SCADA and PLC-based Chemical Plant Process Control System
Keywords:
Analog scaling, Chemical automation, Delta PLC, Resilient control, SCADA network, State machine modelAbstract
The operations within industrial batch processing in small-scale chemical plants pose great difficulties such as lack of batch consistency, high error rates by human operators, hazards from toxic fluids, and lack of real-time process monitoring. Whereas the use of high-end distributed control systems (DCS) eliminates these problems, their costly nature makes it structurally and financially impossible to install them in small manufacturing facilities. In this study, an industrial automation scheme with a budget-conscious and fault-tolerant configuration is proposed using a Delta PLC controller in combination with SCADA networking, for the purpose of managing a sequential three-tank chemical blending system. This configuration features hybrid data streaming and processing whereby the system is able to concurrently handle discrete input signals and continuous 4–20 mA level transmitter readings. An intuitive high-resolution Human Machine Interface (HMI) display with 0.000 precision offers real-time graphical and trend data with automatic process compliance reporting. As part of enhancing hardware security, the system has built-in watchdog timers within ladder logic to implement fail-safe secondary protection mechanisms for any physical level switch contamination. A comprehensive MATLAB-based simulation experiment was carried out for modeling material balance. Simulation waveform results indicated perfect cyclic operation accuracy and no mass loss in the repeated cycle of the filling and draining process. Practical physical deployment and live experiment demonstrated that the automation control cycle framework is capable of eliminating the manual batching difference, controlling the induction spike through the isolation relay, and creating a sustainable, environmentally friendly operating system amid consistent climate conditions.
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