Module 15 · Lesson 4

Capstone integrated industrial project

Design, program, commission and document a complete pump station with VSD, PLC, instrumentation, Modbus/DNP3 telemetry and Wonderware SCADA.

Learning outcomes

Explain the key principles of capstone integrated industrial project.
Carry out a structured practical check or configuration task.
Recognise common faults, risks and evidence needed for diagnosis.

Before you begin

Training simulator or documented design exercise.

Safety: Use site procedures, approved test equipment and competent supervision. Never bypass a protection or interlock without formal control.

Step-by-step learning

Produce P&ID, control narrative, I/O list, network plan and cause-and-effect matrix.
Program duty/standby pumps, level PID, alarms, interlocks and manual/auto modes.
Integrate a Modbus device, DNP3 remote points and SCADA graphics/trends.
Complete FAT/SAT tests, backups, operating instructions and fault-finding guide.

Ian's practical tips:

Treat the capstone as a real handover package, not only a programming exercise.
The strongest project is easy for the next technician to understand and maintain.

Fault-finding questions

What should be happening, and what evidence proves it?
Where is the last known correct signal, voltage, state or process condition?
What changed immediately before the fault?
Can the system be divided into smaller testable sections?

Practical activity

Create a one-page test record for this lesson. Include expected values, measured results, equipment used, risks controlled, defects found and the final proven condition.

I completed the lesson activity. I checked the result safely. I can explain the fault-finding approach.