1. Automation System Design (SCADA & PLC/Relay)

Requirements Analysis

• Identification of processes to be automated: mixing systems, HVAC, water treatment, or utilities

• Definition of control parameters: temperature, pressure, flow, level, speed, and quality

• Determination of automation level: manual, semi-automatic, or full automation

System Architecture

1. PLC (Programmable Logic Controller)

   • Acts as the main controller for reading sensor signals, processing logic, and controlling actuators (pumps, valves, motors)

   • Programmable using ladder diagram, function block, or structured text

2. Relay Control System

   • Used for simple operations such as motor start/stop and alarm on/off

   • Typically applied in small-scale systems or as manual backup

3. SCADA (Supervisory Control and Data Acquisition)

   • Visual interface for real-time monitoring of all process parameters

   • Provides data logging, trending, and alarm functions for analysis

4. HMI (Human Machine Interface)

   • Touchscreen panel at field level for operator control

   • Connected to PLC and SCADA for two-way communication

5. Communication & Networking

   • Industrial protocols such as Modbus, Profibus, Ethernet/IP, and OPC are used to connect all devices

Control & Instrumentation Design

• P&ID (Piping and Instrumentation Diagram) : defines sensor, actuator, and control panel positions

• Control Philosophy : defines control logic, interlocks, alarms, and operating sequences

• Redundancy : ensures system reliability (e.g., dual PLC or redundant SCADA servers)

2. Automation System Installation

Mechanical & Instrumentation Installation

• Installation of sensors (temperature, pressure, flow) at process points

• Installation of actuators such as motorized valves, pumps, and blowers

Electrical & Control Panel Installation

• PLC, relay, and MCC (Motor Control Center) panels assembled in the workshop

• Installation of signal cables, power supply, and communication networks to all devices

SCADA & HMI Integration

• SCADA software installed on industrial servers or PCs

• Integration with PLC for real-time process monitoring and control

3. Testing & System Validation

• FAT (Factory Acceptance Test): testing control panels and logic before shipment

• SAT (Site Acceptance Test): testing system functionality after installation on site

• IQ/OQ/PQ:verification of installation, operation, and performance in compliance with CPOB/GMP standards

• Alarm & interlock simulation: ensure system safety and reliability

4. Standards & Regulations

• ISA-95 & ISA-88: industrial automation standards

• 21 CFR Part 11 (FDA): data integrity requirements for pharmaceutical systems

• GAMP 5: validation guideline for computerized systems in pharmaceutical industries

• IEC 61131-3: PLC programming standards