1

Chapter 1
INTRODUCTION
This project DESIGN OF CONTROL SYSTEM FOR A DE-MINERALIZED
WATER PLANT entails maintaining pH factor of raw water & for the removal of
minerals in order to obtain de-Mineralized water. In the Plant build in this project, acid
& base mix up with the raw water according to the need of the solution & perform
neutralization. This plant is basically a part of many industries including oil and gas,
chemical industry, silicon industry, pharmaceuticals etc. Our intention of selecting this
project was to be able to know how DM water plant works. Secondly it will lead us to
gain knowledge about industry and how things work over there. This project has the
following features:
A pH sensor is used to monitor & control pH factor of raw water.
Conductivity sensor is used to monitor conductivity of raw water.
Level sensors are sensing eight discrete levels from 0-100% in tanks.
An alarm system containing buzzers is used to indicate acid & base level drop
from their respective minimum levels.
Solenoid valves are used to control liquid flow in the entire process.
A stirrer is used to mix the solution in order to achieve stable values.
The controlling device used in this project is Programmable Logic Controller
(PLC). The control system IOs are shown below:

Acid valve
pH sensor Buzzers
Level Detector Water Pump
Conductivity sensor Inlet/Outlet valves
Base valve

Figure 1.1 I/Os of de-Mineralized Water Plant Logic Controller

As indicated by above IOs block, PLC will have inputs from different
components and will generate the desired outputs to perform different tasks
accordingly.
Our project is divided into four different modules which are as follows:

PLC

2
1.1 RAW WATER INJECTION
In this module, raw water from any source is to be injected into the main
process tank (de-Mineralizer). This is achieved by sensing level of water in the de-
Mineralizer by water level detector. Upon sensing a low level, water injection is
started with the help of water pump through the Inlet valve.

Figure 1.2 Water Injection System

1.2 pH & CONDUCTIVITY CONTROL SYSTEM
In this module, the pH & conductivity sensors are deployed inside the de-
Mineralizer where they will generate different voltages according to the pH &
conductivity of water. These sensors are connected to the PLC where a mapping
between pH/conductivity values & voltages is calculated. According to the values
mapped by PLC & set process parameters; PLC will control acid & base valves in
order to vary pH & conductivity.







Figure 1.3 pH & Conductivity Control System

De-Mineralizer
pH sensor
Conductivity
sensor
PLC


Acid
container
Acid
valve


Base
container
Base
valve

De-Mineralizer
Water
Level
Detector
Water Pump
PLC
Inlet Valve
Raw
Water

3
1.3 ACID/BASE LEVEL DETECTOR
Level sensors are installed for liquid level indication in Acid & Base
containers. The purpose of these sensors is to visually indicate current liquid level
in containers & signal an alarm if a container reaches its critical level.







Figure 1.4 Acid/Base Level Indicators & Alarm System
1.4 DRAINING & MIXING SYSTEM
As pH & conductivity sensors are slow to respond to abrupt change in
values, the mixture must be continuously stirred. For this purpose, a stirrer is
installed in the de-Mineralizer which starts working as soon as the main process
tank is filled & stops whenever the required pH & conductivity values are attained.
When the desired pH & conductivity values for the solution are achieved, it
is necessary that the solution is drained in order to restart the whole process with
new raw water. The draining of the solution is automatically done as part of the
process. Apart from the automatic draining of the solution, a manual drain switch
is also installed which can be used in emergency or whenever impurities are
greater than the tolerance level.

Figure 1.5 Liquid Draining & Mixing System

PLC




Acid
container
Acid level
indicator




Base
container
Base level
indicator
Alarm
PLC






De-Mineralizer
Stirrer
Level indicator
Drain Switch
Raw Water
De-Mineralized
Water

4
Chapter 2
BACKGROUND LITERATURE STUDY
2.1 PROGRAMMABLE LOGIC CONTROLLER (PLC)
2.1.1 Introduction
A PLC (Programmable Logic Controller) is an industrial computer
used to monitor inputs, and depending upon their state make decisions based
on its program or logic, to control (turn on/off) its outputs to automate a
machine or a process.
It uses a programmable memory for the internal storage of instructions
by implementing specific functions such as logic sequencing, timing, counting,
and arithmetic to control, through digital or analog input/output modules,
various types of machines or processes. Some of the advantages and
disadvantages of a PLC are as follows.
ADVANTAGES DISADVANTAGES
Rugged and designed to withstand
vibrations, temperature, humidity,
and noise.
Too much work required in connecting
wires. Therefore difficulty when
replacement is required.
Have interfacing for inputs and outputs
already inside the controller.
Difficulty in finding errors; requiring
skillful work force.
Easily programmed and have an easily
understood programming language.
When a problem occurs, hold-up time is
usually long.

Table 2.1 Advantages & Disadvantages of PLC
2.1.2 System Block Diagram
Since a PLC is a type of computer therefore it has all the basic parts of
a computer a central processing unit, memory, input and output interfacing.
A typical PLC block diagram is shown below:

Figure 2.1 Block Diagram of PLC

2.1.2.1 Central processing unit (CPU)
It is the control portion of the PLC. It interprets the program
command retrieved from the memory and acts on those commands.
This unit is a microprocessor based system. It allows arithmetic
operations, logic operators, block memory moves, computer interface,
local area network functions etc.
2.1.2.2 Memory
The system generally consists of a RAM and a ROM. The ROM
memory contains the program information that allows the CPU to
interpret and act on the ladder program stored in the RAM. This is
where information is stored on the status of input and output devices
and the values of timers and counters and other internal devices.
2.1.2.3 I/O interfacing
Inputs monitor field devices, such as switches and sensors. The
input section can accept discrete or analog signals of various voltage
levels. Discrete inputs present the CPU a signal of either 1 or 0.
Whereas analog inputs are passed through an analog to digital
converter and present the CPU an input voltage as a binary number
normalized to the maximum count available from the unit.
The output unit provides either sinking (supplying ground) or
sourcing (providing a voltage) as a discrete or analog voltage, which in-
turn controls other devices, such as motors, pumps, solenoid valves etc.


CPU
Memory
(ROM & RAM)
Digital

INPUTS

Analog
Digital

OUTPUTS

Analog

6
2.2 PLC OPERATION
The first thing that a PLC does when it starts functioning is update I/O.
That is all discrete I/O states are recorded and transferred to the I/O units
respectively. Each I/O point has associated with it a one bit input image register.
PLC is generally configured in 16-bit word. This means that one word of memory
contains states of 16 input points of the PLC.
2.2.1 Input Relays
The relays are connected to the outside world. They physically exist
and receive signals from switches, sensors etc. Typically they are not relays
but rather they are transistors
2.2.2 Internal Utility Relays
The relays do not receive signals from the outside world nor do they
physically exist. They are simulated relays and are what enables a PLC to
eliminate external relays. From programming standpoint all internal relays
have one coil and as many NO (normally open) and/or NC (normally closed)
contacts as the programmer needs.
2.2.3 Counters
They do not physically exist. They are simulated counters and they can
be programmed to count pulses. Typically these counters can count up, down
or both up and down. Since they are simulated they are limited in their
counting speed.
2.2.4 Timers
They also do not physically exist. They come in many varieties and
increments. The most common type is an on-delay type. Others include off-
delay and both retentive and non-retentive types. Increments vary from 1ms
through 1s.
2.2.5 Output Relays
These are connected to the outside world. They physically exist and
send on/off signals to solenoids, lights, etc. Basically they are transistors.
2.3 PLC COMMUNICATION
2.3.1 Serial Communication
Serial communication is when data is transmitted one bit at a time. A
data word has to be separated into its constituent bits for transmission and then
reassembled into the word when received. Serial communication is used for

7
transmitting data over long distances. It is used for the connection between a
computer and a PLC to transfer the program.
RS-232 communications is the method of PLC to external device
communications. There are two types of RS-232 devices normally used:
a) DTE - Data Terminal Equipment and a common example is a computer.
b) DCE - Data Communications Equipment: common example is a modem.
PLC usually has a DCE device.

Figure 2.2 DB9 Male Serial Communication Cable

Figure 2.3 DB9 Female Serial Communication Cable

8
2.3.2 RS-232 Communication
RS-232 is an asynchronous communications method. We use a binary
system to transmit our data in the ASCII format. PLCs serial port is used for
transmission/reception of the data, it works by sending/receiving a voltage,
With RS232, normally, a 1 bit is represented by a voltage -12 V, and a 0 by a
voltage +12 V.
2.4 PLC PROGRAMMING
2.4.1 Introduction to Ladder Logic
Ladder logic uses graphic symbols similar to relay schematic circuit
diagrams. Ladder diagram consists of two vertical lines representing the power
rails. Circuits are connected as horizontal lines between these two verticals.
The symbols which are used in ladder program are as follows
--------| |------------ Normally open switch
--------| |------------ Normally closed switch
--------( )------------ Output / Relay
--------[ ]------------ Special functions

The features of ladder diagram are as follows
Power flows from left to right.
Output on right side cannot be connected directly with left side.
Contact cannot be placed on the right of output.
Each rung contains one output at least.
Each output can be used only once in the program.
A particular input output can appear in more than one rung of a ladder.
The inputs outputs are all identified by their addresses, the notation
used depends on the PLC.

2.5 T100MD2424+ PLC

The PLC that we have used is DCI Technologies T100MD+2424 PLC.

Figure 2.4 Programmable Logic Controller (PLC)

2.5.1 Features
The standard features of the PLC are as follows:
4 to 8 channels of 10-bit Analog Inputs.
1 to 2 channels of 8-bit Analog outputs.
2-channel programmable Motion Controllers for controlling
stepper motors up to 20,000 pulses-per-second.
2-channel Pulse Width Modulated (PWM) outputs.
2-channel 32-bit High Speed Counters (HSC) counts up to
10,000 Hz.
4-channel Interrupt Inputs.
2-channel pulse measurement inputs capable of measuring
frequency and pulse-width of incoming pulses up to 10,000 Hz.
Real time Clock/Calendar for programming multiple scheduled
ON/OFF events.
6016 Words (16-bit) of EEPROM Program Memory.
1700 Words (16-bit) of programmable EEPROM for users
data.
Built-in 16 channels of PID-computation engines let T100MD+
PLCs directly provide Proportional, Integral and Derivative
(PID) type digital control.
One Independent RS232 port for connection to a host PC for
programming or monitoring.
One independent RS485 port for networking or for connecting

10
to external peripherals such as LCD display and RS485-based
analog I/O cards, etc.
Watch-Dog Timer (WDT) which resets the PLC if the CPU
malfunctions due to hardware or software error.

2.5.2 Specifications
The specifications of this PLC are as follows;
It operates at 12 or 24VDC.
All digital inputs and outputs have NPN transistors i.e. they are
active low.
The I/O scan time is 2ms whereas program scan-time is 10us.
It has 64 internal counters.
512 internal timers.
64 internal timers with a resolution of 0.01sec.
8 sequencers with 32 steps each.
A DCE communication Port for RS-232 communication.

11
Chapter 3
SYSTEM ARCHITECTURE AND DESIGN
The design of this project has three major parts. First is the interfacing of the
input devices to the controller. Second is the interfacing of all the loads with the
controller. And third is to make it a stand-alone system and provide it with necessary
and different levels of voltage supplies. The overall architecture of the system is
shown below. The output of various sensors will be given as input to the
Programmable Logic Controller (PLC). Then according to the logic developed the
PLC will control the outputs consequently.






Figure 3.1 System Diagram
3.1 OUTPUT INTERFACING
The output configuration of the Programmable Logic Controller is such
that it is active low, i.e. whenever an output pin of the controller is activated its
voltage shifts from 12 volts to 0 volts. The high and low regions are defined as:
High Region: 9-12 volts
Low Region: 0-2.5 volts.

The special feature of PLC is that it has built in opto-couplers. An opto-
coupler is a passive device for branching or coupling an optical signal. Also it
works as active low which means that when the output is high, there is a virtual
ground at the output port of the PLC. So nothing can be driven/run directly from
the PLC. So there is a need to introduce an output circuit that will run the output
device. One thing to keep in mind is that it should provide high voltage when there

Programmable
Logic
Controller

(PLC)
pH Sensor
Conductivity
Sensor
De-Mineralizer
level indicator
Acid/Base
level indicator
Valves
Stirrer
Water Pump

12
is a virtual ground at the output port and zero when there is a high voltage at
output port. Two scenarios are mentioned below;

Figure 3.2 Scenario 1: ON Condition

Figure 3.3 Scenario 2: OFF Condition

3.1.1 Hardware
Therefore to make the output circuitry or load compatible with the
controller we designed a circuit. The schematic of which is:

Figure 3.4 Output Interfacing

The two scenarios of the operation are explained as under.
One when the PLCs output is high, means there is no output (as the
PLC works as active low). At this time there will be a voltage of about 10
volts at the output terminal. This voltage will act as the input signal to the
output circuit. Next to it is the zener diode in the reverse bias condition.
There will be a voltage drop of about 6.2 volts, thus providing 3.8 volts to
the base of transistor Q1. As a result Q1 will be switched on. A virtual

13
ground will appear at the collector of Q1. This will turn OFF the transistor
Q2. And there will be no Output at the end.

Figure 3.5 OFF Condition

The second way is that when the PLCs output is low, means there
is some output. It will act like there is no signal at the input of the output
circuit. So Q1 will not work thus all the voltage will arrive at the collector.
As a result Q2 will start working and 12 Volts are received at the output
terminal.

Figure 3.6 ON condition

14
3.1.2 Parts List
PART DESCRIPTION QUANTITY
Zener Diode 6.2 V 1
PNP 2N3906 Transistor 1
NPN 2N2222 (or MPS2222A) Transistor 2
1 K Resistor 3
10 K Resistor 2
Table 3.1 Components detail of Output Circuit

3.2 INPUT INTERFACING
As with the output configuration, the input configuration is also active low.
That is, the input of the controller is activated or triggered only when a low signal
is given. The ranges of the high and low regions are the same as the output
High Region: 9-12 volts.
Low Region: 0-2.5 volts.
Therefore the outputs from the sensor are taken from those components
which give a zero voltage drop when a sensor or any other circuit is activated. We
modeled the input circuits in such a way to achieve the low voltage required to
trigger the controllers input.
3.3 DE-MINERALIZED WATER PLANT CONTROL SYSTEM
The system basically had three different modules namely the input, the
output and the controller itself. All these three modules had different requirements
of voltages and currents to operate independently. The voltage requirements for
these modules are summarized as follows:

15
MODULES VOLTAGES REQUIRED
pH Sensor +9 V,-9 V, Grd
Conductivity Sensor +24 V, Grd
Level Indicators + 5 V, Grd
Valves 220 VAC, Grd
Pump 220 VAC, Grd
Stirrer, Buzzers +5V, Grd
Table 3.2 Voltages Required for Each Module
We used a step-down transformer 220/18 VAC & the direct 220 VAC line in
order to acquire these voltages. The specifications of the transformer are as follows:
Multiple voltages
24 V
12 V
9 V
-9 V
5 V all with 3 Amps

The current ratings of the I/O modules and the PLC are summarized as under;
SENSORS Current ratings
pH Sensor: 0.15 A
Conductivity Sensor: 0.15 A
Acid Level Sensor: 0.50 A
Base Level Sensor: 0.50 A
De-Mineralizer Level Sensor: 0.50 A
Total current = 1.80 A

16
PLC Voltage/Current ratings
12 V/ 2A
Output Circuit current ratings
No. of circuits = 10
Current rating = 0.1 A/ circuit
Total current = 1 A
Output devices
Stirrer current rating = 0.8A
Number of Valves = 4
Valves current rating = 0.35A/valve = 1.4A
Number of Buzzers = 2
Buzzers current rating = 0.2A/buzzer = 0.4A
Water Pump = 1 A
Total = 4.0 A

3.4 REALIZATION
This project can be implemented in any industry where de-Mineralized
water is used. It is a completely stand-alone system. Besides that it can also be
implemented in universities and offices for drinking water purposes. This project
was realized on a small scale just for demonstration purposes. For large scale
implementation, all the valves, pumps & the stirrer must be of higher ratings &
capacities.

17
Chapter 4
IMPLEMENTATION
The implementation process had both hardware and software parts involved. In
this chapter there is a detailed discussion on each of the modules that were completed
and realized.
4.1 pH CONTROL SYSTEM
In this module our main agenda is to maintain pH factor of water by
controlling the addition of acid or base in the main process tank through the acid &
base valves. The sensor will be hanged from the top of the tank through a solid
PVC pipe of 1 diameter. This sensor will detect the pH of water & pass the pH
value to PLC after every 30 seconds.







Figure 4.1 Block Diagram of the pH Control System

The basic principle is that the pH sensor probe measures voltages produced
in the solution. These voltages are amplified by the operational amplifier used in
the circuit & passed on to the PLC for further action. These received voltages are
mapped onto the pH scale of 0-14 by the PLC according to the programmed scale.
Based on these calculations, if the desired pH factor is greater than 7 & calculated
comes out to be less than 7, then the PLC opens the base valve in order to increase
the pH factor. On the other hand, if the desired pH factor is less than 7 &
calculated comes out to be greater than 7, then the PLC opens the acid valve in
order to decrease the pH factor. All other conditions are dealt with accordingly.
As soon as the desired pH factor is achieved, the PLC stops the whole
operation & starts draining the solution. Once the whole solution is drained, the
whole process restarts immediately.

PLC



De-Mineralizer
pH Sensor


Acid Tank
Acid Valve


Base Tank
Base Valve

18
4.1.1 Hardware

The sensor used in this project includes a probe from the HANNA
instruments. The reason for using this probe is its accuracy & market name
of HANNA instruments all over the world. The pH sensor circuit includes
the pH probe, a dual J-FET IC TL082, two 9V batteries & a female BNC
connector. The circuit diagram of the pH sensor is shown below:


Figure 4.2 pH Sensor Circuit Diagram
4.1.1.1 Working

The pH probe is inserted in the main process tank from
the top through a solid PVC pipe of 1 diameter. The probe is
held tight so that during stirring of the solution, there is no
chance of damage to the probe. The probe reads voltages
produced in the tank. These voltages are of the order of
micro volts. Due to this reason, TL082 is used in order to
scale these voltages to milli volts range. These readings are
passed to the PLC through one of its analog inputs. The timing
difference between two consecutive readings from the probe is
minimum 30 seconds after mixing the solution. This is because
the probe is too much sensitive to voltage changes on even the
micro volts scale. After 30 seconds of continuous stirring, the
solution produces constant voltages which are accurate.
One thing to remember is that a pH probe needs to be
calibrated before being used in calculations. These calibrations

19
are done by using standard buffer solutions. For our project we
have used three buffer solutions of values 4.01, 7.01 & 10.01
from the HANNA instruments. These calibrations help to verify
the pH readings of different solutions. The graph below shows
the relation between pH values & voltages measured by the pH
sensor circuit from standard buffer solutions.



Figure 4.3 pH as a Function of Voltage


4.1.1.2 Parts list
PART DESCRIPTION QUANTITY
pH Probe 1
9V battery 2
TL082 1
BNC Connector (female) 1

Table 4.1 Components detail of pH sensor

20
4.1.2 Software
Our ladder programming that we used to control the pH factor of
the raw water is given below.


Figure 4.4 Ladder Programming for pH Sensor

Figure 4.5 Custom Functions for pH Sensor Ladder Logic
4.1.2.1 pH sensor
The ladder program for the pH sensor consists of two
parts & includes timers of 30 seconds & 2 seconds along with two
custom functions namely pH & Switching. The detail description of
the logic is discussed below.
The first half of the ladder circuit includes a 30 seconds
timer & the custom function named as pH as shown below.

21

Figure 4.6 pH Sensor Ladder Logic Description

This half of the ladder logic diagram includes two circuits:
first circuit invokes pH custom function every 30 seconds while the
second circuit reloads the timer after it overflows.
One thing to bear in mind is that we have set the value of
pH to 8.5 because it is the WHO standard for de-Mineralized water.
Another reason is that the oil & gas purification process requires
water with a pH of 8.5 on scale.
From the pH custom function, it is clear that the pH sensor
circuit is connected to the analog channel#1 of the PLC. The PLC
reads value from the pH sensor every 30 seconds on its analog
channel#1. After getting the value, this value is scaled for an
accurate reading of up to one decimal place. If the value obtained is
less than 8, the PLC opens the base valve. If the value obtained is
greater than 8, the PLC opens the acid valve. These calculations are
shown in Fig 4.5 in pH custom function.

The second half of the ladder circuit includes a 2 seconds
timer & the custom function named as Switching as shown below.

Figure 4.7 pH Sensor Ladder Logic Description

This half of the ladder logic diagram includes two circuits:
first circuit invokes Switching custom function every 2 seconds
while the second circuit reloads the timer after it overflows. The
purpose of Switching custom function is to close down the acid or
base valves after every 2 seconds as shown in Fig 4.5.

22
4.2 CONDUCTIVITY CONTROL SYSTEM

In the conductivity module our main agenda is to maintain conductivity of
water by defining a range of conductivity. The sensor will be hanged from the top
of the tank through a solid PVC pipe of 1 diameter. This sensor will detect the
conductivity of water & pass the observed value to PLC after every 30 seconds.










Figure 4.8 Block Diagram of the Conductivity Control System
The basic working principle is that external 18 VAC is applied to the two
outer poles (electrodes) of the sensor. The produced voltage is measured between
the two inner poles. This voltage is directly proportional to the conductivity of the
solution. These received voltages are mapped onto the conductivity scale by the
PLC. The range set for conductivity is 0.0-2.0 uS/cm.

4.2.1 Hardware

The conductivity sensor used in this project includes four poles
(electrodes) design of stainless steel.














Figure 4.9 Four Pole Design Conductivity Sensor



De-Mineralizer
PLC
Conductivity
Sensor
HMI
Measuring
Electrodes
Drive
Electrodes
ACVoltage
Source
ACVoltage
Measurement

23
4.2.1.1 Working
The conductivity electrodes are inserted in the main
process tank from the top through a solid PVC pipe of 1
diameter. The electrodes are held tight so that during stirring of
the solution, there is no chance of damage to the electrodes. The
inner electrodes read voltages produced in the tank. These
readings are passed to the PLC through one of its analog inputs.
The timing difference between two consecutive readings
from the electrodes is minimum 30 seconds after mixing the
solution. This is because the electrodes are too much sensitive
to voltage changes in the solution. After 30 seconds of
continuous stirring, the solution produces constant voltages
which are accurate.
4.2.2 Software
The ladder programming done for the calculation of conductivity of
water is discussed below.

Figure 4.10 Ladder Programming for Conductivity Sensor

Figure 4.11 Custom Functions for Conductivity Sensor Ladder Logic

24
4.2.2.1 Conductivity sensor

The ladder program for the conductivity sensor consists of
two parts & includes timers of 30 seconds & 2 seconds along with
two custom functions namely Cond & Switching. The detail
description of the logic is discussed below.
Figure 4.12 Conductivity Sensor Ladder Logic Description
This half of the ladder logic diagram includes two circuits:
first circuit invokes Cond custom function every 30 seconds while
the second circuit reloads the timer after it overflows.
One thing to remember is that we have set the range of
conductivity from 0.0 uS/cm to 2.0 uS/cm because it is the WHO
standard for de-Mineralized water.
From the Cond custom function, it is clear that the
conductivity sensor circuit is connected to the analog channel#2 of
the PLC. The PLC reads value from the conductivity sensor every
30 seconds on its analog channel#2. After getting the value, this
value is scaled for an accurate reading of up to one decimal place. If
the value obtained is not within the range, the PLC opens the acid
valve as clear from Fig 4.11 in Cond custom function.
The second half of the ladder circuit includes a 2 seconds
timer & the custom function named as Switching as shown below.

Figure 4.13 Conductivity Sensor Ladder Logic Description

This half of the ladder logic diagram includes two circuits:
first circuit invokes Switching custom function every 2 seconds
while the second circuit reloads the timer after it overflows. The
purpose of Switching custom function is to close down the acid or
base valves after every 2 seconds as shown in Fig 4.11.

25
4.3 LEVEL MONITORING SYSTEM

In the level monitor module our main aim is to continuously have a check
on liquid level in all the three tanks. The level sensor visual display is installed on
the front of each tank & the sensor itself is inserted into the tank. Each sensor will
detect eight different discrete levels of liquid in the tank & pass the observed level
to PLC immediately.


















Figure 4.14 Block Diagram of the Level Monitoring System
The basic working principle is that a common ground is provided to the
lowest placed steel rod on the level strip. Whenever water reaches a certain level
where a rod is placed, the rod shorts out with the common ground thus providing a
complete flow path. This shorting out of the rod gives a voltage which is easily
detectable. The sensors used in this project are discretized at eight different levels,
giving a percentage difference of approximately 13% between two consecutive
levels.
For generating a conscious about the low level of acid or base in their
respective tanks, buzzers are installed for the acid & base tanks. These are low
powered buzzers operating at just 5 volts. The purpose of these buzzers is to alarm
the supervisor about the critical quantity of acid or base left in their respective
tanks. These alarms start buzzing whenever there is a level drop of acid or base
quantity from the minimum level of 12% in their respective tanks.



PLC



De-Mineralizer
Level Sensor


Acid Tank
Acid Level
Sensor
Alarm



Base Tank
Alarm
Base Level
Sensor

26
4.3.1 Hardware

The sensor used in this project includes nine stainless steel rods of
0.5 length. The reason for using this sensor assembly is its simplicity &
low cost. The circuit diagram of the level sensor is shown below:



Figure 4.15 Circuit Diagram of the Level Sensors
4.3.1.1 Working
The steel rods are attached to a hard PVC pipe at equal
distance from each other. The pipe is tightly bonded with the inner
side of tank so that there is no chance of reading errors. All these
rods of each sensor are wired to a digital input of the PLC.
Whenever a rod is shorted out with the ground, a high is received
by the PLC (PLC being active low). A level change will be detected
only if the rod at that level & all rods below it become shorted
1
2
3
4
5
6
7
8
J 1
CONN-SIL8
1
2
J 4
CONN-SIL2
DIGITAL INPUTS[1] DIGITAL OUTPUTS
1
2
3
4
5
6
7
8
J 2
CONN-SIL8
1
2
3
4
5
6
7
8
J 3
CONN-SIL8
BUZZ_A
BUZZER
BUZZ_B
BUZZER
ACID LEVEL SENSOR BASE LEVEL SENSOR DEMIN LEVEL SENSOR
DIGITAL INPUTS[2] DIGITAL INPUTS[3]

27
simultaneously. This is logical because the liquid cannot attain a
higher level without crossing the lower level.
Whenever the liquid level drops below the lowest level, the
buzzers attached to the digital outputs of the PLC are signaled &
they start generating alarms for the supervisor. This is an indication
that the acid or base is about to end that can halt the process in a
few minutes.
4.3.2 Software
The ladder programming done for the monitoring of liquid level in
different tanks is discussed below separately.

Figure 4.16 Ladder Programming for Level Sensors

Figure 4.17 Custom Function for Acid Level Sensor Ladder Logic

28

Figure 4.18 Custom Function for Base Level Sensor Ladder Logic

Figure 4.19 Custom Function for de-Mineralizer Level Sensor Ladder Logic

29
4.3.2.1 Level sensor
The ladder program for the level sensors consists of a single
circuit with a 0.5 seconds clock & three parallel custom functions
namely Acid_lvl, Base_lvl & DM_lvl. After every 0.5 seconds, the
three custom functions are invoked & level of the three tanks is
measured. The logic behind the level detection is simple: if a steel
rod at a random level is shorted along with all the rods below it to
the ground, then the level is detected. The shorting will only occur
when water reaches that level.
From the custom functions, it is clear that the PLC is
continuously monitoring its digital inputs. Whenever a combination
of the levels is received, PLC displays the appropriate level on the
LCD. In case of acid & base level sensors, buzzers are installed that
will start sounding alarm as soon as the level drops below 12% of
the total volume.

4.4 MAIN SWITCHING CONTROL SYSTEM

In the main switching module our main aim is to continuously monitor & control
the switching of valves, pump & stirrer. The main switching panel is installed on
the front of the de-Mineralizer tank. The switching panel controls the switching of
inlet valve, outlet valve, acid valve, base valve, AC pump & stirrer based on the
feedback from different sensors & some preset conditions.
















Figure 4.20 Block Diagram of the Main Switching Control System
PLC






De-Mineralizer
Stirrer
pH Sensor
Conductivity
Sensor
Level Sensor


Base Tank


Acid Tank
Acid Valve
Base Valve
Inlet Valve
Outlet Valve
AC Pump

30
4.4.1 Hardware
The main switching panel includes 24VDC relays & mechanical
buttons for power ON & OFF. All valves, pump & stirrer are connected to
the power sources through these relays.

Figure 4.21 Circuit Diagram of the Main Switching Control System
4.4.1.1 Working
The relays used in the main switching panel are 24 VDC, 5
pin relays. One of the two pins of the relay coil is connected to 24
VDC source. The second pin is connected to the PLC. In case of
valves & the AC pump, the NO (Normally Open) pin of the relay is
connected to 220 VAC. In case of stirrer, the NO pin is connected
to 5 VDC. The remaining two pins of all relays are left open.
As PLC is active low on its output terminal i.e. PLC gives
24 V for logic 0 & 0 V for logic 1. Therefore all relay coils are
permanently connected to a 24 VDC source. This is because
whenever PLC gives logic high on any of its output pin, the voltage
encountered is 0 volts. So for energizing the coil & completing the
circuit, we have connected the one end of all relay coils to 24 VDC
source. On the other hand, a relay will never switch when PLC
gives logic low (24 V) because both ends of the coil will be at same
potential thus blocking the electric path.
RL1(NC)
RL1
TEXTELL-KBE-24V
RL2
TEXTELL-KBE-24V
RL3
TEXTELL-KBE-24V
RL4
TEXTELL-KBE-24V
RL5
TEXTELL-KBE-24V
RL6
TEXTELL-KBE-24V
RL3(NC)
SWITCHING PANEL
STIRRER AC PUMP OUTLET VALVE
INLET VALVE ACID VALVE BASE VALVE
1 2 3 4 5 6 7
J 1
SIL-100-07
DIGITAL OUTPUTS
PLC

31
4.4.1.2 Parts list
PART DESCRIPTION QUANTITY
24 VDC Relays 6
2 pin MOLEX 7
2 pin Cream Shell 5
ON/OFF Switch 2
Table 4.2 Components detail of Switching Panel
4.4.2 Software
Below is the ladder logic implemented for the switching panel of the
de-Mineralized water plant.
Figure 4.22 Ladder Programming for Switching Panel

Figure 4.23 Custom Function for Switching Panel Ladder Logic

32
4.4.2.1 Switching panel
The ladder program for the switching panel consists of a 0.5
seconds clock & a custom function named Switch.
After every 0.5 seconds the Switch custom function is
invoked. In this function, two digital inputs are constantly
monitored by the PLC namely High_lvl & Low_lvl. These two
levels are the high & low levels of the de-Mineralizer tank
respectively. Whenever the water level reaches its lowest value, the
PLC switches ON the AC pump & the inlet valve. On the other
hand, whenever water level reaches its maximum value, the PLC
switches OFF the AC pump & the inlet valve & starts the stirrer.
On the other hand, the PLC is also continuously monitoring
the pH & conductivity analog inputs. Whenever the pH value
reaches 8.5, the PLC turns off the acid & base valves. If the pH
value is other than 8.5, the PLC switches acid & base valves
according to the logic defined in the custom function.

33
Chapter 5
TESTING & VALIDATION
Before implementing each module the proposed design was first tested through
software. Only after getting satisfactory results the design was put into practical use.
The logic that was developed and transferred to the PLC was first tested on the
TRILOGI Simulator to ensure that it worked as planned.
5.1 SOFTWARE TESTING
The TRILOGi has a built-in simulator for test and debugging. Before
transferring the whole program to the controller; the program was tested through the
simulator. A shot screen of the testing process is shown below:

Figure 5.1 Simulator Screen 1
It shows the various operations being carried out by the PLC. The red
highlighted icons indicate that these inputs and outputs are currently activated. In
addition to this the timer counter and relay icon numbers are also highlighted when the
controller activates them.
Similarly the screen shot shown below shows the values of different variables
used by the programmer from A to Z. it also shows the time, date and the analog

34
values from the A/D and D/A convertors of the PLC. The display area shows the items
that will be displayed on the LCD which is connected to the PLC.

Figure 5.2 Simulator Screen 2
The values of the Data Memory (DM) elements from 0-4000, the contents of
the strings used by the programmer from A$ to Z$ and the values of the relays, timers
and counter bits are also displayed and checked through the simulator. The screen
shots are shown in the same order.

Figure 5.3 Simulator Screen 3

35

Figure 5.4 Simulator Screen 4

Figure 5.5 Simulator Screen 5
5.1.1 SERIAL COMMUNICATION SETUP AND TEST
To test that the COM port is working properly or not, a test
command is sent to the PLC which in return sends its ID number back. The
test command is IR*. The PLC replies with IR*01 if the connection is
correct. Else it sends a message of no response from the PLC. Both the
scenarios are shown below.

36

Figure 5.6 Serial Port Testing 1

Figure 5.7 Serial Port Testing 2

37
Chapter 6
CONCLUSION & RECOMMENDATIONS
6.1 CONCLUSION
In the implementation of this project Design of Control System for a de-
Mineralized Water Plant it was really necessary to develop a strong understanding of
the various component used in this project. Many different ways can be deployed to
make the designing and automation more efficient and time effective. The super
PLCs are more applicable to industrial automation and mechanization where a
multitude of operations are to be conducted in a short time interval.
Such prototype designs can help industries to train there new entrants before
even putting them into practical field. The miniature size of this project as compared
to the actual plants used in industries can help engineers visualize the working of the
whole plant. On the other hand, such small scale plants can be implemented in rural
areas where healthy drinking water is not available. Besides the usage of plant as
drinking water plant, such plants can be applied in rural areas for the need of small
scale industries.
In short this project can go a long distance in acquiring various objectives for
practical & industrial applications which can truly make some major step forward in
achieving a power saving and secure environment around us.
6.2 RECOMMENDATIONS
Some of the future advancements which can be done in this project are
1) A Pre-Carbon filter can be applied so that the free chlorine & oxygen mixed in
the raw water can be removed before passing the water to de-Mineralizer.
2) A boiler can be attached to the output of the plant so that processed water can
be passed to it, leading to a more industrially optimized setup.
3) Cationic & Anionic beds can be attached to the plant so that the pH maintained
water is passed to it, leading to an efficient removal of cations & anions from
the water.
4) Parameters such as TDS, Hardness, and Salinity of water can also be
maintained so that a more refined & optimized industrial product is furnished.

38
REFERENCES
LINKS
T100MD+ PLCs SOFTWARE DOCUMENTATION
http://www.tri-plc.com/documentlist.htm#TRILOGI
SIMPLEST POSSIBLE pH Meter
http://www.66pacific.com/ph/simplest_ph.aspx
CONDUCTIVITY THEORY & PRACTICE
http://www.tcd.ie/Biochemistry/courses/js_conductivity.pdf
PRINCIPLES AND HARDWARE OF ELECTROLYTIC CONDUCTIVITY
M EASUREM ENTS
http://www.alliancets.com/site/files/408/.../White_Paper_-_Conductivity.pdf
pH THEORY
http://www.en.wikipedia.org/wiki/PH
ELECTRICAL CONDUCTIVITY THEORY
http://www.en.wikipedia.org/wiki/Electrical_conductivity
DE-MINERALIZED WATER
http://www.lenntech.com/demi-water.htm
DEMIN WATER FAQs
http://www.lenntech.com/demi-water-faq.htm
T100MD2424+ PLCs DATASHEET
http://www.tri-plc.com/t100md2424.htm
BOOKS
Process Control Systems (Applications, Design, & Tuning) by F. G. Shinskey
(2000), McGraw Hill, Singapore, 393-404 & Appendix A
Process Control Instrumentation Technology by Curtis D. Johnson (2000),
Prentice-Hall, USA, 1-40, 47-97, & 220-222

39
APPENDIX A.1
PIPING & INSTRUMENTATION DIAGRAM (P&ID)

40
APPENDIX A.2
PROCESS FLOW DIAGRAM (PFD)

41
APPENDIX A.3
CAUSE & EFFECT DIAGRAM (C&ED)
ISHIKAWA DIAGRAM or FISHBONE DIAGRAM

42
APPENDIX A.4
FIELD DEVICES
pH PROBE (HI 1333)


CONDUCTIVITY PROBE (InLab731-2m)

43
VALVES (2W-160-15)



PUMP (AI-S)



STIRRER MOTOR (DME38S6HPB)

44
APPENDIX A.5

CONNECTIONS (PLC & FIELD DEVICES)

Device Connection Type Pin #
pH Sensor Analog ADC(1)
Conductivity Sensor Analog ADC(2)
Acid Level Sensor
(Lowest Level)
Digital OUT 11
Base Level Sensor
(Lowest Level)
Digital OUT 12
Water Level Sensor
(Lowest Level)
Digital OUT 14
Water Level Sensor
(Highest Level)
Digital OUT 15
Acid Valve Digital OUT 3
Base Valve Digital OUT 4
Inlet Valve Digital OUT 5
Outlet Valve Digital OUT 6
AC Pump Digital OUT 1
Stirrer Digital OUT 2
Acid Tank Buzzer Digital OUT 7
Base Tank Buzzer Digital OUT 8