PLC Programming
Project Portfolio
Real projects across water treatment, food packaging, automotive, and general manufacturing. Each case includes the application context, technology stack, and delivered outcomes.
Water Treatment
Chemical Dosing Automation System
Siemens S7-1200 + WinCC Comfort
Replaced manual chemical dosing with a fully automated PLC-controlled process. The system manages multiple dosing points based on real-time pH, ORP, and turbidity sensor feedback.
- PID-based closed-loop chemical injection
- Multi-tank level monitoring & auto-switching
- Real-time trending on HMI
- Email alarm notifications for abnormal readings
RO Membrane SCADA System
Omron NJ501 + CX-Supervisor
Built a complete SCADA system for a reverse osmosis water treatment plant. Monitored and controlled 3 RO trains with automated CIP (Clean-In-Place) sequencing.
- Multi-train RO control with auto sequencing
- CIP automation with recipe-based steps
- SCADA with 30-day trending & report generation
- Remote VPN access for off-site monitoring
Municipal Pump Station Controller
Mitsubishi iQ-R + GOT2000 HMI
Developed the control system for a municipal wastewater pump station. Managed 6 variable-speed pumps with level-based sequencing and flow optimization.
- VFD-based pump speed control with energy optimization
- Alternating pump duty cycle for even wear
- Remote telemetry via 4G modem (Modbus TCP)
- 24/7 alarm monitoring & SMS alerts
Food Packaging
Multi-Station Weighing & Sorting Line
Allen‑Bradley CompactLogix 5380 + PanelView 7
Programmed a complete packaging line with dynamic weighing, reject sorting, and production reporting. The line handles 60 packs/min with ±1g accuracy.
- Dynamic weighing with auto-tare
- Three-way sorting (OK / underweight / overweight)
- Production count & OEE dashboard
- Recipe management for 20+ product SKUs
Automotive Parts
Assembly Station PLC Retrofit
Mitsubishi iQ-F FX5U + GT27 HMI
Modernized an obsolete PLC-based assembly station. Migrated legacy relay-ladder logic to structured ST code, added Ethernet/IP networking, and redesigned the operator interface.
- Relay logic → structured ST (structured text)
- Ethernet/IP to vision system & torque tools
- Operator guidance with barcode verification
- Data logging to SQL database via Ethernet
General Manufacturing
S7-300 to S7-1200 Migration
Siemens TIA Portal — S7-1200 1215C
Migrated a legacy S7-300 based material handling system to S7-1200. Rewrote the logic in TIA Portal, replaced Profibus with Profinet, and added a new KTP700 HMI.
- Full logic migration from Step 7 V5.x to TIA Portal
- Profibus → Profinet with zero downtime transition
- Added remote diagnostics via Siemens IoT2000
- Complete documentation package delivered
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