Abhinav Iffcointrenreport

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Abhinav iffcointrenreport
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A
Training Report
on
Instrumentation And Control
In
IFFCO, AONLA
Submitted in the partial fulfillment of the requirements of the Degree of Bachelor of Technology
in Electrical & Electronics Engg.
By
Abhinav Singh
Roll no. 1802721003
DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGG.
AJAY KUMAR GARG ENGINEERING COLLEGE

GHAZIABAD (U.P)
Session: 2021-22

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ACKNOWLEDGEMENT
I express my deepest sense of gratitude towards Mr.OP Mathur (Senior Manager

Training), IFFCO, Aonla for his patience, inspiration, guidance, constant encouragement,
moral support, keen interest, and valuable suggestions during preparation of this Training report.
My heartfelt gratitude goes to all faculty members of Electrical & Electronics Engineering
Deptt., who with their encouraging and caring words and most valuable suggestions have
contributed, directly or indirectly, in a significant way towards completion of this Training
report.
I am indebted to all my classmates for taking interest in discussing my problem and
encouraging me.
I owe a debt of gratitude to my father and mother for their consistent support, sacrifice,
candid views, and meaningful suggestion given to me at different stages of this work.
Last but not the least I am thankful to the Almighty who gave me the strength and health for
completing my report.
Abhinav Singh
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TABLE OF CONTENT
Content Page No.

List Of Figures v
List Of Abbreviations vi
Weekly Report vii
Chapter 1 Introduction 1
1.1 Aonla Unit 1
1.2 Highlights of Aonla Unit 2
Chapter 2 Concept Of Instrumentation 3
2.1 What is Instrumentation? 3
2.2 Measurement in Process Industries 4
2.2.1 Pressure Measurement 4
2.2.2 Flow And Level Measurement 6
2.2.3 Temperature Measurement 10
Chapter 3 Process Control Methodologies 13

3.1 Control elements 13
3.2 Basic Control Loop 15
Chapter 4 Process Control system 16
4.1 Analog Control System 16
4.2 Digital Control System 16
4.2.1 Centralised Control System 17
4.2.2 Distributed Control System 17
Chapter 5 Programmable Control Logic 22

5.1 Components Of PLC 22
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5.2 Types Of Input Output Circuit 24

5.3 Functions Of PLC 25
Recruitment Process Of IFFCO 27
Conclusion 28
Bibliography 29
iv

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LIST OF FIGURES
Fig. NO. FIGURE NAME PAGE NO.
2.2.1 Bourdoun Tube 5
2.2.2 Strain Gauge 6
2.3.1 RF Capacitance Probe 8
2.3.2 Conductance Method Of Level Measurement 8
2.3.3 Ultrasonic Level Measurement 10
2.4.1 Thermocouple Pluged To Multimeter 11
2.4.2 Thermocouple Circuit 11
2.4.3 Resistance Thermometer 12
2.4.4 Bimetallic Thermostat 12
3.2.1 Basic Control Loop 15
3.2.2 Example of Basic Control Loop 15
4.1.1 Analog Control System 16
4.1.2 Digital Control System 17
4.2.1 DCS Closed Loop Diagram 19
4.2.1 Closed Loop Diagram Of Control System 20
5.1.1 Components Of PLC 22
5.1.2 DC Input Module 23
5.1.3 DC output Module 24
5.3.1 Functions Of PLC 26

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List Of Abbreviations
1. IFFCO- Indian Farmers Fertilizers Cooperative Limited

2. MTPD – Metric Tonnes Per Day
3. RF- Radio Frequency
4. PRT –Platinium Resistance Thermometer
5. RTD- Resistance Temperature Detector
6. HMI – Human Machine Interface
7. DCS – Distributed Control System
8. CCS –Centralised Control System
9. PLC –Prorammable Control Logic
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WEEKLY REPORT
Week 1
1. Introduction Of IFFCO
2. UREA Making Procedure (breifly)
3. Plant Visit
4. Concept Of Instrumentation
5. Measurement Process In IFFCO (overview)
Week 2
1. Pressure Measurement
 Baurdoun Tube
 Electronic Transducer
 Strain Gauge
2. Level And Flow Measurement
 RF Capacitance
 Conductance
 Ultrasonic And sonic
3. Temperature Measurement
 Thermocouple
 Bimetallic Thermometer
 Resistance Thermometer
Week 3
1. Process Control Methodologies
 Controlling Elements
 Primary element
 Measuring Element
 Final Elements
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2. Basic Control Loop

3. Plant Visit
4. Process Control System
 Types Of Process Control System
Week 4
1. Type Of Digital Control System
 Centralised Control System
 Distributed Control System
2. Special Lecture
3. PLC ( briefly)
 Major Components
 Basic Functions
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CHAPTER 1
INTRODUCTION
Indian Farmers Fertilizers Cooperative Limited was established on 3rd

November,1967 as a multi-unit cooperative organization with broad objectives of
augmenting, fertilizer production, ensuring fertilizer availability at farmers door-step,
strengthening cooperative fertilizer distribution system and education, training and guiding
the farmers for improving agricultural productivity.
It is the federation of over 37,000 Societies, most of them being village cooperative,
spread over in sixteen states and three union territories. The organization is distinct in the
sense that the farmer owners represented through their village cooperatives also become its
customers.
IFFCO presently own five giant fertilizer units at Kalol and Kandla in Gujarat,
Phulpur and Aonla in Uttar Pradesh and Oman in Saudi Arab.
The production of IFFCO is NPK/DAP/UREA. All four fertilizer Units of IFFCO
have displayed remarkable performance during 2002-2003 by producing 60.47 lakh tonnes
fertilizer material comprising of 36.89 lakh tonnes of Urea and 23.62 lakh tonnes of
NPK/DAP.
1.1 AONLA UNIT

Towards increasing the fertilizer production under the over all national planning for
utilization of natural gas available in Bombay High, a major programme for setting up six
new gas based fertilizer units was envisaged by Govt. of India along the H.B.J. gas pipe line.
IFFCO / Aonla complex is one of the giant cooperative fertilizer manufacturing
industry in India.
• This complex consists of two Ammonia manufacturing units with capacities as 1350 MTPD
using M/s Haldor-Topsoe, Denmark process technology.
• This complex consists of four Urea manufacturing units with capacities as 1100 MTPD
each using M/s Snam-Progetti, Italy process technology.
• Apart from the above main processes we are having other Off-site and Utility facilities to
augment the main process units.
• Under offsite facilities we are having de-mineralized water treatment plants for making
boiler feed water, cooling towers for closed loop cooling water circulation for process
medium cooling at various heat exchangers.

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• Apart from the above facilities we are also having instrument air supply units, plant air
supply units, inert gas supply units, effluent treatment units, ammonia storage units, naphtha
storage units.
• Captive power generation plant with two units of gas turbines having capacities of 24 MW
each supplied by M/s Hitachi, Japan, steam generation plant of 150 TPH high pressure steam
at 105 kg/cm2 pressure at 510° C.
• Two Bagging plants with automatic bagging machines.
• To run the total complex we are having detailed organization setup consisting of various
agencies.
1.2 HIGHLIGHTS OF AONLA UNIT

 PRODUCT PRESENT CAPACITY
Ammonia : 578221 MT/annum
Urea : 1000271 MT/annum
 MAJOR INPUTS
Natural gas : 3.3 million m3/day
Water : 55000 m3/day
 DATE OF COMMERCIAL PRODUCTION OF UREA
Aonla-1 : 16th July,1988
Aonla-2 : 25th Dec,1996
 PLANT TECHNOLOGY
Ammonia : Haldor Topsoe, Denmark

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CHAPTER-2
CONCEPT OF INSTRUMENTATION
2.1 What is INSTRUMENTATION ?

Instrumentation is defined as “the art & science of measurement and control”.
Instrumentation can refer either to the field in which instrument technicians and engineers
work, or to the available methods of measurement and control and the instruments which
facilitate this.
In any manufacturing process or production units the technology of using instruments
for the measurement and controlling of physical and chemical properties of the materials is
also called Instrumentation.
1. The instrumentation used in chemical treatment or conversion industries is called
process instrumentation.
2. Measurement along with controlling facility is called control system.
3. The variable that is object of measurement as well as control is called measured
variable or controlled variable.
4. The variable that affects the value of measured or controlled variable is called
measured variable or control variable.
5. Every scientific and technical discipline develops a language of its own to convey
information and ideas.
6. In general instruments and instrumentation items are identified and represented by a
system of letters and number of simple basic pictorial symbols.
Various Activities of the Instrumentation Section
 Preventative checking/ maintenance.
 Breakdown maintenance.
 Shutdown maintenance.
 Calibration of instruments.
 General maintenance.

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Instrument
Instruments are used in measuring attributes of physical systems. The variable
measured can include practically any measurable variable related to the physical sciences.
These variables commonly include:
pressure
flow
temperature
level
density
current
voltage
frequency
various physical properties, etc.
Instruments can often be viewed in terms of a simple input-output device. For example,
if we "input" some temperature into a thermocouple, it "outputs" some sort of signal. (Which
can later be translated into data.) In the case of this thermocouple, it will "output" a signal in
mill volts.
2.2 MEASUREMENT IN PROCESS INDUSTRIES

2.2.1 PRESSURE MEASUREMENT
Pressure is an important variable in process industry which is measured monitored
& controlled like flow variable. The unit of pressure measured in industryare Pound per
square inch, Kg/cm2 , inches of water column /Inches of Hg etc. Mainly there are three scales
of pressure measurement i.e., gauge pressure, absopressure and vacuum pressure scale.
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 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 10-11 mbar.

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Primary pressure sensing elements are as follows:

 Manometers
 Bourdon tube
 Bellows and Capsule
 Strain gauge
Fig. 2.2.1: Bourdoun tube

ELECTRONIC TRANSDUCERS /TRANSMITER
Most electronic pressure sensors with one of the primary pressure detector used to
vary a measurable electrical quantity to produce a proportionately variable electronic signal.
Among the electronic device used to measure the pressure are strain gauges, load cell,
inductive , capacitve, piezoelectric transducer linear variable differential transformer. The
electronic detector are more accurate , much faster response time Though these are costing
high but reduced movement very nearly eliminates drift , frictions and hysterises as compared
to bellow, diaphagram and a bourdon instrument
Strain Gauge
Strain is define as a deformation or change in shape of a material as a consequence of
applied force . A strain gauge is a device which uses the change of electrical resistance of a
wire under strain to measure pressure i.e. mechanical motion into electrical signal. Generally
srain gauge instrument accuracy is +/-0.1% of full scale scan and range few inches water to
20000 psig accuracy +/-0.5% of full span transducer.

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Fig. : St rain
Fig. 2.2.2 : Strain Gauge

2.3 LEVEL AND FLOW MEASUREMENT
FLOW MEASUREMENT
In a continuous chemical process control of material flow is essential, the flow of
one variable may also control the other variable. Such as the temperature control of
the system can be achieved by controlling/ regulating the flow of heating or cooling media.
Many chemical process are sensitive to ratio of ingradient for proper reaction requires
correct, proportion of materials to achieve quality product. Product properties are affected by
varying the ratio of raw materials flow, the fluid may be liquid, gas or solid, the accurate flow
control is nearly essential. A knowledge of some basic characteristics of fluid and fluid flow
is necessary for choosing best method of flow measurement which need to be considered
includes Viscosity, density, specific gravity, compressibility, temperature, pressure and fluid
viscosity, laminar or turbulent.
Flow measuring elements are as follows:
 Orifice plates
 Venturi meters
 Flow nozzles
 Pitots tubes
 Annubars
 Dahl tube

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LEVEL MEASUREMENT
Still another important function in controlling continuous process is level control. To
obtain material balance, proper functioning of fractionating tower / reactor and also to
regulate the flow of intermediate and finished product, the level measurement and
controlling is closely associated.
Level measuring elements are as follows:
 Gauge glass
 Calibrated Tapes
 Dip Sticks
 Bob & Tap
 Sight Glass
Some of the most commonly used liquid-level measurement methods are:
 RF capacitance
 Conductance (conductivity)
 Hydrostatic head/tank gauging
 Radar
 Ultrasonic
1. RF Capacitance
RF (radio frequency) technology uses the electrical characteristics of a capacitor, in
several different configurations, for level measurement. Commonly referred to as RF
capacitance or simply RF, the method is suited for detecting the level of liquids, slurries,
granulars, or interfaces contained in a vessel. Designs are available for measuring process
level at a specific point, at multiple points, or continuously over the entire vessel height.
Radio frequencies for all types range from 30 kHz to 1 MHz.
The RF impedance method can be provided with specific circuitry capable of

measuring the resistance and capacitance components from the coating and the capacitive
component due to the actual process material level. The circuitry is designed to solve a
mathematical relationship electronically, thereby producing a 4–20 mA current output that is
proportional only to the actual level of the process material. It is virtually unaffected by any
buildup of coating on the sensing probe, enabling an RF system to continue functioning
reliably and accurately.

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Fig. 2.3.1 This view of a typical RF capacitance probe shows the electronic chassis
enlarged to twice the size of its housing.
2. Conductance
The conductance method of liquid level measurement is based on the electrical
conductance of the measured material, which is usually a liquid that can conduct a current
with a low-voltage source (normally <20 V). Hence the method is also referred to as a
conductivity system. Conductance is a relatively low-cost, simple method to detect and
control level in a vessel.
One common way to set up an electrical circuit is to use a dual-tip probe that
eliminates the need for grounding a metal tank. Such probes are generally used for point level
detection, and the detected point can be the interface between a conductive and
nonconductive liquid.
Fig. 2.3.2 : Conductance method of level measurement

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In the conductive type of level measurement, two dual-tip probes detect the maximum
and minimum levels in a tank.
Figure 2.3.2 shows an arrangement with two dual-tip probes that detect maximum and
minimum levels. When the level reaches the upper probe, a switch closes to start the
discharge pump; when the level reaches the lower probe, the switch opens to stop the pump.
3. Ultrasonic and sonic
Both ultrasonic and sonic level instruments operate on the basic principle of using sound
waves to determine fluid level. The frequency range for ultrasonic methods is ~20–200 kHz,
and sonic types use a frequency of 10 kHz. As shown in Figure 2.3.3 , a top-of-tank
mounted transducer directs waves downward in bursts onto the surface of the material whose
level is to be measured. Echoes of these waves return to the transducer, which performs
calculations to convert the distance of wave travel into a measure of level in the tank. A
piezoelectric crystal inside the transducer converts electrical pulses into sound energy that
travels in the form of a wave at the established frequency and at a constant speed in a given
medium. The medium is normally air over the material’s surface but it could be a blanket of
nitrogen or some other vapor. The sound waves are emitted in bursts and received back at the
transducer as echoes. The instrument measures the time for the bursts to travel down to the
reflecting surface and return. This time will be proportional to the distance from the
transducer to the surface and can be used to determine the level of fluid in the tank. For
practical applications of this method, you must consider a number of factors. A few key
points are:
• The speed of sound through the medium (usually air) varies with the medium’s
temperature. The transducer may contain a temperature sensor to compensate for changes in
operating temperature that would alter the speed of sound and hence the distance calculation
that determines an accurate level measurement.
• The presence of heavy foam on the surface of the material can act as a sound
absorbent. In some cases, the absorption may be sufficient to preclude use of the ultrasonic
technique.

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• Extreme turbulence of the liquid can cause fluctuating readings. Use of a damping
adjustment in the instrument or a response delay may help overcome this problem.
To enhance performance where foam or other factors affect the wave travel to and
from the liquid surface, some models can have a beam guide attached to the transducer.
Ultrasonic or sonic methods can also be used for point level measurement, although it
is a relatively expensive solution.. The signal from the receive crystal is analyzed for the
presence or absence of tank contents in the measurement gap. These noncontact devices are
available in models that can convert readings into 4–20 mA outputs to DCSs, PLCs, or other
remote controls.
Fig.2.3.3 : Ultrasonic Level Measurement
2.4 TEMPERATURE MEASUREMENT

The measurement of temperature is an important parameter in process industry. Most
common scales use to measure the temperature are Farhrenheit, Centigrade.
Temperature measuring elements are:
Bimetalic thermometer
 Thermocouple
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 Resistance Temperature Detectors (RTD)

 Radiation Pyrometer And Optical Pyrometer
1. 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 and can also be used to convert heat into electric power
Any circuit made of dissimilar metals will produce a temperature-related difference

of voltage. Themocouples for practical measurement of temperature are made of specific
alloys, which in combination have a predictable and repeatable relationship between
temperature and voltage. Particular alloys are used for different temperature ranges
Fig. 2.4.1: Thermocouple plugged to a multimeter displaying room temperature

in C
Metal B
junction 1 at junction 2 at
temperature temperature T2
metal A
Fig. 2.4.2 : Thermocouple Circuit
2. Resistance thermometer:
Resistance thermometers, also called resistance temperature detectors (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
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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.
Fig. 2.4.3 : Resistance Thermometer
3. Temperature Sensor
The temperature sensor work on the principal of temp. difference . The tip of the
temp. sensor is dip on where the temperature measured. The tip of the temperature sensor
contained Bimetalic Element strip as from the property of the bimetal when the temp.
increases the bimetal change it’s shape and then it has been pull out the wire which is join the
bimetal then it pull the pointer which is join to the wire and pointer be move as from as the
bimetal bend .
Fig. 2.4.4 : Bimetallic Thermostat
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CHAPTER 3
PROCESS CONTROL METHODOLOGIES
CONTROL
In instrumentation parlance control means regulating the process in respect of a
certain measured variable, so that this measured quantity stays at a fixed value or around it.
3.1 CONTROL ELEMENTS

Primary Elements
It is the name given in control study to the device that senses changes in the name of
measured variable. It may be a thermocouple or orifice plate, afloat or other element. It is the
device used to measure the value of the process variable and convert it into a usable form
which can further be converted into usable electrical or pneumatic signal. For example orifice
plates are used to develop the differential pressure DP which is the signal proportional to the
flow in the Process .
SN VARIABLES PRIMARY ELEMENTS USED TO MEASURE
1 Flow Venturi tubes,flow nozzles,orifice plates etc.
2 Level displacers, floats ,capacitors etc.
3 Temprature Thermocouple,resistance temperature

detectors(RTD),Infrared sensors etc.
Measuring Elements
It is the device (or apparatus) that receives the output of the primary element , it may
include indicating or recording devices when it does not it is termed “blind”. It is the
electrical or pneumatic signal coming out of the primary transducer in the form of volt,
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pressure of different range etc.. this is converted into 4 to 20 mA or 3 to 15 psig and fed
directly to the controller.
SN VARIABLE MEASURED PROCESS SIGNAL
1 Flow Differential pressure
2 Pressure Direct pressure
3 Level Pressure,differential pressure, back pressure
The Controlling Element (Controller)

Uses the changes in the value of the measured variables sensed by the primary
element and measured by the measuring element to regulate a source of power in accordance
with these changes. The power may be mechanical, pneumatic or electrical. The electrical or
pneumatic signal is fed directly to the controller as representative of measured signal.
Controller compares it with the Set point(required signal ) and the difference of the two is
called deviation or error signal this error /deviation goes to a final control element like
control valve so as to increase or decrease the measured signal to come very near to the set
point. Finally if set point is equal to measured signal the control loop becomes stable.
The Final Element

It is the device that actually varies the input to the process so that the value of the
measured variable remains within the desired range. It is the final element of control loop
which acts according to the error signal provided by controller output. In process industries it
a control valve. It throttles the process fluid for making necessary adjustments in the signal
required at the primary element.
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Fig. 3.2.1 Basic control loop
3.2 BASIC CONTROL LOOP

Terminologies used in a control loop are :
PV –Process Variable or Input.
SV –Set Variable/ Set Value.
MV –Manipulated Variable or Output.
I/P –Current to Pneumatic signal converter converts 4-20 mAcurrent signal to 0.2 to 1
Kg/cm2 or 3-15 psi pressure signal.
Fig. 3.2.2 :Example of basic control loop
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CHAPTER 4
PROCESS CONTROL SYSTEMS
A process control system comprises of multiple simple and complex control loops.
Process control systems are primarily classified into:
 Analog control system
 Digital control system
4.1 ANALOG CONTROL SYSTEM

Analog control system uses operational amplifier to do the control function.
Fig. 4.1.1: Analog control system

4.2 DIGITAL CONTROL SYSTEM
Digital control system uses microprocessors to do the control function.
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Fig. 4.1.2 : Digital control system

Digital control systems are preferred over analog control system because
it is easy to interface with computers for data analysis.
TYPES OF DIGITAL CONTROL SYSTEM
 Centralised control system(CCS)
 Distributed control system(DCS)
4.2.1 CENTRALISED CONTROL SYSTEM
In this system one component is designated as the controller and is responsible for
managing the execution of other components. The centralized control system is a simple
control system but has few disadvantages:
 If the CPU fails the entire plant gets affected.
 Redundancy concept was not available.
4.2.2 DISTRIBUTED CONTROL SYSTEM
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 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.
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Elements
A DCS typically uses custom designed processors as controllers and uses both
proprietary interconnections and Communications protocol for communication. Input &
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) or
control consoles.
DCS System consists minimum of the following components.
FIELD CONTROL STATION (FCS): It consists of input/output modules, CPU and
communication bus.
OPERATOR STATION: It is basically human interface machine with monitor, the
operator man can view the process in the plant and check if any alarm is presents and he can
change any setting, print reports..etc.
ENGINEERING STATION: It is used to configure all input & output and drawing
and any things required to be monitored on Operator station monitor.
Working:
Working of DCS as from privious fig. signal from transmitter(pressure, temp,level
transmitter) comes in JB(junction Box) and then from junction box it’s came in Marselling
Room which is exist in control room then it’s input in isolater(8 I/P) as from fig then in the
system
system cabinet which is based on PLC in which analog signal converted in

digital(A/D) as shown above fig. after that it comes in set point cabinet where where a PID
controller which is set the value as from requird after that it is gose in D/A converter then it is
in the isolater then positioner Then control valve as from fig. We have Yokogawa make
Centum –XL DCS in Aonla-II unit.
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DCS CLOSE LOOP DIAGRAM
pressure Input signal conditioner control Section

Set point
I/P 1-5V A/D
I/P 1-5V
PI
D/A D
Isolator 8 I/p 8 o/p
bus
I/P
Sequence Bus
Multipoint Analog cord for Digital Signals
Sequence Bus
Terminal Board
16 I/P
16 I/P
Relay Boared
I/P nest
Signal conditioner nest terminal Boared Station Control

nest
EFCD(Duplex field control Station)
Fig. 4.2.1: Digital Closed Loop Diagram
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Close Loop Diagram of Control System:

Orifice positioner
Control valve
flow inlet flow outlet
pneumatic line
transmitter I/P converter
Indicater I/P
I/C
Controller
Fig. 4.2.2 :Closed Loop Diagram Of Control System
Working of close loop control system is as from fig. when the flow coming in the
flow pipe then we have seen the orifice which is give the pressure difference . Pressure
difference is feedback in the transmitter and the transmitter give the response to indicater
which is show the reading how much pressure and the flow in the pipe. Transmitter give the
detailed to controller how much the flow pass. After that the controller the signal gose in the
current to pneumatic converter and it convert signal in the from of pneumatic then through
the pneumatic line it will go in the positioner and then it have shift the position of control
valve how much the output we have need.
Applications
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. Processes are not limited to
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fluidic flow through pipes, however, and can also include things like paper machines and
their associated variable speed drives and motor control centers, cement kilns, mining
operations, ore processing facilities, and many others.
A typical DCS consists of functionally and/or geographically distributed digital

controllers capable of executing from 1 to 256 or more regulatory control loops in one control
box. The input/output devices (I/O) can be integral with the controller or located remotely via
a field network. Today’s controllers have extensive computational capabilities and, in
addition to proportional, integral, and derivative (PID) control, can generally perform logic
and sequential control.
DCSs may employ one or several workstations and can be configured at the
workstation or by an off-line personal computer. Local communication is handled by a
control network with transmission over twisted pair, coaxial, or fiber optic cable. A server
and/or applications processor may be included in the system for extra computational, data
collection, and reporting capability.
ADVANTAGES OF DCS SYSTEM

Control function is distributed among multiple CPUs (Field Control Stations). Hence failure
of one FCS does not affect the entire plant.
 Redundancy is available at various levels.
 Instruments and interlocks are created by software.
 Generation and modifications of the interlocks are very flexible and simple.
 Information regarding the process is presented to the user in various formats.
 Field wiring is considerably less.
 Maintenance and trouble shooting becomes very easy.
 Cost effective in the long run.
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CHAPTER-5
PROGRAMMING CONTROL LOGIC
PLC is digitally operating electronic apparatus which uses a programming memory

for the internal storage of instructions for implementing specific functions such as logic,
sequencing, timing, counting and arithmetic to control through digital or analog modules,
various types of machines or process.
PLC Size
1. SMALL - it covers units with up to 128 I/O‟s and memories up to 2 Kbytes.
- these PLC‟s are capable of providing simple to advance levels or machine controls.
2. MEDIUM - have up to 2048 I/O‟s and memories up 32 Kbytes.
3. LARGE - the most sophisticated units of the PLC family . They have up to 8192
I/O‟s and memories up to 750 Kbytes - can control individual production processes or entire
plant.
5.1 Major Components of a Common PLC
POWER SUPPLY Provides the voltage needed to run the primary PLC components
I/O MODULES Provides signal conversion and isolation between the internal logic-
level signals inside the PLC and the fields high level signal.
PROCESSOR Provides intelligence to command and govern the activities of the
entire PLC systems.
Fig. 5.1.1 :Components Of PLC
SUPPLY
POWER
SUPPLY
I M OM
N O UO
P D TD
U U PROCESSOR PU
T L UL
From E TE
SENSORS To
OUTPUT
Pushbuttons,
Solenoids,
contacts,
contactors,
limit switches,
alarms
etc. etc.
PROGRAMMING
DEVICE
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PROGRAMMING DEVICE used to enter the desired program that will determine
the sequence of operation and control of process equipment or driven machine.
I/O Module
The I/O interface section of a PLC connects it to external field devices.
• The main purpose of the I/O interface is to condition the various signals received
from or sent to the external input and output devices.
• Input modules converts signals from discrete or analog input devices to logic levels
acceptable to PLC‟s processor.
• Output modules converts signal from the processor to levels capable of driving the
connected discrete or analog output devices.
DC INPUT MODULE
IS NEEDED TO:
USE TO  Prevent voltage
DROP THE transients from
VOLTAGE damaging the
TO LOGIC processor.
LEVEL Helps reduce the
effects of electrical
Noise
Current Buffer,
FROM Limiting Filter, TO
OPTO-
INPUT Resistor Hysteresis
ISOLATO PROCESSOR
DEVICE R Circuits
Fig. 5.1.2: DC Input Module
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DC / AC OUTPUT MODULE
IS NEEDED TO:
 Prevent voltage
transients from
damaging the
processor.
Helps reduce the
effects of electrical
noise
Amplifier
FROM TTL OPTO-
RELAY TO
TRIAC
PROCESSOR Circuits ISOLATO OUTPUT
R X’SISTOR
DEVICE
Fig. 5.1.3: DC Output Module
5.2 DIFFERENT TYPES OF I/O CIRCUITS

1. Pilot Duty Outputs : Outputs of this type typically are used to drive high-current
electromagnetic loads such as solenoids, relays, valves, and motor starters. These loads are
inductive and exhibit a large inrush current. Pilot duty outputs should be capable of
withstanding an inrush current of 10 times the rated load for a short period of time without
failure.
2. General - Purpose Outputs: These are usually low- voltage and low-current and
are used to drive indicating lights and other non-inductive loads. Noise suppression may or
may not be included on this types of modules.
3. Discrete Inputs Circuits of this type are used to sense the status of limit switches,
push buttons, and other discrete sensors. Noise suppression is of great importance in
preventing false indication of inputs turning on or off because of noise.
4. Analog I/O Circuits of this type sense or drive analog signals. Analog inputs
come from devices, such as thermocouples, strain gages, or pressure sensors, that provide a
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signal voltage or current that is derived from the process variable. Standard Analog Input
signals: 4-20mA; 0-10V
Analog outputs can be used to drive devices such as voltmeters, X-Y recorders,
servomotor drives, and valves through the use of transducers. Standard Analog Output
signals: 4-20mA; 0-5V; 0-10V
5. Special - Purpose I/O Circuits of this type are used to interface PLCs to very
specific types of circuits such as servomotors, stepping motors PID (proportional plus
integral plus derivative) loops, high-speed pulse counting, resolver and decoder inputs,
multiplexed displays, and keyboards.
OUTPUTS
INPUTS MOTOR
CONTACTOR
LAMP
PLC
5.3 Basic Function of a Typical PLC

Read all field input devices via the input interfaces, execute the user program stored
in application memory, then, based on whatever control scheme has been programmed by the
user, turn the field output devices on or off, or perform whatever control is necessary for the
process application.
This process of sequentially reading the inputs, executing the program in memory,
and updating the outputs is known as scanning.
While the PLC is running, the scanning process includes the following four phases,
which are repeated continuously as individual cycles of operation:
PHASE 1 – Input Status scan A PLC scan cycle begins with the CPU reading the
status of its inputs.
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PHASE 2– Logic Solve/Program Execution The application program is executed

using the status of the inputs PHASE 3– Logic Solve/Program Execution Once the program
is executed, the CPU performs diagnostics and communication tasks
PHASE 4 - Output Status Scan An output status scan is then performed, whereby
the stored output values are sent to actuators and other field output devices. The cycle ends
by updating the outputs.
ReadPhase
Inputs
1
Read Input Scan
Scan
PHASE 2
Phase 2
Program
Program Execution
Execution
PHASE 3
Diagnostics/
Phase 3
Diagonistic/
Comm
Communication
PHASE 4
Output
Phase 4
ScanScan
Output
Fig. 5.3.1 : Functions Of PLC
As soon as Phase 4 are completed, the entire cycle begins again with Phase 1 input
scan.
The time it takes to implement a scan cycle is called SCAN TIME. The scan time
composed of the program scan time, which is the time required for solving the control
program, and the I/O update time, or time required to read inputs and update outputs. The
program scan time generally depends on the amount of memory taken by the control program
ms to 100 ms. and type of instructions used in the program.
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RECRUITMENT PROCEDURE IN IFFCO
Till 2015 , IFFCO used to select engineers by 2 tier examination followed by an

interview then selected candidates would work GET(GRADUATE ENGINEERING
TRAINEE) for 1 year then followed confirmation and probation for 6 months.
From the last year (2016) ,IFFCO stopped requiting engineers as GET now they are
being recruited ad GEA (Graduate Engineer Apprentice).
For GEA candidate will be required to appear for preliminary Online test in free
environment i.e. they will use their own resources .Those who qualify in preliminary Online
test will be required to appear for final Online test. Only those candidates who qualify the
Final Online test will be called for interview.
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CONCLUSION
My four weeks industrial attachment with IFFCO , Aonla has been one of the most
interesting, productive and instructive experience of my life. Through this training, I have
gained new insight and comprehensive understanding about the real working conditions and
practise, it also improved my soft and functional skills. All thee valuable experience and
knowledge’s that I have gained were not only acquired through the direct involvement in the
task but also through other aspects of training such as : work observation, interaction with
collogues, supervisors and other people related to field. I am sure that industrial training has
achieved its primary objectives. As result of training we are more confident to build our
future carrier.
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BIBLIOGRAPHY
 Information are collected from IFFCO AONLA Unit

 Journals & Diary of IFFCO.
 Magazines of IFFCO
 Booklets & Pamphlets Issued at IFFCO Unit
 Website of IFFCO
 Trainer & Other Employees Of IFFCO.
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B tech (Galgotias University)

Studocu is not sponsored or endorsed by any college or university

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGG.

AJAY KUMAR GARG ENGINEERING COLLEGE

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I express my deepest sense of gratitude towards Mr.OP Mathur (Senior Manager

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Content Page No.

Chapter 3 Process Control Methodologies 13

Chapter 5 Programmable Control Logic 22

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5.2 Types Of Input Output Circuit 24

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1. IFFCO- Indian Farmers Fertilizers Cooperative Limited

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2. Basic Control Loop

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Indian Farmers Fertilizers Cooperative Limited was established on 3rd

1.1 AONLA UNIT

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1.2 HIGHLIGHTS OF AONLA UNIT

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2.1 What is INSTRUMENTATION ?

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2.2 MEASUREMENT IN PROCESS INDUSTRIES

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Primary pressure sensing elements are as follows:

Fig. 2.2.1: Bourdoun tube

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Fig. 2.2.2 : Strain Gauge

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Some of the most commonly used liquid-level measurement methods are:

The RF impedance method can be provided with specific circuitry capable of

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Fig. 2.3.2 : Conductance method of level measurement

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3. Ultrasonic and sonic

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Fig.2.3.3 : Ultrasonic Level Measurement

2.4 TEMPERATURE MEASUREMENT

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 Resistance Temperature Detectors (RTD)

A thermocouple is a junction between two different metals that produces a voltage

Any circuit made of dissimilar metals will produce a temperature-related difference

Fig. 2.4.1: Thermocouple plugged to a multimeter displaying room temperature

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Fig. 2.4.3 : Resistance Thermometer

Fig. 2.4.4 : Bimetallic Thermostat

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3.1 CONTROL ELEMENTS

SN VARIABLES PRIMARY ELEMENTS USED TO MEASURE

1 Flow Venturi tubes,flow nozzles,orifice plates etc.

2 Level displacers, floats ,capacitors etc.

3 Temprature Thermocouple,resistance temperature