or
processed further on-site. Chemical plants are thus often adjacent
to oil refineries or a number of further chemical processes are
integrated into it. For example, light hydrocarbons are steam-
cracked in an ethylene plant, and the produced ethylene is
polymerized to produce polyethene.

Gaseous fuel such as liquified petroleum gas and propane, stored

and shipped in liquid form under pressure.
Lubricants (produces light machine oils, motor oils, and greases,
adding viscosity stabilizers as required), usually shipped in bulk to
an offsite packaging plant.

Paraffin wax, used in the candle industry, among others. May be

shipped in bulk to a site to prepare as packaged blocks. Used for
wax emulsions, candles, matches, rust protection, vapor barriers,
construction board, and packaging of frozen foods.

Sulfur (or sulfuric acid), byproducts of sulfur removal from

petroleum which may have up to a couple of percent sulfur as
organic sulfur-containing compounds. Sulfur and sulfuric acid are
useful industrial materials. Sulfuric acid is usually prepared and
shipped as the acid precursor oleum
.
Bulk tar shipping for offsite unit packaging for use in tar-and-gravel
16
roofing.

17
Asphalt used as a binder for gravel to form asphalt concrete, which
is usedfor paving roads, lots, etc. An asphalt unit prepares bulk
asphalt for shipment. Petroleum coke, used in specialty carbon
products like electrodes or as solid fuel.

Petrochemicals are organic compounds that are the ingredients for

the chemical industry, ranging from polymers and pharmaceuticals,
including ethylene and benzene-toluene- xylenes ("BTX") which are
often sent to petrochemical plants for further processing in a
variety of ways.

The petrochemicals may be olefins or their precursors, or various

types of aromatic petrochemicals.

 GasolineNaphtha
 Kerosene and related jet aircraft fuels
 Diesel fuel and fuel oils
 Heat
 Electricity

Over 6,000 items are made from petroleum waste by-products,

including fertilizer, floor coverings, perfume, insecticide, petroleum
jelly, soap, vitamin capsules.

18
 2. CPCL REFINERY I

At Refinery I crude oil is separated into several fractions, all of

which require further processing or blending to meet the quality
requirements. The separation is effected in atmospheric tower and
two stage vacuum towers.
The streams obtained are gas, overhead naphtha, kerosene, diesel
from atmospheric tower and gas oil, spindle Oil, intermediate
neutral from first stage vacuum tower and 500 neutral & heavy
neutral and vacuum residuum from second stage vacuum tower.

The gas is used as refinery fuel gas along with the off gases from
unifiner (Plant No.3), kerosene hydro desulphuriser (Plant No.4) and
the thermal cracker and visbreaker (Plant No.6) after recovery of
H2S by amine treatment in PIantNo.12.

The overhead naphtha is sent to vapor recovery unit (VRU) where it

is split into gas, LPG, light straight run gasoline and light naphtha.
The gas is used as feed to hydrogen plant after amine treating.
The light naphtha stream is reformed in plat former to improve its
octane number and blended to gasoline. Catalytic reforming of
naphtha produces hydrogen as by-product which is used for
desulphurising the naphtha feed to the plat former.
The heavy naphtha stream from the atmospheric tower is the first
side stream. Part of the heavy naphtha is sweetened using merox
catalyst and blended with SK. The balance will be blended with
diesel oil draw off to produce high speed diesel oil. The second side
19
stream from atmospheric tower is kerosene. This draw off is
adjusted to make aviation

20
The second side stream from atmospheric tower is kerosene. This
draw off is adjusted to make aviation.Turbine fuel (ATF - KSO) to
meet the specifications whenever the plant is producing ATF- KSO.

The bottom product of atmospheric tower is the feed to the first

stage vacuum distillation. Four streams are separated from the
feed viz. gas oil, spindle oil, light neutral and intermediate neutral.
These form the feedstock for the plant 8,9 NMP and thermal
cracker. The spindle oil, light neutral and intermediate neutral streams
required to meet the feed stock requirement of furfural or NMP
extraction and MEK dewaxing units are sent to intermediate tanks.

The bottom product of first stage vacuum tower is separated into

vacuum residue and 500 neutral & heavy neutral fraction in the
second stage vacuum tower. Asphalts are produced by air blowing
of the vacuum bottoms / pitch.
The furfural extraction unit (FEU) processes the spindle oil, light
neutral, inter neutral. 500 neutral and heavy neutral are processed
in NMP Extraction unit. The extracted aromaticscalled lube extracts.

MEK dewaxing unit processes all the finished raffinate from

furfural / NMP extraction unit and also light neutral I intermediate
neutral heavy neutral to produce HVI / LVI lube.. The finished lube oil is
stored in finished LOBS tank farm.

The H2S rich gases from plant Nos. 3,4,5,10 and 13 are amine
treated to recover the H2S. This recovered H2S is converted into
21
sulphur in plant 75.

22
3.Introduction to Control System:

The word control says about a thing to keep under control or in

safe. For this purpose controller is used. It is a device used to
control a process with the given set point. Set point is nothing a
value to keep the process in safe position. The controller is
broadlyclassified into two types.
They are,

 Analogue Controller

 Digital Controller

It is indeed difficult to say that analogue controllers are definitely

better than digital controllers. The point is, they both work.
Analogue controllers are based on mechanical parts that cause
changes to the process via the final control element. Again like final
control elements, these moving parts are subjected to wear and
tear over time and that causes the response of the process to be
somewhat different with time. Analogue controllers control
continuously.

Digital controllers do not have mechanical moving parts. Instead,

they use processors to calculate the output based on the measured
values. Since they do not have moving parts, they are not
susceptible to deterioration with time. Digital controllers are not
continuous. They execute at very high frequencies, usually 2-3
23
times a second.

24
Advantages:
 High accuracy and flexibility.
 Immune to noise (since it operates digitally).
 Easy to modify and reprogram.

Disadvantages:
 Sampling issues (controller performance depends on the
sampling rate).
 May introduce delays because of the computational steps
involved.

Analogue controllers should not be confused with pneumatic

controllers. Just because a controller is analogue does not mean it
is pneumatic. Pneumatic controllers are those that use instrument
air to pass measurement and controller signals instead of electronic
signals. An analogue controller can use electronic signals.
Compared to pneumatic controllers, electronic controllers (can be
analogue or digital) have the advantage of not having the same
amount of dead time and lag due to the compressibility of
instrumentair.

Advantages:
 Smooth and continuous control.
 Typically faster in operation since they don't involve digital
sampling.

Disadvantages:
 Susceptible to noise and drift over time.
25
 Harder to modify once the system is implemented (limited
flexibility).

26
4.HISTORY OF DCS:

During the evolution of industries, the term control also born. It is

to control the process done in industry. In older days they use
manually control the process later to this they invented the
pneumatic controllers to control the process. Here we use the air to
control the process elements thus by introducing the air to the
closed controller close or open the valves etc. Then these electrical
switches are used to control the process. To operate the switches
manual power is used. Then to this mechanical Relays are found
which acts like switch by using some logics of circuit due to this the
circuit become very complex and the interconnections are given by
wires causes some damage in regular usage which makes the
whole process to shut down.Here we can’t easily rectify the errorin
27
the circuit.

28
To overcome this later we found PLC to control the process which
works according to the LOGIC implemented in the PLC
microprocessor. The main advantage is that the stored logics are
easily viewed by a handheld device by this we can alter the logics to
increase the efficiency of the process. But the major disadvantage
of PLC that the process can’t be monitored. To overcome this
problem DCS came which makes the all the industry into compact
size where use of less manual power. Here it uses large number of
input and output modules.

Key Manufacturers Today:

 Honeywell (Experion PKS)

 Yokogawa (CENTUM VP)
 Siemens (SIMATIC PCS 7)
 Emerson (DeltaV)
 ABB (System 800xA)

The history of DCS reflects the continuous innovation in control

systemdesign, from the early days of centralized control to the
highly distributed, flexible, and intelligent systems seen today. The
ongoing evolution of DCS continues to revolutionize process
automation, making industries more efficient, reliable, and capable
of handling complex processes with precision.

29
4.1 Introduction to Distributed Control System (DCS)

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. To be able to do so in DCS we need the following

PROCESS

CSS CSS CSS

BUS TYPE NETWORK

HIS DBMS GATEWAY

30
OTHER NETWORK

CSS- Control Sub-Station

HIS - Human Interface System

DBMS- Data Base management System

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 fieldinstruments.

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 aswell 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 someplant operating data
31
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 thanthat 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.

Input and output

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 veryoften used is Ethernet.

32
The top vendors of DCS and their introduction are as follows :

ABB / Industrial IT - Advant Master DCS

Advant OCS (Open Control System) is an ABB solution for operators

to improve their manufacturing productivity and achieve
sustainable competitive advantages.

In 1992, based on the success of the Master systems in the 80's,

the Master system began its evolution to Advant OCS. This
evolution introduced high capacity controllers and I/O with an
improved redundancy scheme. Also included were modern UNIX
workstations, and in 1996 S800 I/O was added providing modular
flexible remoteI/O.

In 2000, Advant OCS with Master Software began its next step in
the evolution process with the introduction of Industrial IT enabled
products. ABB's commitment to protecting your investment
continues with these enhancements by providing connectivity to
our latest control offering.

A versatile and complete range of process I/O systems within the

Advant familyenables optimal user configurations.
S100I/O - A rack-based I/O system for AC400 controllers S600I/O - A
rack- based I/O system for AC100 controllers S800I/O - A highly
modularized and flexible I/O-system

33
Numerous characteristics and functions facilitate and improve
operation, monitoring, and reengineering of each process in a
company. 800xA Operations (Process Portal) and the proven
Advant Command for Unix

34
The intuitive operator software provides consistent access and
interaction withdata from multiple control and I/O to plant and
enterprise information.

Honeywell Experion™ Process Knowledge System (PKS)

Experion is Honeywell’s unified system for process, business, and

asset management that helps industrial manufacturers increase
their profitability andproductivity.

Experion takes customers well beyond Distributed Control System

(DCS) functionality with an advanced automation platform solution
and innovative application integration to improve business
performance and peace of mind. And there’s no need to worry
about upgrading from TDC 2000®/TDC 3000® or Total Plant®
Solution (TPS).

The unique, patent pending design of Series C combines sleek

styling and function to provide process I/O with reduced footprint,
easier installation and maintenance, and longer life. The Series C
form factor benefits extend to multiple modules, such as the Series
C C300 Controller, the Field bus Interface Module, the Control
Firewall, and HART analog modules.

The Control Execution Environment (CEE) is the common core

software used in the various controllers supported by Experion TM.
This includes the C200 Process Controller, the C300 Process
35
Controller, the Application Control Environment (ACE) and the C200
Simulation Environment (SIM- C200).

36
The CEE provides an execution and scheduling environment where
control strategies are configured from a rich set of standard and
optional function blocks using a single builder tool, Control Builder.

Function blocks are grouped and wired together in a container to

perform a specific control function such as a valve control strategy.
The Control Execution Environment (CEE) supports two types of
containers: the Control Module in which continuous and discrete
controls are combined; and an SCM, which is used for sequence
control. Function blocks support the complete control application
range, such as continuous, discrete and batch control.

Emerson Process Management / Delta-V

Delta-V is the creation of Emerson Process Management's

technological innovators, who worked in an off-site "out-of-the-box"
think tank to build an automation system that could integrate and
leverage today's digital world and cutting-edge technological
innovations to make a value step-change in the process industries.
The name Delta-V is derived from the engineering equation for
acceleration: dv/dt, the change in velocity over the change in time.
The Delta-V system makes planning, engineering, installing,
commissioning, training, operating, and maintaining your process
EASY, which accelerates your success in improving your plant
performance.

The Delta-V system scales the complete range of applications from

37
an isolated process area to a complete plant-wide automation
system.

38
Whether you need tens of I/O or tens of thousands of I/O-any size
you want! The Delta-V system provides all the tools to manage your
process easier than ever before.

The complete family of controllers is available to power your most

advanced control strategies. Full controller and power supply
redundancy is available for your mission-critical applications. The
controller and I/O sub-system is rated for Class I, Division 2 and
Zone 2 environments to reduce your installation costs.

Delta-V workstations are based on the latest Intel-based

microprocessors running the Microsoft Windows XP /Windows 2003
operating system. A complete range of applications is provided to
cover system configuration, operator interface, engineering,
maintenance, and integration functions.

The Delta-V control networks a high-speed Ethernet LAN provides

system communications and connects the various system nodes.
The control network can befully redundant. Delta-V remote services
extend the operations, engineering, and diagnostic applications
across your enterprise network.

Unlike PLC/HMI solutions, the completely integrated Delta-V system

features a single database that coordinates all configuration
activities. System configuration is globally distributed in the run-
time environment

39
.

40
5. PLC BASICS
5.1 INTRODUCTION:

The development of low cost computer has brought the most

recent revolution in control engineering, Programmable Logic
Controller. It is a software control language which has been the
most common choice for manufacturing control system.
A programmable logic controller (PLC) or programmable controller
is a digital computer used for automation of electromechanical
processes. Programs to control machine operation are typically
stored in battery-backed or non-volatile memory. A PLC is an
example of a real time system since output results must be
produced in response to input conditions within a bounded time,
otherwise unintended operation will result.
When we consider a PLC there are inputs, outputs, and the logic.
The programming is such that it performs the function of relay logic
control decisions. It is actually a computer program that the user
can enter and change. PLCs have been gaining popularity on the
factory floor and will probably remain predominant for some time to
come. Most of this is because of the advantages they offer.
 Cost effective for controlling complex systems.

 Flexible and can be reapplied to control other systems

quickly and easily.

 Computational abilities allow more sophisticated control.

 Trouble shooting aids make programming easier and reduce

downtime.

41
 Reliable components make these likely to operate for years
before failure.

42
PROGRAMMABLE LOGIC CONTROLLER SYSTEM DIAGRAM

Fig 3.1: PLC controller system diagram

5.2 HISTORY

The PLC was invented in response to the needs of the American

automotive manufacturing industry. Programmable logic controllers
were initially adopted by the automotive industry where software
revision replaced the re-wiring of hard-wired control panels when
production models changed. Before the PLC, control, sequencing,
and safety interlock logic for manufacturing automobiles was
43
accomplished using hundreds

44
or thousands of relays, cam timers, and drum sequencers and
dedicated closed-loop controllers. The process for updating such
facilities for the yearly model change-over was very time
consuming and expensive, as electricians needed to individually
rewire each and every relay. Digital computers, being general-
purpose programmable devices, were soon applied to control of
industrial processes. Early computers required specialist
programmers, and stringent operating environmental control for
temperature, cleanliness, and power quality. Using a general-
purpose computer for process control required protecting the
computer from the plant floor conditions. An industrial control
computer would have several attributes, it would tolerate the shop-
floor environment, it would support discrete (bit-form) input and
output in an easily extensible manner, it would not require years of
training to use, and it would permit its operation to be monitored.
The response time of any computer system must be fast enough to
be useful for control, the required speed varying according to the
nature of the process. In 1968 GM Hydramatic (the automatic
transmission division of General Motors) issued a request for
proposal for an electronic replacement for hard-wired relay
systems. The winning proposal came from Bedford Associates of
Bedford, Massachusetts.
Early PLCs were designed to replace relay logic systems. These
PLCs were programmed in "ladder logic", which strongly resembles
a schematic diagramof relay logic. Other early PLCs used a form of
instruction list programming, based on a stack-based logic solver.
Modern PLCs can be programmed in a variety of ways, from ladder
45
logic to more traditional programming languages such as BASIC
and C.
PROGRAMMING IN PLC:

46
Early PLCs, up to the mid-1980s, were programmed using
proprietary programming panels or special-purpose programming
terminals, which often had dedicated function keys representing
the various logical elements of PLC programs. Programs were
stored on cassette tape cartridges. Facilities for printing and
documentation were minimal due to lack of memory capacity. The
very oldest PLCs used non-volatile magnetic core memory. More
recently, PLCs are programmed using application software on
personal computers. The computer is connected to the PLC through
Ethernet, RS-232,RS-485 or RS- 422 cabling.

Generally, the software provides functions for debugging and

troubleshooting the PLC software, for example, by highlighting
portions of the logic to show current status during operation or via
simulation. The software will upload and download the PLC
program, for backup and restoration purposes. In some models of
programmable controller, the program is transferred from a
personal computer to the PLC through a programming board which
writes the program into a removable chip such as an EEPROM or
EPROM.

PLC can be programmed not only in ladder logic or C, but there is a

galore of possibilities:
 Ladder logic.
 Structural languages - mostly C.
 Low-level languages- assembler, basic.
 Block languages, like FBD, PD, and FUP.
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 Sequential function charts

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5.3 FUNCTIONALITY:

The functionality of the PLC has evolved over the years to include
sequential relay control, motion control, process control, distributed
control systems and networking. The data handling, storage,
processing power and communication capabilities of some modern
PLCs are approximatelyequivalent to desktop computers.

5.4 FEATURES:

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 input and output. The main difference
from other computers is that PLCs are armored for severe
conditions (such as dust, moisture, heat, cold) and have the facility
for extensive input/output (I/O) arrangements. These connect the
PLC to sensors and actuators. PLCs read limit switches, analog
process variables (such as temperature and pressure), and the
positions of complex positioning systems. Some use machine
vision.

On the actuator side, PLCs operate electric motors, pneumatic or

hydraulic cylinders, magnetic relays, solenoids, or analog outputs.
The input/output arrangements may be built into a simple PLC, or
the PLC may have external I/O modules attached to a computer
network that plugs into the PLC.

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 Fig 3.2: PLC system overview

5.5 LADDER LOGIC:

Ladder logic is the main programming method used for PLCs. By

selecting ladder logic as the main programming method, the
amount of retraining needed for engineers was greatly reduced.
Modern control systems still include relays, but these are rarely used
for logic.The contact that closes when the coil is energized is called
normally open. Normally open contacts are shown as two lines, and
will be open (non-conducting) when the input is not energized.

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6. REFERENCE:

 Eckardt, D. and Rufli, P. "Advanced Gas Turbine Technology -

ABB/ BBC Historical Firsts", ASME J. Eng. Gas Turb. Power,
2002, p. 124, 542-549
 Kay, Antony, German Jet Engine and Gas Turbine
Development 1930- 1945, AirlifePublishing, 2002

 Gas Turbine Theory" by H.I.H. Saravanamuttoo, G.F.C. Rogers

and
H. Cohen,Pearson Education, 2001, 5th ed.,

 Gas Turbine Performance, 2nd Edition" by Philip Walsh and

Paul Fletcher, Wiley-Blackwell, 2004

 Liu Meilan, The design PLC control, Teaching Experiment

System, LaboratoryDisquisition and Search, 2004

 ‘Automating Manufacturing Systems with PLCs’-version

5.0,may 4,2007-Hugh Jack Boucher, T.O., “Computer
Automation in Manufacturing; An Introduction”,Chapman and
Hall, 1996.

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INTERNSHIP AT ACMEGRADE

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NPTL CERTIFICATE

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