PLC & SCADA Integration Checklist for Industrial Projects
From I/O lists and network topology to alarm rationalisation and FAT/SAT sign-off — the checklist automation engineers actually use.
Updated · 10 min read
Automation projects rarely fail on the PLC code. They fail on undefined I/O, an unmanaged OT network, and a handover with no documentation. Work through the five stages below in order — each one gates the next.
1. Requirements and I/O definition
- Frozen I/O list with tag names, engineering units, ranges and failure states
- P&ID and control narrative agreed with the process owner before coding starts
- Spare I/O budget (typically 15–20%) reserved per rack
- Safety functions separated from process control; SIL target documented
2. Network and architecture
- Topology diagram: PLC, HMI, SCADA server, historian, remote I/O, VFDs
- Protocol map — PROFINET, EtherNet/IP, Modbus TCP, OPC UA — with cycle times
- IP addressing plan, VLAN segmentation and an IT/OT firewall boundary
- Time synchronisation (NTP) so alarms and trends correlate across nodes
3. Controller software
- Standard library of reusable function blocks (motor, valve, PID, analog input)
- Consistent naming convention and version-controlled project files
- Interlocks documented as a cause-and-effect matrix, not buried in ladder logic
- Simulation or soft-PLC test of every sequence before hardware is energised
4. SCADA and HMI
- High-performance HMI: grey process graphics, colour reserved for abnormal states
- Alarm rationalisation — priorities, deadbands, delays; no nuisance alarm floods
- Historian tag list with sample rates and retention matching reporting needs
- Role-based access control and audit trail for operator actions
5. Testing and handover
- FAT protocol covering every I/O point, interlock and alarm, signed by both parties
- SAT on site with loop checks and instrument calibration certificates
- Backup of PLC, HMI and SCADA projects delivered to the client, plus restore test
- As-built documentation, operator training and a defined warranty support window
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