Centralized Monitoring and Control of Process Plants using PLC

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 07 | July 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 482
Centralized Monitoring and Control of Process Plants using PLC
Athappan V1, Ranganathan S2, Saravanabalaji M3, Sounder Raj S4, Balaji S B5, Siva Nikesh S R6,
Eniya K M7, Perinban P8
1,2,3Faculty 4,5,6,7,8Student, Department of Electronics and Instrumentation Engineering, Kumaraguru College of
Technology, Coimbatore, Tamil Nadu, India.
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Abstract - The main objective of this project is to monitor
and control all the available process plants in the
department laboratory. This project involves fetching the
real time process variable data from each process plant and
communicating the process data through a common
communication protocol via Ethernet medium that will run
through the entire field. These real time process plant data
will be monitored and controlled in the centralized facility
that is available in the remote location. The control decision
will be taken based upon the behavior of the process plant
and the decision will be communicated back to the
respective process plant via the communication protocol
available and the process plant considers this as input and
varies its behavior accordingly. The centralized and remote
monitoring and control facility will facilitate the entire
operation for implementing the required control
specifications for all the process plants available in the
department laboratory with the updated real time control
data.
Key Words: Process plants, PLC, DCS, IoT, Profinet,
Weintek
1. INTRODUCTION
The process plants available in the department are in need
for constant monitoring and control remotely, which will
also bring up an advantage of eliminating human errors
during physical analysis.
Identifying trends and fluctuations while constantly
reading data from the input sensors help us understand
their liability of the particular equipment over a specific
runtime helping in identifying faults and risks at an early
stage.
1.1 PROPOSED IDEA
These connected process stations with the Weintek IIOT
module from PLC have been established via Ethernet cable
and the module itself is being powered by a 12v battery.
The entire station is linked to the easy Access 2.0 app
which helps us monitor the remote HMI by providing
secure communication, which can be visualized via CMT
viewer
2. MATERIALS AND METHODS
The Siemens PLC (S7-1500) receives the sensor data from
the process plants. This data is converted to readable
format and is being stored in a cloud database provided by
EasyAccess2.0.
EasyAccess2.0 provides secure connection with remote
HMI and view screens configured for it. The real time data
that is being stored in the cloud can be visualized and
controlled by providing input to the process station
remotely using the same interface. The modified input is
instantaneously reflected on the process station and new
output is received. This allows for centralized remote
monitoring and control.
Table -1: Materials
Components Used
Product/ Materials Quantity
Siemens PLC - S71500 1
ALE111 module 1
Yokogawa DCS System
(Centum VP)
1
Process Stations 3
Ethernet Cables As required
3. DESIGN
The design aims in building a model that assist in
developing the centralized monitoring and control
application for the process plant that aims to achieve
control over different process variables such as level, flow,
temperature and pressure. The final control element is
majority of the process plant available in the department
laboratory is the control valve. Individual process plant or
station available is a single input single output system
(SISO). Thus, there exists one process variable and one
controlled variable from each process plant. The main
objective is to achieve individual control of the process
plant along with centralized monitoring and remote-
control facility.

Figure -1: Block Diagram
Pressure: The mainframe is made of a metal structure
which is placed in an open area. The bottom plate has a
reservoir tank, a pump and a plumbing fixture. The frame
consists of a plate, level transmitter, I / P converter,
control valve, process tank and cabinet. The cabinet picks
up DC power outages, an overhead wide acquisition
system and a disconnected system and an inlet connector
for large AC pipelines. The filter part filters the primary air
entering the entrance, leaving the debris in the bowl.
When the knob is correctly turned, the spring acts on the
diaphragm, causing the main valve to open and let a
second stream of fresh air with a specific pressure out.
Through the feedback hole, exit pressure is returned to the
diaphragm, lowering it to the desired pressure. A level
investigation and a conditional signal section make up the
typical transmitter. Two straight cylinders make up the
level probe. Water can enter the center cylinder at any
time and behave as a dielectric medium. The power probe
level rises as the water level does. The level changes in
direct proportion to the power shift. The bridge of the AC
power gauge is coupled to voltage variation. The AC
millivolt signal includes the bridge's output. A precise
adjustment converts the AC signal to DC. Unwanted high-
end signals are abundant in the redesign output. It is
amplified at (4–20) mA after being filtered with a low pass
filter as tank level is represented.
Level: The mainframe is a metal building that is situated
outside. It has a reservoir tank, a pump, and a plumbing
fixture on the bottom plate. A plate, level transmitter, I/P
converter, control valve, process tank, and cabinet make
up the frame. The cabinet detects disconnected systems,
huge AC pipeline inlet connectors, overhead broad
acquisition systems, and DC power failures. The filter part
filters the primary air entering the entrance, leaving the
debris in the bowl. When the knob is correctly turned, the
spring acts on the diaphragm, causing the main valve to
open and let a second stream of fresh air with a specific
pressure out. Through the feedback hole, exit pressure is
returned to the diaphragm, lowering it to the desired
pressure. A level investigation and a conditional signal
section make up the typical transmitter. Two straight
cylinders make up the level probe. Water can enter the
center cylinder at any time and behave as a dielectric
medium. The power probe level rises as the water level
does. The level changes in direct proportion to the power
shift. The bridge of the AC power gauge is coupled to
voltage variation. The AC millivolt signal includes the
bridge's output. A precise adjustment converts the AC
signal to DC. Unwanted high-end signals are abundant in
the redesign output. It is amplified at (4–20) mA after
being filtered with a low pass filter as tank level is
represented.
Temperature: Selective Catalytic Reduction has 3
terminals as in anode, cathode and gate. It is a four-layer
PNPN tool. In normal state, it will block the voltage
applied in any direction, but when the proper voltage or
pulse current is applied to the gate electrode, the current
will flow through the anode to the cathode thus opening
the power in the circuit. of load. The SCR will then act as a
semiconductor switch which has three operating circuits,
namely, reverse inhibition, forward blocking, and
operating conditions. If the anode has a negative relative
to the cathode, junctions J1 and J3 are reverse biased and a
small recurrent leak will flow to the SCR. This current has
two parts, in which one is saturation current which is
related to the type of material used, as it is much lower in
silicon. Another current "generation" is because of the
filming and release of the network company in the capture
centers within the reduction layer of the merger. In silicon
the current generation is more advanced compared to the
current leak. As the voltage across the device increases,
generational power also increases and eventually leads to
avalanche cracking. The voltage at which this avalanche
breakage occurs is determined by the geometry and
construction of the device and is a function of the
temperature of the device. Therefore, the SCR will need to
be operated under a specified high temperature and
deceleration voltage in order to operate effectively in its
blockchain retraction mode. In the case of a forward block
the anode is right relative to the cathode. Junctions J1 and
J3 are forward biased. Junction J2 blocks the full voltage
used. In this case too, the current device is made up of two
parts, the current leak and the current generation. As the
voltage across the device increases the current generation
increases to make the J2 as forward biased junction thus
assuming SCR to be fully functional. The maximum voltage
the device can block when moving forward is
approximately equal to the reverse voltage drop. The SCR
can be brought to the operating state, with all forward
links biased, by increasing the anode voltage across the
forward break above the voltage or through the current
gate. There are still other ways to take the device into
operating condition. In the case of running the current

through the device is limited mainly by the external
circuit.
4. WORKING
The available process stations are connected to a singular
PLC (Siemens S7-1500) and the program to control each
station is designed using TIA portal which also facilitates
the use of remote monitoring and control. To visualize the
entire process, we make use of easy Builder software by
which we create an interface that shows real time data and
accepts inputs from the user. The user Input is
instantaneously transmitted to the PLC with the help of
Weintek IIOT module.
These connected process stations with the Weintek IIOT
module from PLC have been established via Ethernet cable
and the module itself is being powered by a 12v battery.
The entire station is linked to the easyAccess2.0 app which
helps us monitor the remote HMI by providing secure
communication, which can be visualized via CMT viewer.
5. HARDWARE IMPLEMENTATION
Figure -2: Implementation
6. FLOW CHART
7. RESULT AND DISCUSSIONS
In our analysis, we reviewed and analyzed the above-
mentioned process stations and their work flow. The
sensors that are used in each process station were
examined and its working principles were read. With the
knowledge of sensors and its output in the process
stations, we got to know about the parameters that are to
be checked. Studied on the communication protocol
(PROFINET) and tried establishing the connections.
Each ProfiNet device is recognized based on the IP address
and device name which is configured using Siemens
Totally Integrated Automation (TIA) portal. The
communication occurs based on the IP address assigned to
the ProfiNet devices. In this way the ProfiNet devices and
the MODBUS were configured and used.
8. CONCLUSIONS
The real time monitoring of the process stations has been
implemented and the user Input at the app reflects on the
process station which was made possible by the IIOT
module which facilitates instantaneous transfer of real
time data.
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system based on real-time Ethernet and Windows NT", Int.
J.Adv. Manuf. Technol., vol. 65, pp. 1383-1395, 2013.
[3] P.A. Sherring da Rocha Jr., R.D.S. Souza, and M. Emilia
de Lima Tostes, "Prototype CNC machine design", J. of
Energy and Power Engineering, vol. 6, pp. 1884-1890,
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[4] X. Xu, Y. Li, J. Sun, and S. Wang, "Research and
development of open CNC system based on PC and motion
controller", Procedia Engineering, vol. 29, 1845-1850,
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