ELECTRICAL ENGINEERING DEPARTMENT

BACHELOR OF SCIENCE IN ELECTRICAL AND CONTROL ENGINEERING

YEAR FOUR SEMESTER ONE

PROJECT

DESIGN OF AUTOMATIC WATER TANK FILLING SYSTEM USING PROGRAMMABLE

LOGIC CONTROLLER

BY GROUP 3

JOHN DOGGALE FAUSTINO - 19/728/BSEE-S

A report Submitted to the Department as a Partial Fulfillment of the Requirements for the Award of
Bachelor Degree in Electrical Engineering of International University of East Africa.

January, 2023

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 DECLARATION
I declare that this is my original work and that any other person‘s work referred to has been properly cited
and not plagiarized. I also declare that this work has never been submitted anywhere else for the award of
any other certificate, diploma or degree.

JOHN DOGGALE FAUSTINO

19/728/BSEE-S

Signature: ....................................... Date.................................................

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 APPROVAL
This research report titled “Design of automatic water tank filling system using programmable logic
controller.” Has been submitted by John Doggale Faustino for examination with my approval as the
University Supervisor Mr. Richard Bagaiga.

SIGNATURE .....................................................................DATE...................................

NAME: .....................................................................

(SUPERVISOR)

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 DEDICATION
This project is dedicated to my beloved parents Mr. Faustino Joseph and Miss. Thereaza Celestino who
supported me financially through all these years. May the almighty God bless you, thanks so much.

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 ACKWNOLEDGDMENT
I would like to express my special thanks of gratitude to my lecturer as well as our supervisor and also my
group members who gave me the golden opportunity to do this wonderful project on the topic (Automation
Water Tank Filling Using PLC) which helped me do a lot of research and gain knowledge through all
period. I Came across and learned many new things during this research. I am really thankful for that.

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 LIST OF FGIGURES
Figure 1. Programmable Logic Controllers ................................................................................................ 19
Figure 2.Solenoid Valve ............................................................................................................................. 19
Figure 3. Symbols for Normally Open and Normally Closed Inputs ......................................................... 20
Figure 4. Solenoid Valve ............................................................................................................................ 21
Figure 5.Operation of the Level Sensor in Relation to the Pump ............................................................... 25
Figure 6.Operation of Level Sensor in Relation to Valve. .......................................................................... 25
Figure 7.Operation of Level Sensor in Relation to Valve. .......................................................................... 26
Figure 8. I/O’s connections to the PLC....................................................................................................... 28
Figure 9. Flow Chart and Schematic diagram of the system operations ..................................................... 31
Figure 10 .schematic diagram of the automatic water tank filling system using plc .................................. 32
Figure 11. Ladder Logic Programme for the System. ................................................................................. 34

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 TABLE OF CONTENTS

Contents
DECLARATION ............................................................................................................................................... 2
APPROVAL ..................................................................................................................................................... 3
DEDICATION .................................................................................................................................................. 4
ACKWNOLEDGDMENT .................................................................................................................................. 5
LIST OF FGIGURES ......................................................................................................................................... 6
TABLE OF CONTENTS..................................................................................................................................... 7
LIST OF ACRONYMS ....................................................................................................................................... 9
ABSTRACT.................................................................................................................................................... 10
CHAPTER ONE ............................................................................................................................................. 11
1.0 INTRODUCTION ................................................................................................................................. 11
1.1 BACKGROUND ................................................................................................................................... 11
1.2 PROBLEM STATEMENT ...................................................................................................................... 12
1.3 OBJECTIVES ....................................................................................................................................... 13
1.4 JUSTIFICATION .................................................................................................................................. 13
1.5 SCOPE OF STUDY ............................................................................................................................... 14
1.6 ORGANIZATION OF THESIS ................................................................................................................ 14
CHARPTER TWO .......................................................................................................................................... 15
LITERATURE REVIEW ................................................................................................................................... 15
2.0 INTRODUCTION ................................................................................................................................. 15
2.1 RELATED PROJECT ............................................................................................................................. 16
2.2 THIS PROJECT .................................................................................................................................... 17
2.2.1 Programmable Logic Controller. .................................................................................................... 18
2.2.2 Functions of a Programmable Logic Controller ............................................................................. 19
2.2.3 Solenoid valve works...................................................................................................................... 19
2.2.4 PLC Ladder Logic Inputs ................................................................................................................. 20
2.2.5 Selecting a Programmable Logic Controller (PLC).......................................................................... 20
2.2.6 Human Machine Interface (HMI). .................................................................................................. 21
CHARPTER THREE. ....................................................................................................................................... 23
METHODOLOGY. ......................................................................................................................................... 23
3.1. System Component Description ...................................................................................................... 23

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 3.1.1. Level Sensors ................................................................................................................................. 23
3.1.2. Level Sensing Methods for liquids ................................................................................................ 24
3.1.3 Solenoid Valve................................................................................................................................ 25
3.1.4. Relay and pump ............................................................................................................................ 27
3.1.5. Programmable Logic Controller (PLC) ........................................................................................... 27
3.1.6. I/O Connections to the PLC and Ladder Programming ................................................................. 28
3.1.7 Human Machine Interface ............................................................................................................. 29
CHAPTER FOUR ........................................................................................................................................... 30
DESIGN AND SIMULATION OF THE SYSTEM................................................................................................ 30
4.1 System design ................................................................................................................................... 30
4.1.1 Flow Chart and Schematic diagram of the system operations. ..................................................... 31
4.2 Simulation of the water tank filling system ...................................................................................... 34
4.2.1 Filling the Tank ............................................................................................................................... 34
CHAPTER FIVE ............................................................................................................................................. 36
CONCLUSIONS AND RECOMMENDATIONS ................................................................................................. 36
5.1. Conclusions. ..................................................................................................................................... 36
5.2. Recommendations From the study, it is recommended that: ....................................................... 36

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 LIST OF ACRONYMS

MPI – Message passing interface

BH-L – Borehole at Low Level

DTP – Dual TIP probe

GUI – graphical user interface

HMI – Human Machine Interface

I/O – Input and Output

PLC – Programmable Logic Controller

SCADA – Supervisory Control and Data Acquisition

TL1-H – Tank 1 at High Level

TL1-L – Tank 1 at Low Level

TL2 – Tank 2 Level

TL3 – Tank 3 Level

TL4 – Tank 4 Level.

LED – Light Emitting Diode

S0V – Solenoid Operated Valves

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 ABSTRACT
Automation has been an integral part of industries which provides safety, accuracy, efficiency and less

human intervention with dangerous chemical process. So, our project work is on “Water Tank Level

Controller by using PLC”. Water level management using PLC is design to control the level of water and

avoid wastage of water in the tank. The system has an automatic pumping system attach to it. We are

controlling the water level by using PLC, Sensors and motor. The purpose for doing this project is reducing

time consumption and human resource consumption, increase product revenue and greater accessibility

or more security. Also by using this project the wastage of water occurred by overflowing of tanks can be

avoided. In future by making some changes this project can be used in different industries related to fluids

like petroleum industries or oil refineries for controlling the level of filling the tanks and avoid wastage.

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 CHAPTER ONE
1.0 INTRODUCTION
The Controlling of water level tank is crucial mechanism in our day to day activity. In many industries it is
common to observe that large amount of water is wasted from the tank. The project “Water level
management using PLC and SCADA visualization” is designed to monitor the level of water in the tank.
The system has an automatic pumping system attached to it. The pump starts automatically when water in
tank goes to lower level to fill the tank and turns OFF. When sufficient level of water is reached. Water is
commonly used for agriculture, industry and domestic consumption. Therefore, efficient use and water
monitoring are potential constraint for home or office water management system. The problem such as poor
water allocation, inefficient use, lack of adequate and integrated water management can be solved by using
this system. The common method of water level control for home appliance is simply to start the feed pump
at a low level and allow it to run until a higher water level is reached in the water tank. But humans are
required to start and stop the motor also there is chances of overflow of water and dry run of motor. Proper
monitoring is needed to ensure water sustainability so PLC based automated water level sensing and
controlling can be used. We are controlling the water level automatically by using PLC, sensor and motor.
The float switches senses the presence of water and give indication to the PLC. The PLC produce control
signal to drive the motor. If there is no water content the PLC give signal to start the motor and if there is
sufficient water in the tank the PLC give signal to stop the motor. It also prevent dry run of the pump in
case the level in the tank goes below the suction level. In this project Siemens PLC is used which lie in the
cheapest category or entry level of PLC. The reason of it been cheap is that it has limited number of input
and output ports. In this project automation of water tank is achieved by using float switch as level sensor
in order to set a low level and high level inside the tank.

1.1 BACKGROUND
In the past, humans were the main methods for controlling a system as Manual controller. When the operator
operates the process to a desired condition, then it carries out the corrective action is said to be manual
control. The operator adjusts the output to operate the plant. During start-up, this mode is normally used.
More recently electric city has been used for control and early electrical control was based on Conventional
control system. Conventional control system consists of electromagnetic relay, timer, and switch etc. Which
can be used to control a specify process operation. But if any changed is required in the process then whole
control system has to be changed and rewiring is need. Relays- This relay allows power to switch on and
off without a mechanical switch. It is common to use relay to make simple logical control decisions. The
development of low cost computer has brought the most recent revolution. At the outset of industrial
revolution, especially during sixties and seventies, relays were used to operate automated machines, and

11
these were interconnected using wires inside the control panel. In some cases a control panel covered an
entire wall. To discover an error in the system much time was needed especially with more complex process
control systems. On top of everything, a lifetime of relay contacts was limited, so some relays had to be
replaced. If replacement was required, machine had to be stopped and production too. Also, it could happen
that there was not enough room for necessary changes. Control panel was used only for one particular
process, and it wasn’t easy to adapt to the requirements of a new system. As far as maintenance, electricians
had to be very skill full in finding errors. In short, conventional control panels proved to be very inflexible.
As explained above manual or conventional control has some draw backs due to this case we forced to
make automatic control system using PLC.

Therefore, in modern industry, PLC control systems have been extensively implemented in many
applications, such as water and wastewater treatment control system, Sun-tracking system, wind energy
system, photo-voltaic applications, heating ventilating and air- conditioning (HVAC) control,
manufacturing and so on.

1.2 PROBLEM STATEMENT

The traditional (manual) water/fluid level control for tanks had many disadvantage such as;

 Traditional fluid level must draw the water manually to the tank when there is no water in the tank.

 The problem of manual control is sometimes people turn off or turn on the valve.

 There is over flow of in the open container in the industries.

 Time delay

 High cost, less reliable.

 Difficult to maintained

 Have large panel

 An automatic water tank filling system using PLC would help eliminate or reduce a lot of the
problems associated with the manual operations.

The application of sensors, solenoid valve/motors to monitor and control the water tank filling system will
drastically reduce human contact with the operations of the system.

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1.3 OBJECTIVES
General objective

The main purpose of the project is to maintain water in a desire level to any control system. PLC is used in
this project as an Automation tool to reduce manual operation and get better accuracy.

Specific objective

 Monitoring
 To control and measure the liquid level in the tank
 To ensure that enough material is available to complete a particular batch
 To designed an Automatic water monitoring system
 To incorporates an interactive medium between the end user and the machine
 To develop controller using PLC as programming.
 Safety
 To prevent an industrial accident by over filling an open container
 To monitor tank over filling.
 Economy
 Good level control of solid also desirable, excessive built up in hoppers can be expensive to
clear
 To avoid wastage of Water
 To prevent over labor of the pumping Machine Since the demand of electric city is very high,
Automatic water level control saves energy
1.4 JUSTIFICATION
 In industries, the water level control problem is a typical process control problem.

 In the past, humans were the main methods for controlling a system as Manual controller.
 The manual control has a lot of setbacks such as, overflowing of water, dry running of pumps, time
delay, high cost, unreliability.
 More so water purification and supply plants have numerous tanks whose level need to be
monitored and controlled, hence this becomes a tedious job for the operators.
 This justifies the benefits that can be accrued from automating the tank filling system, which are
cost reduction and time saving, less human contact means less cost in terms of labour, maintenance,
utility bills waste.

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1.5 SCOPE OF STUDY
 Technical scope

 This project covers automatic water tank filling system using programmable logic controller.

 It involves the use of level sensors to detect the water level in the tank and the PLC accordingly
starts or stops the feed pump or transfer pump depending on the level of water in the respective
tanks tank.

 The addition of SCADA system helps in monitoring and controlling the process from a central
computer (HMI). For example, pump running status, solenoid valves open/closed status can be
monitored and manual start/stop of pumps.

 Geographical scope

 This project is not only limited to controlling the level of water tanks/tank filling but could also
be applied in petroleum and petrochemical industries to monitor and control the tanks/vessels
filling for the different processes involved.

1.6 ORGANIZATION OF THESIS

The thesis was structured into five chapters. The introduction, background, which is the subject of
Chapter1, consists of the problem statement, general objectives specific objective, justification, scope and
organization of project report. Literature review is the subject of Chapter 2 and contains a review of
automation of water filling tank and related project did by others, logic ladder logic inputs, Programmable
Logic Controller, Functions of a Programmable Logic Controller, Solenoid valve works, PLC Ladder Logic
Inputs, Selecting a Programmable Logic Controller (PLC), and human machine interface. Chapter 3
presents the method for the design and implementation of the water tank filling system using PLC, system
components description which includes level sensors, solenoid valves, relay and pump motor,
programmable logic controller and human machine interface etc. Chapter 4 presents the design and
simulation of the system which consists of the flow chart, complete schematic design of the water tank
filling system, solenoid valve implementation, sensor implementation, ladder programming simulation
diagrams whiles the conclusions and recommendations is presented in Chapter 5.

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 CHARPTER TWO

LITERATURE REVIEW
2.0 INTRODUCTION
In the past, humans were the main methods for controlling a system as Manual controller. When the
operator operates the process to a desired condition, then it carries out the corrective action is said to be
manual control. The operator adjusts the output to operate the plant. During start-up, this mode is normally
used. More recently electric city has been used for control and early electrical control was based on
Conventional control system. Conventional control system consists of electromagnetic relay, timer, and
switch etc. Which can be used to control a specify process operation. But if any changed is required in the
process then whole control system has to be changed and rewiring is need. Relays- This relay allows power
to switch on and off without a mechanical switch. It is common to use relay to make simple logical control
decisions. The development of low cost computer has brought the most recent revolution. At the outset of
industrial revolution, especially during sixties and seventies, relays were used to operate automated
machines, and these were interconnected using wires inside the control panel. In some cases a control panel
covered an entire wall. To discover an error in the system much time was needed especially with more
complex process control systems. On top of everything, a lifetime of relay contacts was limited, so some
relays had to be replaced. If replacement was required, machine had to be stopped and production too. Also,
it could happen that there was not enough room for necessary changes. Control panel was used only for one
particular process, and it wasn’t easy to adapt to the requirements of a new system. As far as maintenance,
electricians had to be very skill full in finding errors. In short, conventional control panels proved to be
very inflexible. As explained above manual or conventional control has some draw backs due to this case
we forced to make automatic control system using PLC.

Therefore, in modern industry, PLC control systems have been extensively implemented in many
applications, such as water and wastewater treatment control system, Sun-tracking system, wind energy
system, photo-voltaic applications, heating ventilating and air- conditioning (HVAC) control,
manufacturing and so on.

One common feature of these applications is that they can be modeled as process control problems. For
example in the water and wastewater treatment control system, the pumps and valves are controlled
according to the real time data of the process.
To be more specific, water level control problem is a typical process control problem. Therefore, in this
section, some related literature is reviewed and discussed.

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2.1 RELATED PROJECT
1. Automation of tank level by using PLC and establish of HMI by SCADA by das, Rishabh Das,
Sayantan Dutta, Anusree Sarkar, Kaushik Samanta, (2013).

They analyzed the level control of single tank and implemented control strategy. From their paper, we got
knowledge about PLC automation that can be used in controlling water level in different tanks.

Also came to know the process of interfacing the PLC to the HMI by using SCADA. Understood input and
output components that are required to connect with PLC.

In their project, three inductive Proximity sensors were used to sense presence of water at required levels.
The sensors are UG_LL – Low Level Sensor Underground tank, OH_LL – Low Level Sensor Overhead
tank, OH_HL – High Level Sensor Overhead tank used.

Theses sensors give open contact when they are inside water and they give close contact when they are
outside water.

The overhead Tank is to be filled by a Pump. The pump will automatically start when the water level of
Over Head Tank reaches below Low Level and stop when the level reaches High Level. Dry run is checked
by the Low Level sensor of the Under Ground Tank.

In that case Pump will not run. Run time monitoring of the pump in Second and minute is recorded and
Reset Switch is also provided. Provision of Manual Start/Stop switch is incorporated which will totally
override the automatic system. Provisions are also made for various alarms, such as “Underground Tank
Empty Alarm” and “Pump run time exceeded 10 Minutes” (If pump runs continuously for 10 Minutes).

2. Gebremaryam Alem and Dr.Krishnanaik Vankdoth did a project “

Automatic Fluid Level Control Using Programmable Logic Controller” (2016)

In their project, an Automatic fluid level control for reserve tank, overhead and underground tank with
switching device is designed using electronics control to refill the water without human intervention.

The system design was arranged to refill the water tank any time water get low to a certain level and the
system automatically shut down the water pump by putting the electric pump off when the tank is full.

The overhead tank is to be filled by a pump. The pump will automatically start when the water level the
overhead tank reaches below the low level and stop when the level reaches high level.

16
Dry run is checked by the low level sensor of the reserve tank. Switch is also provided. Provision of manual
start or stop switch is incorporated which will totally override the automatic system.

They used pressure switches to detect the level of water in the tanks and operate solenoid valves and the
pump.

3. Design of automatic water tank filling system using a programmable logic controller by Emmanuel
Assare- Mokwah. (2015)

In his report, he described automatic tank filling for a water purification plant as he related it to water
processing unit such as Everpure Ghana Limited.

He designed a system consisting of three tanks being filled from an underground (borehole) by a pump.

The system has a pump that supplies water to the tanks via pipelines. The solenoid valves open for the
pump to start automatically when the water level in the water tanks reach a low level and close when the
level of water reaches high level.

The pump will not run when the level sensor in the borehole detects that the water in the borehole is at a
low level or is empty.

This was to ensure that the pump does not run dry. Provision was made for a manual Start/Stop switch
which totally overrules the automated system in offline mode.

Alarms such as low level alarm or empty alarm for borehole level and Pump run time (ON/OFF delay) time
exceeding 10 Minutes (If pump runs continuously for 10 Minutes)

The system was implemented using dual tip probes. This senses the required level of water in the tank. The
dual tip sensing devices consist of two probes that is able to sense the water level when is high and when
water level is low

Solenoid valves were also implemented in the system. These open or shut against flow of water from one
tank to the other.

2.2 THIS PROJECT

Therefore this project, the automatic tank filling system using PLC, we have adopted several ideas from all
the other related projects as discussed above to design an automatic tank filling system for water
pretreatment plant as related to Melut water treatment plant in Upper Nile state-south Sudan.

17
We have however expanded the control horizon by adding more equipment to the system (our system
consists of four tanks, three solenoid valves, a feed pump and a transfer tank).

This plant treats water from White Nile before supplying it to Paloch field production facility and Paloch
Operation based camp where further treatment is done to provide potable water.

Here, we have designed a system to control the level of a single train/stream consisting of four tanks (pre-
settling tank, flocculation tank, clarifier and buffer tank) and associated isolation valves (solenoid operated
valves, SOV1, SOV2 and SOV3) and pumps.

Feed pump (an electrical submersible pump) is used to pump water from the Nile to the treatment plant and
a transfer pump is provided to pump water from the treatment plant to the users.

The feed pump starts automatically once the low level sensor for the pre-settling is activated and stops on
activation of either the high level sensor of the pre-settling tank or low level of borehole/Nile water.

The solenoid valves close once the level of the associated tank is high to prevent the tank from overflow
and or over pressure for a closed tank.

An indication is also provided to indicate the status of the valves and pumps.

2.2.1 Programmable Logic Controller.

The evolution of control engineering has spanned for years and manual means of controlling a system (or
equipment) were long associated with humans. In recent times there has been a dramatic shift from relay
based controls to other control systems such as PLC’s. Relays are able to switch power ON /OFF
automatically and is possible can be used to make decisions that are simple and logical. Consistent
research and development of simple and affordable computers gave birth to the PLC. Many industrial
controls are very comfortable with PLC’s which work began on its creation in the 1970s. PLCs have gained
reputation in many industrial establishments and may offer some advantages as follows:

 It remains cost effective and able to control complex systems

 It is flexible and easy to re-apply to control other systems quickly

 Its high computational abilities can allow for more sophisticated control

 Troubleshooting aids make programming easier and reduce downtime

 Its components are dependable so it is expected to function for a long time.

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2.2.2 Functions of a Programmable Logic Controller
A PLC has a central processing unit (CPU) that is able to accommodate an application programme and
input/output modules. Plant and equipment controls and processes are executed by instructions stored in a
PLC memory. The PLC memory stores the values of timers, relays, sequencers, and counters. The PLC
offers certain advantages such as reliability, low cost, and can be re-programmed (Excel Automation
Solutions, 2014). Figure 1 shows a schematic diagram of a programmable logic controller.

Figure 1. Programmable Logic Controllers

2.2.3 Solenoid valve works

Solenoids valves are the most popular controlling devices. A piston moves inside a wire coil but is normally
held to a spring outside the coil. Current then flows when voltage is applied to the coil, which builds up a
magnetic field that attracts the piston and pulls it into the center of the coil. The piston can be used to
supply a linear force. Well known applications of these include pneumatic valves and car door openers.
Figure 2 shows a schematic diagram of a solenoid valve.

Figure 2.Solenoid Valve

 Valve Body

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  Inlet Port
 Outlet port
 Coil Solenoid
 Coil Windings
 Lead Wires
 Piston
 Solenoid Spring
 Orifice

2.2.4 PLC Ladder Logic Inputs

Ladder logic is a PLC programme that regularly scrutinize all input values than the normal cycle times.
Figure 3 shows the schematics of ladder logic inputs. Figure 3 (A) is a normally open circuit, so input A
will close the contact and there will be current flow. Figure 3 (B) is a normally closed circuit, so input B
will open the contact ceasing current flow (Anon., 2014b).

Figure 3. Symbols for Normally Open and Normally Closed Inputs

2.2.5 Selecting a Programmable Logic Controller (PLC)

The decision to use the desired PLC would usually be based on certain dependent factors such as:

 Needed inputs

 Needed outputs

 Memory capacity – at least 1kilobyte. The size of the ladder logic determines the need.

 The quantity of “custom” I/O modules needed – could be applied to special systems.

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 Time for cycle scan – less time for scanning is suitable for faster processes but will result in higher cost.
Scan cycle times may be 1 microsecond per simple ladder instruction

 Communications – how the PLC may be able to talk to other PLC’s. Serial and networked connections
provides the avenue achieve that. The type of application determines the need.

 Available software – programming and debugging with ease depends on the how easy tools and software
can be accessed. To design a PLC system to control a process, these must be done:

 Firstly, the process to be controlled must be understood

 Secondly, inputs/output requirements must be listed

 Thirdly, determine how the process it to be controlled

2.2.6 Human Machine Interface (HMI).

A graphical user interface, also known as HMI is a device that an operator can use to either regulate, control
or interact with an equipment or machine. There is a part of the HMI which the user or operator can touch
and see. Examples of such interactive systems are rubber Keypads and Touchscreens. For specialized
systems, the GUI is fully computerized. Ergonomics factors are hugely considered in the design of human-
machine interfaces. Other disciplines that relate to HMI’s are human engineering (H/E), user-centered
design and cognitive economics which is part of systems engineering. Basic foundations which involves
operating systems and programming languages, are used as a basis in the interface design which will
incorporate human factors (Anon., 2012). Another expression used to represent HMI on computers is
known as Graphical User Interface (GUI) since mostly all of them are now using graphics. Simulation and
building of prototypes are fundamentally used in the interface design.

Figure 4. Solenoid Valve

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An HMI has a simple task of interacting with a plant or equipment. HMI’s are given varied names such as
console, graphical user interface, smart screens etc. These allow the user or operator to use simple displays
or click an icon to determine machine condition or status to enable him make changes to settings. The most
common uses are, fault alarms, machine position, allowing user to run and monitor equipment’s. The
devices have the following advantages:

 Use of color codes to allow for easy identification. For example red for fault.

 Display images and representations to allow for clarity;

 Easy alteration of screen displays to provide access to information at different stages.

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 CHARPTER THREE.

METHODOLOGY.
To achieve the automation of the process for tank filling, a programming software called XG 5000 together
with other devices was used for the application. The water tank filling system has four (4) main modules:

 The level probe or sensor transmits the current level of water tank to the PLC.

 The PLC will then make a decision whether to put the pump ON or OFF and also CLOSE or OPEN the
solenoid valves.

 By a message passing interface (MPI), the position of the system is then transmitted to the computer.

 The system position is viewed and controlled remotely by the operator or user via the human machine
interface (HMI).

3.1. System Component Description

For a water tank filling system design, the main components used is divided into five main parts as follows:

 Level Sensors.

 Solenoid Valves.

 Relay and Pump.

 PLC

 HMI

3.1.1. Level Sensors

The liquid level sensors used for the design of the system played a major role in detecting, measuring, and
monitoring of the water tank levels. In selecting the right liquid level sensors for the automated water tank
filling system, the following technical considerations were given:

 The kind of liquid to be measured. In the case of this project water was used.

 The positioning of the level sensor. It will either be inserted into or outside of the water tank.

 The type or kind of level sensor required.

There are two main sensing methods and these are continuous sensing and point sensing.

 The method of contact with the water.

23
This refers to whether the sensor touches the water or does not make contact with the water.

 Water level measurement by direct or indirect means. When the sensor directly senses the water level, it
is known as direct measurement. Indirect means of measurement depends on certain measurable elements
and translate them to height or level.

 When a sensor is retracted or taken off from its installed position or maintenance carried out, it is known
as process shut down but it is also acceptable.

 Pricing.

 Calibration or programming convenience.

The selection of the best possible level monitoring method for the automated water tank filling system was
affected by many physical and application factors. These factors include the following: temperature,
pressure, vibration, density (specific gravity) of the water, and environmental conditions particular to the
automated water tank filling system. Selection of the best possible sensor applicable to the system designed
is of much importance.

3.1.2. Level Sensing Methods for liquids

In effect there are two main methods o

Level sensing for liquids and these are point and continuous level sensing. Continuous level sensors have
the capacity to indicate the water level but is limited to a specific range. It may also determine how much
water is found in the tank. Point-level sensors will specify whether the level of water is higher or lower than
the point of sensing. Point level sensors can detect excessively high or low levels.

The water in the tank is able to conduct a current at a very low voltage probably less than 20 Volts (< 20).
A dual tip probe was used to set up an electrical circuit for the system and that means grounding is
eliminated especially when a non-metallic tank was used. Figure 5 (A, B and C) shows a schematic
arrangement of a dual-tip probe that detects maximum and minimum water levels. There is the supply
pump, Figure 5 (A) and the dual tip sensor fixed in tank 1 of Figure 5 (B). Figure 5 (C) shows how the
pump for the system will be triggered ON and OFF. When the water level reaches the upper probe, a switch
closes to start the pump to fill the receiving tank 1; when the water level reaches the lower probe, the switch
opens to stop the pump.

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 Figure 5.Operation of the Level Sensor in Relation to the Pump

In Figure 6 when the water level reaches the upper probe, a switch closes to open the valve for water to

flow from the receiving tank to the other tanks; when the water level reaches the lower probe, the switch

opens to close the valve.

Figure 6.Operation of Level Sensor in Relation to Valve.

3.1.3 Solenoid Valve

Solenoid valves were used in the water tank filling system. These devices have two components, a valve
and a solenoid. The valve is also actuated by a solenoid. The solenoid is also controlled by a circuit known
as a cascade switched circuit.

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By energizing the relay coil, the contacts close which allows flow of current from the 12V supply through
the solenoid. By energizing the solenoid coil, the valve opens, allowing the flow of water from one water
tank to the other. The relay and transistor are powered from a 5V circuit and the solenoid is powered by a
12V supply. Figure 7 shows the internal circuit of the solenoid valve used in the water tank filling system

Figure 7.Operation of Level Sensor in Relation to Valve.

Valves are used extensively for affecting the process; we often say that values are the “handles” by which
we operate a process. We have many goals in influencing the process; therefore, we use the flow and valve
principles in many applications. There are many types of valves. The four most prominent types of valves
are summarized below.

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Control Valve Selection Process the under listed considerations were used as the criteria for selecting the
suitable valve for the system:

1. The type of liquid to be controlled. Water was used.

2. The flow rate and temperature required.

3. The type of valve required. Whether a two (2) - way or three (3) –way valve will be used and should it
be normally closed (NC) or normally open (NO).

4. Working environment. The sort of conditions under which the device is going to be used, which may be
flammable, explosive or wet.

5. The pipe specifications. This is dependent on size of piping used and its orientation.

6. Available control voltage. Whether the power is AC or DC.

7. Another important consideration was energy efficiency. Low watt valves can save substantial energy
over lifetime, making them a wise investment. They also produce little heat build-up, which can also be
important, especially if multiple valves are located within single enclosure.

3.1.4. Relay and pump

 We have two pumps which are, the feed pump and the transfer pump.

 Feed pump

 This is used to pump water from the Nile/ borehole to supply the tanks in the water
processing plant

 Transfer pump

 It is used to transfer/pump the processed/treated water from the plant to various users
 Centrifugal pumps have been used

3.1.5. Programmable Logic Controller (PLC)

The automated system used the PLC as its main control unit and with its non-volatile memory having the
ladder logic prewritten on it. The ladder logic was written using XG 5000 software.

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3.1.6. I/O Connections to the PLC and Ladder Programming
The PLC used for the project was designed for the following arrangements:

 Multiple inputs and outputs

 Wide temperature ranges

 Has immunity to electrical noise

 Is cushioned against vibration and impact. In the project, XG 5000 was used. The water tank filling
system is has three main functions and these are, sensing (or detection), making decisions and
implementation. The status of the whole system is communicated by the PLC to the HMI. During the
implementation, three dual probe sensors were used. The function of the sensors was to detect the presence
of water in the tank whiles the XG 5000 PLC uses the readings of the sensors to make the required decision
of starting or stopping the pump, and also opening or closing the solenoid valves. Finally the decision is
implemented by the PLC through a relay switch. The XG 500 (PLC) provides information on the current
status of the system through the IM port to the computer which is accessible by the HMI.

Figure 8. I/O’s connections to the PLC

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3.1.7 Human Machine Interface
The Human Machine Interface is the means through which an operator or user can communicate with the

system. The present status of the system is sent to the operator or user by means of a graphical user interface

(GUI). The operator or user can interact with the system by turning ON or OFF various functions from the

interface.

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 CHAPTER FOUR

DESIGN AND SIMULATION OF THE SYSTEM

4.1 System design
The pump in the circuit supplies water to the tanks via pipelines. The solenoid valves open for the pump to
start automatically when the water level in the water tanks reach a low level and close when the level of
water reaches high level. The pump will not run when the level sensor in the borehole detects that the water
in the borehole is at a low level or is empty. This was to ensure that the pump does not run dry. Provision
was made for a manual Start/Stop switch which totally overrules the automated system in offline mode.
Alarms such as low level alarm or empty alarm for borehole level and Pump run time (ON/OFF delay) time
exceeding 10 Minutes (If pump runs continuously for 10 Minutes)

The implementation is divided into four parts:

 Flow chart and schematic design of the system with the pump;

 Sensor implementation

 Solenoid valve implementation;

 Ladder programming;

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4.1.1 Flow Chart and Schematic diagram of the system operations.

START

Open valve V1, V2, & V3

Is borehole level low

YES

NO

Start/run pump NO

YES

Is tank 4 full

Close Valve 3
YES

Is tank 3 full

Close Valve 2
YES
Is tank 2 full

Close Valve 1
YES
Is tank 1 full
NO

YES

Figure 9. Flow Chart and Schematic diagram of the system operations

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The flow chart in figure 9 explains the process steps for the automated water tank filling system using PLC.

Figure 10 is a schematic diagram of the automatic water tank filling system. Both figure 9 and 10 explains
the workings of the system. The process steps were as follows:

1. Opens valves (SOV1 SOV2 & SOV3) when the tank 1 (T1) is at low level. This means the pump can
start/run to draw water from the borehole to fill the receiving tank 1 (T1).

2. This will also depend on whether the water in the borehole is sufficient or not. If it is not sufficient
(BHL) the pump will not start (or run). It presupposes that there’s little or no water in the borehole.

3. If tank 3 (T 3) is full, the valve (SOV2) closes otherwise it remains open till it gets full. So the pump
still runs.

4. If tank 2 (T 2) is full, the valve (SOV1) closes otherwise it remains open till gets full. So the pump still
runs. 5. The tank 1 (T1) is the first tank or the collecting water tank from the borehole. So tank 2 draws
water from tank 1(T1) and tank 3 (T 3) draws water from tank 2 (T 2) and tank 4 (T 4) also draw water
from tank 3 (T 3). If tank 1 (T 1) is at high level the pump will stop running till it goes to low level. . If tank
1 (T 1) is at high level the pump will stop running till it goes to low level.

6. Transfer pump to processed/treated water from the plant to various users.

Figure 10 .schematic diagram of the automatic water tank filling system using plc

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The system was implemented using dual tip probes. This senses the required level of water in the tank. The
dual tip sensoring devices consist of two probes that is able to sense the water level when is high and when
water level is low. In figure 10 the dual tip probes were represented by DTP 1, DTP 2, DPT 3 and DTP 4.
Solenoid valves were also implemented in the system. These open or shut against flow of water from one
tank to the other. These valves were labeled as SOV 1, SOV 2, & SOV 3

4.1.2 Ladder diagram.

The Ladder programming was done in XG 500 software. Figure 11 shows a ladder logic programme for
controlling the water tank level which was simulated for four (4) water tanks and a borehole.

 The pump in the circuit supplies water to the tanks via pipelines.
 The solenoid valves open for the pump to start automatically when the water level in the water tanks
reach a low level and close when the level of water reaches high level.
 The pump will not run when the level sensor in the borehole detects that the water in the borehole is at
a low level or is empty. This was to ensure that the pump does not run dry.
 Provision was made for a manual Start/Stop switch which totally overrules the automated system in
offline mode.
 Alarms such as low level alarm or empty alarm for borehole level and Pump run time
 The implementation process is entirely described by ladder diagram as shown in the Figure 11.

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 Figure 11. Ladder Logic Programme for the System.

4.2 Simulation of the water tank filling system

4.2.1 Filling the Tank
The feed pump will start when the PLC is turned on for the first time presuming all the four Tanks are
empty and there is no water flow from the borehole. The sensors which have normally close contact will
all be closed at this time because the water in the Tank have not reach the tips of the sensor for the contacts
to open.

The feed pump and the three solenoid valves will be opened this will show indicator by activation of the
LED for pump running status & SOV status. The contacts of Tank 4 will open first because it takes it water
from Tank 3, Tank 3 takes it water from Tank 2 and tank 2 takes its water from tank 1.

34
The low sensor in Tank 1 will open its contact when the water reaches it tip but when the water get to the
tip of the high leg of the sensor it causes the pump to stop to prevent overflow from tank 1.When the upper
sensor for T2, T3, & T4, opens indicating that the water level is full it causes the solenoid valve to close.

When water reaches to the of the high leg of dual tip probe tank 4 the transfer pump is turn ON to supply
water to the users.

When the Tanks are all not full but the water in the bore hole is low, in order not for the pump to run dry
the contact of the sensor in the Borehole Low level closes causing the pump to stop and turning on an LED
indicator signifying that the water level is low.

When the water in Tank 1 gets to the low level sensor, the contact of the low level closes and the pump
starts; all the valves will be opened at this time. At this stage, the cycle continues until the manual stop
button is pressed to stop the entire process.

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 CHAPTER FIVE

CONCLUSIONS AND RECOMMENDATIONS

5.1. Conclusions.
Manually operated systems requires frequent human contact with the system so tend to put pressure on
persons working with it to be precise in all details of their work and at all times.

However, it must be noted that human’s aren’t consistent with what they do with their hands and minds.
The effective and efficient running of such manual systems is heavily dependent on individuals and
therefore management shoulder the responsibility to run training continuously for staff to keep them
motivated and to ensure they are following the correct procedures.

In water purification process or unit there are multiple number of tanks or units to control so monitoring is
difficult. Some of the problems that will be found in a manual process such as in the water purification
system are as follows:

a. Tank overflow leading to water spillages and loss;

b. Overheating of pumps due to the neglect of not stopping them when they run dry.

An automated system of water tank filling at a water processing unit using a PLC system has been designed
and implemented through simulation. The simulation clearly shows that the automation of the water tank
filling will prevent or minimize the following

: i. The incidence of tank overflow since water tank filling is automatically controlled

ii. The incidence of pump overheating since the pump will not run dry.

iii. The stress associated with manual operation and the human dependent of the system;

iv. This system is applicable to food and beverage and chemical producing factories.

5.2. Recommendations From the study, it is recommended that:

1. The simulated automatic water tank filling system should be prototyped and the test run.

2. The number of pumps should be increased to further reduce filling time.

3. The PLC programme should be improved to include measurements of quantity of water in the tank and
filling time.

4. The number of sensors or sensing levels should be increased as per the requirement.

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REFERENCE.

[1] https://www.irjet.net/archives/V3/i7/IRJET-V3I7415.pdf

[2]http://ir.knust.edu.gh/xmlui/bitstream/handle/123456789/10186/FULL%20PROJECT%20REPORT.pd
f?sequence=1

[3] https://www.iosrjournals.org/iosr-jeee/Papers/Vol7-issue2/J0726167.pdf?id=6638

[4] https://www.ijareeie.com/upload/2017/april/61_Design_M.pdf

[5] https://www.ijsr.in/upload/863031802Chapter_41.pdf

[6] PLC Programming For A Water Level Control System: Design and System Implementation by
Haoqiang Ji

[7] Water Tank Level Controller by using PLC by Rushikesh. S. Bhapkar, Mandar. M. Kulkarni, Akash. S.
Darekar, Jagdish. H. Pawar, Prashant. R. Karad

37