Description of Project:

The Reliance 132 TR Compressor Upgrade Project at Hazira Ethylene Production Unit
Within Reliance Industries Limited's critical ethylene production unit at Hazira, a
project was undertaken to modernize the control and monitoring system for the vital
RIL 132 TR Compressor. This upgrade aimed to replace an aging system with a modern
Rockwell Automation platform to enhance process visibility and improve operational
reliability. As a Control Systems Intern within the Rockwell India LCS team, my key
contributions were focused on the development of the operator interface and the
configuration of the control logic for this upgraded system.
My Contributions to the Modernization Project:
A significant aspect of my internship involved the development of the Human-
Machine Interface (HMI) using FactoryTalk View Site Edition (SE). I designed and
configured intuitive graphical screens that provide operators with a clear, real-time
overview of the RIL 132 TR Compressor's critical operating parameters, including
pressures, temperatures, and flow rates. This included integrating displays for key
performance indicators and implementing alarm and event management systems to
ensure timely operator awareness of any process deviations or equipment
malfunctions.
Furthermore, I actively participated in the configuration and programming of the
Allen-Bradley ControlLogix PLC logic using Studio 5000 Logix Designer. Under the
guidance of senior engineers, I learned and implemented control sequences necessary
for the automated operation of the RIL 132 TR Compressor, such as start-up and shut-
down procedures. I also assisted in the integration of safety interlocks within the PLC
program to ensure safe and reliable operation within the hazardous ethylene
production environment.
To gain a broader understanding of the complete control system, I also assisted in the
physical building and conducted inspections of the electrical control panels that house
the PLC, HMI terminals, and other essential control components for the RIL 132 TR
Compressor. This hands-on experience provided valuable insight into the physical
implementation and wiring standards of industrial control systems.
The primary Rockwell Automation tools I utilized during this project were FactoryTalk
View Site Edition (SE) for HMI development and Studio 5000 Logix Designer for PLC
configuration and programming. My contributions directly supported the overall goal
of providing a modern, user-friendly, and reliable control system for the RIL 132 TR
Compressor within the Hazira ethylene production unit.
 Fig 1. Input-Process-Output Flow in SCADA/PLC Engineering

Major Modules and their Description:

The Reliance 132tr Project was structured into several key modules to systematically address
the degradation of the existing compressor control system and implement the necessary
upgrades. These modules encompassed the core activities required for assessment, design,
implementation, and commissioning of the modernized system.
a. System Assessment and Planning Module: This initial module focused on a comprehensive
evaluation of the existing 132tr compressor control system. Key activities included:
• Detailed Site Survey: On-site inspection of the compressor panel, associated
instrumentation, and existing control hardware at the Hazira ethylene production
unit. This involved documenting the current system architecture, identifying existing
hardware and software versions, and assessing the physical condition of the
equipment.
• Performance Evaluation: Analyzing the historical performance data of the compressor
and its control system (if available) to quantify the extent of degradation, identify
recurring issues, and understand the limitations of the existing setup. This might have
involved reviewing maintenance logs, alarm history, and operational data trends.
• Functional Requirements Specification (FRS) Development: Collaborating with
operations, maintenance, and process engineering teams at the Hazira plant to define
 the specific requirements for the upgraded system. This included identifying critical
process parameters to be monitored, control functionalities needed, desired operator
interface features, data logging requirements, and safety system specifications.
• Technology Selection and Architecture Design: Based on the FRS and the assessment
of the existing system, this sub-module involved selecting the appropriate Rockwell
Automation hardware (PLC, HMI) and software (Studio 5000, FactoryTalk View SE,
FactoryTalk Historian). A detailed system architecture for the upgraded control system
was designed, outlining the communication pathways, network topology, and
integration with other plant systems.
• Migration Strategy Development: Planning the cutover strategy to the new system,
considering potential impacts on ethylene production and defining procedures to
minimize downtime during the upgrade process. This included risk assessment and
contingency planning.
b. Rockwell Automation Platform Configuration and Programming Module: This core
module involved the configuration and programming of the new Rockwell Automation
platform:
• PLC Programming (Studio 5000): Developing the control logic for the 132tr
compressor using Studio 5000. This included implementing control algorithms for
compressor operation (start/stop, load/unload, capacity control), integrating safety
interlocks specific to ethylene compression (e.g., high pressure shutdown, low suction
pressure trips), and configuring communication interfaces with field instrumentation
and the HMI.
• HMI Application Development (FactoryTalk View SE): Designing and developing the
operator interface using FactoryTalk View SE. This involved creating process graphic
displays that provided a clear visualization of the compressor's operation within the
ethylene production context, configuring real-time data displays, implementing alarm
and event management systems with clear and actionable messages, and developing
navigation structures for efficient operator interaction.
• Data Historian Configuration (FactoryTalk Historian): Configuring FactoryTalk
Historian to collect and archive relevant process data from the 132tr compressor,
including pressure, temperature, flow, motor current, vibration, and equipment
status. This involved defining data tags, configuring data storage parameters, and
setting up data retrieval mechanisms for analysis and reporting.
• Communication Network Configuration: Setting up the communication network
infrastructure using Ethernet/IP to ensure seamless data exchange between the PLC,
HMI, Historian server, and potentially other plant information systems. This involved
configuring IP addresses, network devices, and communication drivers.
• Security Configuration: Implementing security measures within the Rockwell
Automation platform to protect the control system from unauthorized access and
 cyber threats, adhering to Reliance's security policies and best practices for industrial
control systems.
c. Instrumentation Integration and Calibration Module: This module focused on the physical
integration of the new control system with the existing and potentially new instrumentation
associated with the 132tr compressor:
• Wiring and Termination: Connecting field instruments (pressure transmitters,
temperature sensors, flow meters, vibration sensors, etc.) to the new PLC
input/output (I/O) modules within the upgraded compressor panel. Ensuring proper
wiring, shielding, and termination according to relevant standards and best practices.
• Signal Conditioning and Scaling: Configuring the PLC I/O modules to correctly
interpret the signals from the field instruments, including signal conditioning (e.g.,
converting analog signals) and scaling the raw data into engineering units.
• Instrument Calibration and Verification: Verifying the calibration of critical
instruments to ensure accurate data acquisition by the new control system. This might
have involved working with instrument technicians to perform calibration checks and
adjustments as needed.
• Loop Checking: Performing loop checks to verify the complete signal path from the
field instrument to the PLC and back to any control elements (e.g., control valves),
ensuring proper operation of the entire control loop.
d. Testing and Commissioning Module: This critical module involved rigorous testing and
commissioning of the upgraded 132tr compressor control system:
• Factory Acceptance Testing (FAT): Conducting tests in a simulated environment (if
feasible) to verify the functionality of the programmed PLC logic, HMI application, and
data historian configuration against the FRS. This involved simulating various process
conditions and verifying the system's response.
• Site Acceptance Testing (SAT): Performing on-site testing with the actual 132tr
compressor and associated equipment at the Hazira plant. This involved verifying the
integration with field instrumentation, testing control functionalities under real
operating conditions, validating alarm and safety interlock operation, and ensuring
data accuracy in the HMI and historian.
• Cutover and Startup: Implementing the planned migration strategy to switch over
from the old control system to the new one. This involved careful coordination with
operations and maintenance teams and close monitoring of the ethylene production
process during the startup phase.
• Performance Monitoring and Tuning: After the system was live, continuous
monitoring of the compressor's performance and the control system's operation to
identify any issues and fine-tune control parameters for optimal efficiency and
stability.
e. Documentation: This module ensured that comprehensive documentation was created
and that plant personnel were adequately trained on the new system:
• System Documentation: Developing detailed documentation of the upgraded control
system, including system architecture diagrams, hardware and software
specifications, PLC logic descriptions, HMI screen layouts, data historian configuration
details, communication network diagrams, and troubleshooting guides.
• Standard Operating Procedures (SOPs): Updating or creating new SOPs for operating
and maintaining the 132tr compressor with the upgraded control system.
• Training for Operations and Maintenance Personnel: Conducting training sessions for
operators and maintenance technicians at the Hazira plant on the functionality,
operation, and basic troubleshooting of the new Rockwell Automation platform and
the specific application for the 132tr compressor.

Work Environment:
I. Software Tools:
• Rockwell Automation Software Suite:
o Studio 5000 Logix Designer: For programming and configuring the Allen-
Bradley ControlLogix PLC. This includes creating and editing ladder logic,
function block diagrams, or structured text code for the compressor control
algorithms and safety interlocks. Specific license levels would be required
based on the PLC hardware.
o FactoryTalk View Site Edition (SE) Studio: For developing and configuring the
HMI application. This involves designing graphical screens, linking graphics to
real-time data tags from the PLC, configuring alarms and events, and setting
up navigation and security features. A developer license is essential.
o FactoryTalk Historian SE Server and Client: For configuring the data historian
to collect, store, and retrieve process data from the PLC. This includes defining
data tags for archiving, setting storage parameters, and configuring client tools
for data analysis and trending. Appropriate server and client licenses would be
necessary.
o RSLinx Classic/Gateway: For establishing and managing communication
pathways between the Rockwell software on engineering workstations and
the target hardware (PLC, HMI). This acts as the OPC server for data exchange.
o FactoryTalk AssetCentre: For managing the project files, configurations, and
versions of the PLC and HMI applications. This aids in change management,
backup, and disaster recovery.
 o Rockwell Automation Integrated Architecture Builder (IAB): Potentially used
during the initial design phase to select and configure the Rockwell hardware
components (PLC, I/O modules, network devices).
• Operating System Software:
o Appropriate versions of Microsoft Windows Server for the FactoryTalk
Historian server and potentially for the FactoryTalk View SE server.
o Appropriate versions of Microsoft Windows for the engineering workstations
running the Rockwell software.
• Networking Tools:
o Network Configuration Utilities: For configuring IP addresses, subnet masks,
and other network settings on the engineering workstations, servers, and
Rockwell hardware.
o Network Monitoring Tools (e.g., Wireshark): May be needed for
troubleshooting network communication issues between different
components of the control system.
• Documentation and Collaboration Tools:
o Microsoft Office Suite (Word, Excel, PowerPoint, Visio): For creating project
documentation (FRS, design specifications, test plans, reports, training
materials), spreadsheets for data analysis, and presentations for stakeholders.
Visio would be useful for creating system architecture diagrams and network
topologies.
o Project Management Software (e.g., Microsoft Project, Jira): For planning
tasks, tracking progress, managing resources, and facilitating communication
within the project team.
o Version Control System (e.g., Git): For managing and tracking changes to
project documentation and potentially configuration files (if not solely relying
on FactoryTalk AssetCentre).
o Collaboration Platforms (e.g., Microsoft Teams, SharePoint): For team
communication, file sharing, and document management.
II. Hardware and Equipment:
• Engineering Workstations: High-performance computers with sufficient processing
power, memory, and storage to run the Rockwell Automation software suite and other
engineering tools.
• Servers: Dedicated servers for hosting FactoryTalk Historian SE and potentially
FactoryTalk View SE (depending on the system architecture). These servers would
need appropriate hardware specifications (CPU, RAM, disk space) based on the
expected data volume and user load.
 • Rockwell Automation Hardware:
o Allen-Bradley ControlLogix PLC: The new PLC hardware intended to replace
the legacy system. This includes the CPU module, power supply, and the
necessary input/output (I/O) modules for interfacing with field
instrumentation.
o PanelView Plus HMI Terminals: The new operator interface panels to be
installed in the control room or at local operator stations.
o Network Switches and Routers: Industrial-grade Ethernet switches and
routers to establish the communication network between the PLC, HMI,
servers, and other network devices.
o Cables and Connectors: Appropriate Ethernet cables (Cat 5e or higher), power
cables, and connectors for wiring the new hardware components.
• Instrumentation and Calibration Equipment:
o Multimeters: For electrical troubleshooting and verification.
o Calibration Tools: Specific calibration equipment for verifying and calibrating
pressure transmitters, temperature sensors, flow meters, and other field
instruments connected to the compressor. This would likely involve specialized
calibrators for different types of instruments.
o Loop Calibrators: For testing and verifying the integrity of control loops from
the field instrument to the PLC and back to the final control element.
• Wiring and Termination Tools:
o Wire strippers, crimping tools, screwdrivers, and other hand tools necessary
for wiring and terminating electrical connections within the compressor panel
and to field devices.
o Cable labeling tools for clear identification of wires and cables.
• Safety Equipment:
o Personal Protective Equipment (PPE) such as safety glasses, gloves, hard hats,
and safety shoes, as required by Reliance's safety regulations for working in
the Hazira plant environment.
o Lockout/Tagout (LOTO) equipment to ensure the safety of personnel during
installation and maintenance activities.
III. Other Essential Things:
• Project Team: A multidisciplinary team comprising:
o Rockwell Automation Engineers with expertise in PLC programming, HMI
development, and data historian configuration.
 o Instrumentation and Control Engineers with knowledge of process
instrumentation and control loops.
o Electrical Engineers for power distribution and wiring aspects.
o Process Engineers from the Hazira ethylene production unit with a deep
understanding of the compressor's role in the process.
o Operations and Maintenance Personnel from the Hazira plant to provide input
on operational requirements and participate in testing and training.
o Project Manager to oversee the project execution, budget, and timeline.
• Detailed Engineering Drawings and Documentation of the Existing System:
Schematics, wiring diagrams, loop diagrams, and control narratives of the legacy
system were crucial for understanding the existing configuration and planning the
upgrade.
• Reliance Industries' Standards and Specifications: Adherence to Reliance's internal
engineering standards, safety regulations, and IT policies was essential throughout the
project.
• Communication and Collaboration: Effective communication channels and regular
meetings between the project team members and stakeholders at the Hazira plant
were vital for ensuring alignment and addressing any issues promptly.
• Access and Permissions: Necessary access to the Hazira plant site, control rooms, and
equipment areas, along with the required system access permissions for configuring
and testing the control system.
• Testing and Commissioning Procedures: Well-defined test plans and commissioning
procedures were essential for ensuring the quality and reliability of the upgraded
system.
• Training Materials and Plan: Comprehensive training materials and a well-structured
training plan were needed to effectively train the Hazira plant personnel on the new
system.
Results and Outcomes:
The successful modernization of the RIL 132 TR Compressor panel's monitoring and control
system within the Hazira ethylene production unit, utilizing the upgraded Rockwell
Automation platform, was anticipated to yield tangible improvements across key operational
metrics. While specific quantifiable outcomes necessitate a comparative analysis against the
pre-upgrade baseline and established project targets, potential measurable enhancements
include a significant reduction in unplanned compressor downtime (expressed as a
percentage decrease annually), a notable decrease in the Mean Time To Repair (MTTR) for
compressor-related malfunctions, and an improved energy efficiency profile for the
compressor (potentially measured as a percentage reduction in power consumption per unit
of ethylene produced). Furthermore, the enhanced control system was expected to
contribute to fewer process upsets or deviations directly attributable to compressor
instability, alongside facilitating faster operator response times to critical alarms and events
due to the improved Human-Machine Interface (HMI). Finally, the implementation of
FactoryTalk Historian was set to deliver a marked increase in the availability and granularity
of historical process data, enabling more comprehensive analysis and informed decision-
making for operational optimization and predictive maintenance strategies.
References
1. Studio 5000 Logix Designer Programming Manual: (Specific version number relevant
to your project). This manual provides detailed information on programming the
ControlLogix PLC.
2. FactoryTalk View Site Edition (SE) User's Guide: (Specific version number). This guide
covers the development, configuration, and deployment of HMI applications.
3. FactoryTalk Historian Site Edition User Manual: (Specific version number). These
manual details the configuration, data collection, and analysis features of the historian
software.
4. Allen-Bradley ControlLogix System Documentation: (Specific module numbers and
versions). Manuals and guides related to the specific PLC hardware used in the
upgrade.
5. Ethernet/IP Specification and Application Notes: Documentation on the industrial
Ethernet protocol used for communication within the system.
6. Rockwell Automation Best Practices for Industrial Control System Design: White
papers or application notes from Rockwell Automation on designing robust and
reliable control systems.
7. Rockwell Automation Security Guidelines for Industrial Automation and Control
Systems: Documentation on implementing security measures within Rockwell
platforms.
8. Relevant Rockwell Automation Knowledgebase Articles: Specific articles or technical
notes found on the Rockwell Automation support website related to the hardware
and software used in your project or specific challenges you encountered.