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CH4510: Process Control Lab

Controlling Water Level in Tank using PLC

Submitted by
CH12B024 E. Aswin Jayan
CH12B025 E. Sai Krishna Koushik
CH09B068 Kaniganty Prudhvy Vamsy Krishna
CH08B009 A Chakravarthy Thalluri

Introduction
A Programmable Logic Controller, or PLC, is more or less a small computer with a built-in
operating system (OS). This OS is highly specialized to handle incoming events in real time, i.e.,
at the time of their occurrence. The PLC has input lines where sensors are connected to notify
upon events (e.g. temperature above/below a certain level, liquid level reached, etc.), and output
lines to signal any reaction to the incoming events (e.g. start an engine, open/close a valve, etc.).
The system is user programmable. It uses a language called "Relay Ladder" or RLL (Relay
Ladder Logic). A PLC is primarily used to control machinery. Programs written for PLCs
consists in simple terms on instructions to turn on and off outputs based on input conditions and
the internal program. In this aspect, it is similar to a computer. However, one designed to be
programmed once, and run repeatedly as needed. In fact, a crafty programmer could use a PLC
to control not only simple devices such as a garage door opener, but their whole house, including
switching lights on and off at certain times, monitoring a custom built security system, etc.
Most commonly, a PLC is found inside of a machine in an industrial environment. A PLC can
run an automatic machine for years with little human intervention. They are designed to
withstand most harsh environments.

Using Siemens Software


1. Create a new project or open an existing project for the programming
2. Configure the device by going to Device and Networks, and clicking Add new device
3. Choose the controller (here, simatic S7 1200).
4. Choose the CPU number and model, then add it.
5. Go to Properties>Ethernet option and give the ip address (192.168.0.1)
6. Click on Download to device
7. Under Type of the PG/PC interface, select PN/IE
8. Successful configuration message should appear
9. Create a new program by clicking Main(OB1)
10. Drag and drop the Nc contacts from right side instruction window
11. Give the address for all instruction in the program window
12. Download software and hardware configuration by clicking on Download to Device icon
in taskbar.
13. Click on Go online in taskbar to observe the execution of the program

Problem Statement 1
1. Initially, all the valves are closed, and the tank is empty.
2. At start, open the input valve until the upper sensor is activated.
3. Perform the following iteratively:
a. When the water level rises above the upper sensor, close the input valve and open
the output valve
b. When the water level falls below the lower sensor, close the output valve and
open the input valve.
4. Execute Step 3 for 5 iterations.
5. Close the input valve and open the output valve. When the tank is empty, terminate.

Network 1

Label

Equipment

i0.0

Top Sensor

i0.1

Bottom Sensor

Q0.0

Motor

Q0.1

Solenoid Valve

Problem Statement 2
1. Initially, all the valves are closed, the mixer and the heater are off, and the tank is empty.
2. At start, open the input valve until the upper sensor is activated.
3. Perform the following iteratively:
a. When the water level rises above the upper sensor, close the input valve and start
the mixer and the heater
b. When the temperature of the water rises above 50 oC, stop the heater and the
mixer, and start the output valve.
c. When the water level falls below the lower sensor, close the output valve and
open the input valve.
4. Execute Step 3 for 5 iterations.
5. Close the input valve, and open the output valve. When the tank is empty, terminate.

Network 2
Label

Equipment

i0.0

Top Sensor

i0.1

Bottom Sensor

Q0.0

Motor

Q0.1

Solenoid Valve

Q0.2

Heater

Q0.3

Stirrer

Problem Statement 3
1. Initially, all the valves are closed, the mixer and heater are off, and the reaction tank is
empty.
2. At start, open the solution input valve until the intermediate sensor is activated.
3. Perform the following simultaneously:
a. When the solution level rises above the intermediate sensor, start the mixer. When
the solution level drops below the lower sensor, stop the mixer
b. Whenever the temperature of the solution is below a preset value, start the heater.
c.
i.
Whenever the pH of the solution is unbalanced, open the neutralizer input
valve
ii. If the tank becomes full, close the neutralizer input valve. Then open the
secondary output valve until the solution level falls to the position of the
intermediate sensor Then close the secondary output valve and continue
(i).
4. When both the temperature and the pH of the solution are correct, stop the heater and
close the neutralizer input valve. Then open the primary output valve.
5. When the tank is empty, close the primary output valve and continue from 1.

Network 3

Conclusion
By simulating the network through Siemens with physical equipment, we have observed the
system to follow the guidelines stipulated in the problem statement.

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