A Mini Project-2 Report on

AUTOMATED BATCH PROCESS SYSTEM USING

TIA OPENNESS SOFTWARE

Submitted in partial fulfilment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY IN

ELECTRONICS AND INSTRUMENTATION ENGINEERING

by

MUNGI VENKATA SUBRAHMANYA SAI 218W1A1079

URRINKALA NAGA SANKARA VARA PRASAD 228W5A1017

KATRAGADDA SATYA SAI 228W5A1011

BATTULA VEERA KUMARI 218W1A1056

Under the guidance of

Dr.P.SRINIVAS, M.Tech., Ph.D.

DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION ENGINEERING

V.R. SIDDHARTHA ENGINEERING COLLEGE (AUTONOMOUS)

(Affiliated to JNTUK, Kakinada)

Sponsored by SAGTE, Kanuru, Viijayawada – 520 007

(Approved by AICTE, Accredited by NBA and NAAC A+ GRADE)

2024-2025
 DEPARTMENT OF ELECTRONICS AND INSTRUMENTATION ENGINEERING

V.R. SIDDHARTHA ENGINEERING COLLEGE (Autonomous): Vijayawada-7

CERTIFICATE

This is to certify that the Mini Project-2 report titled “AUTOMATED BATCH PROCESS SYSTEM
USING TIA OPENNESS SOFTWARE” is a bonafide record of work done by MUNGI VENKATA
SUBRAHMANYA SAI (218W1A1079), URRINKALA NAGA SANKARA VARA PRASAD
(228W5A1017), KATRAGADDA SATYASAI (228W5A1011), BATTULA VEERA KUMARI
(218W1A1056) under my guidance and supervision and is submitted in partial fulfilment of the
requirements for the award of the degree of Bachelor of Technology in Electronics & Instrumentation
Engineering, V.R. Siddhartha Engineering College, (Autonomous Affiliated to JNTUK, Kakinada) during
the academic year 2024-2025.

Guide: Dr.P.SRINIVAS Dr.G.N.SWAMY

M.Tech., Ph.D. M.Tech., Ph.D.

Associate Professor Professor & Head

Dept. of EIE Dept. of EIE

 ACKNOWLEDGEMENT

The satisfaction that accompanies that the successful completion of any task would be incomplete without
the mention of the people whose ceaseless cooperation made it possible, whose constant guidance and
encouragement crown all efforts with success. We are grateful to our mentor Dr.P.SRINIVAS, for his
guidance, inspiration throughout the course which was very helpful for us in the preparation of this report.

We are profoundly grateful to Dr.G.N.Swamy, Professor, Head of the department, Electronics and
Instrumentation Engineering, V.R.Siddhartha Engineering College, Kanuru, Vijayawada, for his kind and
whole hearted support and valuable guidance throughout the Mini Project-2 Report.

We are also grateful to Project Review Committee members for their supervision and valuable
suggestions and other teaching and non-teaching staff for their kind cooperation.

We are thankful to Dr.A.V.Ratna Prasad, Principal, V.R.Siddhartha Engineering College Kanuru,

Vijayawada, for his support during the completion of the Mini Project-2 Project.

We would like to express our gratitude to our Mini Project-2 coordinator, Dr.N.SWATHI, M.E., Ph.D.,
Assistant Professor, for her utmost support and encouragement and regular monitoring of our work
throughout the Mini Project-2 Report.

We would also like to express our special gratitude and thanks to family and friends for their continuous
support.

M.V.SUBRAHMANYA SAI

U.N.S.V.PRASAD

K.SATYA SAI

B.VEERA KUMARI
 Automated Batch Process System Using TIA
Openness Software
Venkata Subrahmanya Sai Mungi Srinivas Paruchuri Naga Sankara Vara Prasad Urrinkala
Student, Dept. of EIE Assoc. Prof., Dept. of EIE Student, Dept. of EIE
V. R. Siddhartha Engg. College V. R. Siddhartha Engg. College V. R. Siddhartha Engg. College
Vijayawada, India Vijayawada, India Vijayawada, India
[email protected] [email protected] [email protected]

Satya Sai Katragadda Veera Kumari Battula

Student, Dept. of EIE Student, Dept. of EIE
V. R. Siddhartha Engg. College V. R. Siddhartha Engg. College
Vijayawada, India Vijayawada, India
[email protected] [email protected]

Abstract—Batch process systems are essential in industries like II. L ITERATURE SURVEY
pharmaceuticals, chemicals, and food processing. These systems
involve discrete manufacturing steps to process specific mate- • A comprehensive review by Qin and Badgwell (2003)
rial quantities. This paper explores the fundamental principles,
operations, control strategies, and challenges associated with delves into the challenges and opportunities in batch
batch processes. It also investigates the potential of advanced process control and optimization. They discuss the im-
technologies, including automation and AI, to optimize these portance of effective control strategies, such as model-
systems. By leveraging TIA Openness and C# code conversion, predictive control and real-time optimization, to improve
industries can enhance efficiency, product quality, and cost- product quality and reduce cycle times [12].
effectiveness in batch processes.
Index Terms—TIA openness, TIA portal, PLC, Batch process
• Li et al. (2009) present a survey on fault detection and
system, Notepad++, Ladder logic, Rung, Power rail. diagnosis techniques for batch processes. They explore
various methods, including statistical process control,
I. I NTRODUCTION neural networks, and fuzzy logic, to identify and diagnose
deviations from normal operating conditions [13].
Batch process systems are prevalent in industries such as • Srinivasan and Bonvin (2008) provide a detailed review
pharmaceuticals, chemicals, and food processing. These sys- of real-time optimization techniques for batch processes.
tems involve discrete manufacturing processes where specific They discuss the challenges of uncertainty and variability
quantities of material are processed through a series of oper- in batch processes and how advanced optimization algo-
ations [1] [2]. Historically, Programmable Logic Controllers rithms can be used to improve economic performance
(PLCs) with ladder logic programming have been the primary [14].
method for controlling these systems [3]. • Floudas and Lin (2004) offer a comprehensive review of
This paper delves into a comparative analysis of ladder logic batch process scheduling, focusing on the complexity and
and C# programming in the context of batch process systems challenges associated with optimizing production sched-
[4]. It scrutinizes the inherent limitations of ladder logic, ules. They discuss various mathematical programming
including its restricted flexibility, challenges in debugging, techniques, including mixed-integer linear programming
and susceptibility to errors [5] [6]. Conversely, C# offers a and nonlinear programming, to address these challenges
more potent and adaptable programming paradigm, enabling [15].
the implementation of intricate algorithms, modular design, • Barton (1995) presents a review of modeling and simula-
and enhanced code readability [7] [8]. tion techniques for batch processes. He discusses the im-
By examining the specific strengths and weaknesses of portance of accurate models for design, optimization, and
each approach, this paper aims to provide a comprehen- control. The paper covers various modeling approaches,
sive understanding of the factors influencing the selection including first-principles models, empirical models, and
of programming languages for batch process systems [9] hybrid models [16].
[10]. Ultimately, the objective is to underscore the potential • Lee and Lee (2010) explore the application of data-driven
advantages of transitioning from ladder logic to more advanced techniques, such as machine learning and data mining,
programming paradigms to augment the efficiency, reliability, to improve batch process performance. They discuss the
and adaptability of batch processes [11]. potential of these techniques to extract valuable insights
 from historical process data and to develop predictive B. Resistance Temperature Detector (RTD)
models for process optimization [17]. RTDs are temperature sensors that exhibit a change in
• Wang et al. (2017) discuss the emerging field of cyber- electrical resistance with temperature variations. In batch
physical systems (CPS) and their application to batch processes, RTDs are used to monitor and control temperature
process control. They highlight the potential of CPS to profiles within reactors, tanks, and other process equipment.
enable real-time monitoring, control, and optimization Accurate temperature control is crucial for maintaining prod-
of batch processes, leading to improved efficiency and uct quality and preventing thermal runaway reactions.
flexibility [18].
C. Heater
III. P ROPOSED M ETHOD
Heaters are devices that supply thermal energy to the
This Paper discloses the problem of increasing complexity
process. They are used to heat reaction mixtures, maintain
and stringent quality requirements of modern batch processes
temperature setpoints, and control the rate of chemical reac-
demand advanced control and automation strategies. Siemens
tions. Heaters can be electric or steam-based, and their output
TIA Portal, with its open architecture, provides a powerful
is often regulated by controllers to ensure precise temperature
platform to customize and extend its capabilities. By leverag-
control.
ing TIA Openness, engineers can develop tailored solutions
to address specific process needs and enhance overall system D. Stirrer
performance.
Stirrers are mechanical devices used to agitate and mix
IV. BLOCK DIAGRAM OF BATCH P ROCESS S YSTEM substances. In batch processes, they are employed to ensure
uniform mixing, enhance mass transfer, and promote heat
transfer. Different types of stirrers, such as impeller, turbine,
and anchor stirrers, are selected based on the specific process
requirements.

E. Pump Motor
Pump Motors are used to transport fluids from one location
to another within a batch process system. They are essential
for transferring raw materials, intermediates, and final products
between various process vessels. Centrifugal pumps, positive
displacement pumps, and diaphragm pumps are commonly
used in batch processes, depending on the fluid properties and
flow requirements.

F. Programmable Logic Controller (PLC)

PLCs are digital computers used to automate control sys-
tems. In batch process systems, PLCs are employed to coor-
dinate the operation of various components, including valves,
Fig. 1. Block diagram of Batch Process System. pumps, heaters, and stirrers. They execute control algorithms,
monitor process variables, and respond to alarms and distur-
Fig. 1 presents a functional block diagram of a Batch bances. PLCs play a crucial role in ensuring the safe, efficient,
Process System. Each element is explained in below: and reliable operation of batch processes.
• Solenoid Valve
V. TIA O PENNESS M ODEL
• Resistance Temperature Detector (RTD)
• Heater TIA Openness is a powerful framework provided by
• Stirrer Siemens that empowers users to extend and customize the
• Pump Motor capabilities of the TIA Portal. By leveraging the .NET
• Programmable Logic Controller (PLC) Framework, SIMATIC ML, and AML, engineers can develop
tailored automation solutions that address specific industry
A. Solenoid Valve challenges and enhance operational efficiency. TIA Openness
Solenoid valves are electromechanical devices that control software boasts several advantages that make it ideal for Batch
the flow of fluids. In batch processing, they are used to process system design simulations:
precisely regulate the flow of raw materials, intermediates, and • Automation: Automate repetitive tasks and streamline
final products into and out of various vessels. They are often engineering processes.
employed in tasks such as feeding, draining, and transferring • Customization: Create custom user interfaces and tailor
materials between process stages. the system to specific workflows.
 Fig. 2. Empty Ladder logic. Fig. 3. TIA openness Software project tree page.

Fig. 4. Exported code of Empty ladder logic. Fig. 5. Batch process C# code (a).

Fig. 6. Batch process C# code (b).

• .NET Framework: A robust programming framework for

building a wide range of applications, including custom
HMI screens, data analysis tools, and advanced control
algorithms.
By harnessing the power of TIA Openness, engineers
can significantly enhance the flexibility, efficiency, and Fig. 7. Converted C# code into ladder logic of Batch Process System.
performance of batch process systems, ultimately leading
to improved product quality and reduced operational
costs.
and configuring automation solutions, including those for
a) TIA portal for specified PLC: Siemens TIA Portal batch process systems. This integrated engineering environ-
Version 16 serves as a powerful software suite for developing ment allows users to design, program, and simulate complex
 Fig. 8. Filling Tank 1 upto High level Float sensor. Fig. 9. Filling Tank 2 upto High level Float sensor.

Fig. 10. Solenoid Valve 3 and 4 opened after both Tanks filled up. Fig. 11. When initial temperature is less than setpoint heater should on (a).

Fig. 12. When initial temperature is less than setpoint heater should on (b). Fig. 13. Initial temperature is equal/greater than setpoint heater off & S5 open

automation systems efficiently. new project is created, specifying the hardware configuration,
Within the Siemens PLC family, the S7-1200 series is including the selected PLC and its modules. Subsequently, an
often selected for batch process systems due to its optimal empty main block is created, which serves as the foundation
balance of performance and cost-effectiveness. The choice for the ladder logic program. This block will house the logic
of a specific CPU, such as the S7-1214C DC/DC/DC, is necessary to control the various stages of the batch process,
determined by factors like the number of required inputs and such as initiating and terminating batches, monitoring process
outputs, processing power, and communication capabilities. parameters, and activating actuators like valves and pumps as
The ”DC/DC/DC” designation indicates the power supply shown in Fig. 2.
configuration, with the first ”DC” referring to the power supply b) Connection between TIA portal to TIA openness:
source for the PLC, the second ”DC” to the internal power To effectively utilize TIA Openness for C# code generation,
supply within the PLC, and the third ”DC” to the power supply the first step involves locating the project directory. This can
for the output modules. be achieved by copying the project’s address within the TIA
To initiate the development process within TIA Portal, a Portal environment and pasting it into the DLL. Once the DLL
 Fig. 14. Hot water Batch comes out as output of the process tank.

is provided with this path, it can seamlessly access and parse imported into the TIA Portal environment through the TIA
the project’s structure, including the software components, Openness software as shown in Fig. 6.
connected PLC, logic, tags, and blocks. Upon importing the C# code, the TIA Portal refreshes and
As depicted in Fig. 3, the DLL extracts comprehensive updates the project, reflecting the newly defined ladder logic.
information about the project, providing a detailed overview of Fig. 7 illustrate the generated ladder logic within the main
its elements. This granular level of insight empowers engineers block of the project, demonstrating the seamless integration
to precisely identify and target specific components for code of C# code into the TIA Portal environment.
generation. With the ladder logic successfully implemented, it can be
In the context of batch process systems, a common approach loaded into the PLC to execute the control strategies and
involves exporting the main block of the ladder logic program. automate the batch process system. This integration of C# and
This block encapsulates the core control logic, encompassing TIA Openness empowers engineers to create sophisticated and
tasks such as initiating and terminating batches, monitoring customized automation solutions, optimizing the performance
process parameters, and controlling actuators. By exporting and efficiency of batch processes.
this block, engineers can obtain the underlying C# code, as
illustrated in Fig. 4. VI. R ESULTS AND D ISCUSSION
This C# code serves as a valuable starting point for further By effectively leveraging TIA Openness, this project
customization and optimization. It can be modified to incorpo- demonstrates the feasibility of enhancing the scalability and
rate advanced control algorithms, data analysis techniques, and adaptability of batch process systems. The ability to modify
other enhancements, thereby elevating the overall performance system behavior by making changes to C# code offers signif-
and efficiency of the batch process system. icant advantages, particularly in large-scale industrial plants.
c) C++ Code in Notepad++ and Convert: The exported This approach streamlines the engineering process, reducing
C# code, consisting of two empty networks with empty rungs, the time and effort required to implement modifications. Addi-
serves as a foundational framework for the batch process tionally, C# code, being more readable and maintainable than
system’s control logic as depicted in Fig. 5. By carefully traditional ladder logic, makes it easier for non-core engineers
crafting the C# code, engineers can define the specific logic to understand and contribute to the system’s development and
for each network and rung, incorporating timers, comparators, optimization. Key results include:
measuring instructions, and other necessary elements. The Mainly there are 6 stages they are shown below
code, developed using a text editor like Notepad++, is then 1) Filling of two tanks
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C# programming, to optimize these systems. By leveraging
these technologies, industries can enhance efficiency, reduce
costs, and improve product quality.