Development of an IOT Based SCADA System for a Chemical Manufacturing Plant

Liew, Chow Hoe (2022) Development of an IOT Based SCADA System for a Chemical Manufacturing Plant. Final Year Project (Bachelor), Tunku Abdul Rahman University College.

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Abstract

Chemical plant in operation currently may still requires human workers to manually switch the chemical hoses from different chemical tank to a mixer tank every work shift following the production schedule. Due to manual works, the production is exposed to human error where the workers sometimes connect wrong hoses to the mixer tank. Therefore, IoT based SCADA proposed, the remote monitoring and control can provide tracking on the process status without affecting the environment or putting workers in danger and reduce manual work to minimize human error.. This paper studies the structure of SCADA, IoT and OPC UA as well as how the combination of these technologies for Industry 4.0. The SCADA have the features of user level, data logging, scheduling and trending. The SCADA system also acts as OPC UA client that connect to the OPC UA server to obtain the RFID reader value. The SCADA system will have its local database and integrate with cloud and uploading the data to it. The objective of this paper is to develop a SCADA system and establish connection to OPC UA server, establish sensors network using IO-Link Master and connect to a cloud via OPCUA and integrate the SCADA system with the OPCUA and cloud for implementation in the Industrial 4.0 manufacturing environment. The scope of this project is to develop open-source IoT based SCADA using C# .NET in Visual Studio IDE, wireless communication between the sensory devices and database server and integrate the SCADA system with OPC UA and cloud. A SCADA system is successfully developed in this projec designed with the features such as graphic user interface (for process monitor and control), data logging, scheduling, recipe, trending and alarms. A sensor network is established using IO-Link Master. The RFID Read/Write station is connected to it to form a sensor network to read and write a RFID tag. The SCADA system also acts as a OPC UA client which connect to the OPC UA server to read the data from it. The RFID tag data from the RFID reader is obtained by the SCADA system via OPC UA server. The SCADA system is integrated with OPC UA and the cloud. It acts as OPC UA client and at the same time, the data in the SCADA system is uploaded to the Azure MySQL database server. Automation process in SCADA system with OPC UA and cloud is integrated for implementation in the Industrial 4.0 manufacturing environment.