Phase I: PLC & HMI Core Development

• Control System Architecture & Programming

  • Comprehensive review of PLC hardware, architecture, and the execution of Ladder Logic.

  • Focus on efficient, compliant programming using advanced instruction sets, including Timers, Counters, Math Operations, and Move instructions.

• Data Structure Management

  • In-depth instruction on complex Data Types (Integer, Real, Array) and memory addressing schemes.

  • Developing high-integrity control logic for critical process applications (level, flow, pressure).

• HMI Interface Design & Protocol Integration

  • Developing intuitive operator interfaces, alarms, and trending screens.

  • Implementing robust Recipe Management systems for reliable batch control.

  • Establishing seamless data communication using industrial protocols like Ethernet/IP and Modbus.

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Phase II: SCADA & Advanced Diagnostics

• SCADA System Deployment

  • Understanding the complete SCADA architecture, its role in enterprise monitoring (IIoT), and centralized control strategies.

  • Setting up reliable connections to multiple PLCs and devices across the network.

• Historical Data Integrity and Reporting

  • Implementing robust Historical Data Logging solutions necessary for compliance and process analysis.

  • Designing and deploying performance reports and advanced Trend Charts for operational analysis.

• System Troubleshooting and Fault Analysis

  • Mastering Alarm Management Philosophy (logging, classification, and acknowledgment) for system stability.

  • Utilizing diagnostic software and applying fault analysis techniques to significantly reduce mean time to repair (MTTR).