Project Synopsis

The Project
Process Automation through PLC Programming
with Supervisory Control And Data Acquisition
(SCADA)

Aim/Objective
The main Aim and Objective of this project is to
demonstrate Process Automation as in the real time
environment.

Introduction
In this cut throat market, minimizing cost and maximizing
profit is the key to survival with the increasing
competition and negligible room for errors. For the
achievement of such goals either it is to have the best of
skilled manpower available or a system which is flawless.
Here Process Automation steps in. In the literal sense it
is the process of Automating each and every bit of the
manufacturing process with the help of PLC’s and
supervising it with software’s like SCADA which can give
real-time analysis and projections of the Production
procedure and also effectively minimize manpower thus
reducing recurring costs to the company and thus these
systems prove to be a very good investment to the
Manufacturing Unit.

Conceptualization
As the name suggests, Process Automation is a concept
wherein all the processes are self controlled through a
Programmed Logic Controller Unit which is commonly
known to us as PLC.

In this project considering a process of a tank reactor

where a liquid is being filled in the tank. Then the liquid is
heated to a certain temperature say 50⁰C. After the liquid
is heated it needs to be emptied and a new batch of
process needs to be started. We require many different
conditions to be satisfied such as:
1. Maintaining of minimum and maximum LEVELS of
the container or tank where fluid such as water, oil is
put in.

2. Measuring of a TEMPERATURE and raising it to the

required level.

3. Control of the liquid inlet and outlet as per the

volume and the process of the tank.
 4. Setting the different levels for the tank to be filled
according to the density of the liquid. This is done as
there is a weight bearing capacity of the tank beyond
which tank is unable to bear.

Thus in short we are considering the following inputs &

outputs:
➢ ANALOG INPUTS
1. LEVEL- LEVEL PROBE CONDUCTIVE TYPE
2. TEMP. – USING RTD

➢ DIGITAL INPUTS
1. PUSH BUTTON
2. CONTACTOR FEEDBACK
3. SOLENOID VALVE FEEDBACK
4. DENSITY

➢ DIGITAL OUTPUTS
1. SOLENOID VALVE
 2. CONTACTOR
3. HOOTER
4. LED

Now all these parameters will be continuously monitored

as well as controlled and maintained to their preset
ranges with the help of PLC. Also the PLC will give a
particular output or a command to execute a process
when a certain permutation of the given parameters is
sensed.
Supervisory Control and Data Acquisition (SCADA), a
software that is used to supervise and keep a track of the
real time activities of the manufacturing unit is used to
keep a continuous check and the record of all the ongoing
processes in the plant.

Concluding, we have some parameters to be controlled

which is done with the help of PLC and simultaneously a
continuous observation of the process is monitored and
analyzed graphically using SCADA.

Hardware to be used
1. Level Probe
2. RTD
3. Solenoid Valve
 4. PLC
5. Output (Relay/bulbs)
6. Communication Cable (RS232)

Software to be used
1. PLC Programming
2. SCADA

OVERHEAD TANK