PLC and SCADA Based Industrial Trainer with Web Page Enabled Process Monitoring & Control

Project Title

PLC and SCADA Based Industrial Trainer with Web Page Enabled Process Monitoring & Control

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

To develop a trainer that would assist students in learning about advanced industrial systems and simulating industry scenarios in institutes.The SCADA system is an important component of our project. The SCADA system will allow us to monitor process data, control processes, and quickly detect any process issues, reducing downtime. The SCADA's basic architecture starts with a Programmable Logic Controller (PLC). A PLC monitors the status of switches and sensors using input terminals and based on this status they will give the command to the output devices through the output terminals. PLC is a microprocessor that communicates with the field devices such as valves, pumps, sensors, HMIs, other end devices, etc. These devices route all this collected data from end devices to SCADA computers. Then SCADA software will implement our scenarios with PLC and display the data on the HMI to better understand the operator about the prevailing condition

Project Objectives

• The remote monitoring and automation  of industrial processes using Supervisory Control and Data Acquisition (SCADA) systems.
• The improvement in communication between the systems or processes.
• The utilization of SCADA and Web Page for monitoring of industrial process and data logging of different industrial events.
• To make a Trainer that will enable us to implement and control different industrial scenarios

Project Implementation Method

The first stage is to build the hardware structure of the trainer after which we'll install SCADA software on our main computer.The program will be written in main computer on SCADA/WINCC software.This program's ladder logic is subsequently passed to the Siemens PLC S7-1215C through communication cables, where it is implemented.The system will be interfaced with via a human-machine interface (HMI) We also have a Webpage option through which we can monitor and control our processes using SCADA and PLC.Then we have option of 14 digital inputs such as push- buttons, limit switches, relay contacts, proximity switches, photo sensors (On/Off), pressure switches and more.10 Digital Outputs for functions like motor on/off, Conveyor belt forward and reverse etc. We will also provide 2 inputs ports for analog inputs such as temperature sensor and pressure sensor and 2 analog outputs such as motor speed control and valve control etc.

Benefits of the Project

• The SCADA system will be used to monitor and manage industrial processes, reducing human effort in supervision and control while also increasing the efficiency of the operation.
• Web Page monitoring and data logging will also help in monitoring and analyzing the different industrial scenarios
• The remote monitoring and automation of industrial processes using Supervisory Control and Data Acquisition (SCADA) systems
• The improvement in communication between the systems or processes.

Technical Details of Final Deliverable

Our Trainer consists of these components:

• Supervisory Control and Data Acquisition (SCADA)
• Human Machine Interface (HMI)
• Programmable Logic Controller(PLCs)
• Web Page
• Digital Inputs and Outputs
• Analog Inputs and Outputs

Writing a program is the first stage. The application will be written in WINCC/SCADA software on the main machine. This program's ladder logic is subsequently passed to the Siemens PLC S7-1215C through communication cables, where it is implemented. The system will be interfaced with via a human-machine interface (HMI). We also have a Webpage option through which we can monitor and control our processes using SCADA and PLC. Then there are 14 digital inputs to choose from, including pushbuttons, limit switches, relay contacts, proximity switches, light sensors (On/Off), pressure switches, and others. 10 Digital Outputs for motor on/off, conveyor belt forward and reverse, and other tasks. In addition, we will provide two analogue input ports for temperature and pressure sensors.

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries IT Core Technology Internet of Things (IoT)Other Technologies OthersSustainable Development Goals Quality EducationRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	70000
Siemens PLC S7-1215C	Equipment	1	45000	45000
Siemens HMI	Equipment	1	10000	10000
Trainer Hardware	Equipment	1	10000	10000
Ethernet Cables	Equipment	1	5000	5000