GES AUTOMATION
"Control with Precision"
PLC-SCADA-HMI PROGRAMMING SERVICE PROJECTS
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ROTATING ANFD SYSTEM
This project involved the complete PLC and SCADA development for a Rotating Agitated Nutsche Filter Dryer (ANFD) used in the pharmaceutical process line at Trish Pharma (USA). The ANFD system supports 0° to 180° rotation, enabling the equipment to function both as a filtration unit and a reactor, enhancing process flexibility and reducing equipment footprint.
0° Rotation → Filtration mode: solid-liquid separation
180° Rotation → Reactor mode: for mixing, washing, or processing
Technologies & Platforms
PLC: Allen-Bradley CompactLogix 5380 (Studio 5000)
SCADA: Rockwell FactoryTalk View SE
Database: Microsoft SQL Server
Reporting: SQL Server Reporting Services (SSRS)
RAW WATER CHLORINATION
Successfully executed a complete automation programming solution for a Raw Water Chlorination System, ensuring accurate chemical dosing, safe water treatment, and reliable tank level management.
• Siemens S7-200 PLC logic for Controlling of dosing pumps, agitators, motorized valves.
• Siemens WinCC ADVANCE SCADA for real-time monitoring, control, and alarm management.
• Integrated sensors such as LT, FT, DP, and analog dosing control (FCA, DP transmitters).
• Developed operator-friendly mimic screens for:
WATER TREATMENT AND UF SYSTEM
Designed and implemented a fully automated wastewater treatment and ultrafiltration (UF) system using Siemens PLC and HMI. The system manages complete process sequences, from raw effluent inflow to final treated water delivery, with safety interlocks, alarms, and process efficiency logic.
• Created WinCC HMI for intuitive operator control and monitoring with animated mimic screens
• Integrated level, flow, pressure sensors for real-time control and alarming
• Configured VFDs and interlocks for energy-efficient motor operation
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UTILITY AND ENERGY MONITORING SYSTEM
Designed and implemented a comprehensive Utility Monitoring System to track, analyze, and optimize the performance of key utility equipment such as: Chillers (Brine and Chilled Water Coolers), Boilers, Air Compressors, Nitrogen Generators, Raw water and DM water
Key Features
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Real-Time Monitoring of utility equipment across generation and distribution lines using Siemens SCADA.
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Generation vs. Distribution Loss Analysis: Identifies and quantifies distribution losses, enabling proactive decisions.
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Efficiency Monitoring: Compares generation with design capacity to determine performance degradation.
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Energy Cost Analysis: Captures electrical energy consumption per utility equipment and calculates cost per unit of utility generation.
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Daily Reporting: Auto-generated daily reports covering:
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Utility generation and consumption
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Electrical energy consumption
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Equipment-wise efficiency and cost metrics
Benefits & Impact
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Maintenance Optimization: Efficiency insights help in predictive maintenance decisions.
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Energy and Cost Savings: Identifies leakage, unnecessary generation, and underload operation—enabling shutdown of idle equipment.
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Data-Driven Decisions: Equipment-wise and section-wise analytics (chiller, boiler, compressor, nitrogen system) with trend analysis using historical data.
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Centralized Monitoring: Unified dashboard via Siemens SCADA providing live and historical performance insights.