🚰 Project 2: Pump Control System with PID & Alarm Handling
This project simulates a real-world pump-tank automation system using Rockwell Studio 5000 and Logix Emulate. It supports both manual and PID-driven automatic modes, with analog signal scaling, alarm latching, and modular ladder logic.
🧠 System Overview
- Manual & Auto mode with operator selection
- PID-based flow regulation with live analog scaling (4–20 mA)
- High/Low tank level alarm system with one-shot + latch logic
- Resettable alarms and mode indicators for HMI readiness
- Modular routines:
IO,CTRL,MODE_SELECTION,ALARMS_NOTIFICATION - Developed and tested using emulator-compatible modules
📄 Project Reports
1. Summary Report
Detailed system design, PID logic behavior, alarm structure, hardware setup, and test procedures.
2. Ladder Logic Overview
Structured ladder code screenshots for all key routines (JSRs, IO mapping, PID, alarms).
🖼️ HMI Screens (FactoryTalk View)
Auto Mode Active with Normal Tank Level
High-Level Alarm Active
These screens visualize:
- Process variables (Tank Level %, Flow LPM, VFD Speed %)
- Real-time system state: Manual vs Auto
- Alarm activation and reset handling
- Mode and start/stop control logic