Industry: Manufacturing

Control System for Biodiesel Blending Skid

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Requirement

Automated Control System for Biodiesel Blending Skid at Indian Oil Corporation Ltd.

Challenges

Indian Oil Corporation Limited (IOCL) operates oil storage terminals at Asanur, Achutapuram, Motihari, and Manmad. These terminals facilitate the distribution of diesel and blended biodiesel to various remote locations across India.

At these terminals, biodiesel is blended with diesel at a ratio ranging between 5% and 7%. The primary challenge lies in ensuring precise adherence to the specified blending ratio. Maintaining accurate ratios is critical to ensure the density and purity of diesel remain within the prescribed range as per government regulations.

Maintaining detailed and accurate records of the blending percentages in the diesel.

Scope of Work

Detailed functional requirements analysis
Design and configuration of the PLC-based control system
SCADA development for real-time monitoring and control
Design and integration of Exd Enclosures, flameproof glands and flameproof work station for SCADA system
System testing, commissioning, and operator training

Solution

We successfully completed the Supply, Installation, Testing, and Commissioning (SITC) of an Emerson PLC control system housed in Exd (flameproof) enclosures with a pedestal mounting arrangement. This setup was designed to accommodate the hazardous area near the blending skid, enabling operators to monitor and achieve accurate blending ratios directly in the field.

Customer Benefit

The installation of the SCADA system in the hazardous area allowed operators to monitor the physical status of instruments and valves directly on-site.

Furthermore, the data from the SCADA system was seamlessly integrated with the client’s DCS, located in the safe area control room, ensuring centralized monitoring and control.

By maintaining the blending ratio within the prescribed range, complaints related to fuel impurity on government portals have significantly decreased, reflecting improved operational accuracy and compliance.