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Liquid Level Monitoring and Flow based Liquid

Distribution System using PLC and SCADA
Mr. Lavanuru Ashok Prof. B. Rama Murthy
Research Scholar, Research Supervisor (Retd.),
Department of Instrumentation, Department of Instrumentation,
Sri Krishnadevaraya University, Sri Krishnadevaraya University,
Ananthapuramu, A.P., India-515003. Ananthapuramu, A.P., India-515003.

Abstract—The objective of the present work is to design, 50% then adjust feed valves to their positions to feed water
develop &testing of the Liquid Level Monitoring and Flow and then control temperature.
Based Liquid distribution System Using PLC and SCADA In
simulation mode. The paper mainly focuses on liquid level Waste water treatment is the process of
monitoring; calculate the flow rate in liquid flow line and the remove contaminants wastage minerals from wastewater and
process in automatic mode with proper safety interlock and converts it into an effluent pure drinking water that can be
alarm. The system will provide real time process operation and returned to the water cycle with minimum impact on the
parameters monitoring by process animations. The essence of environment, or directly reused. Wastewater treatment process
this paper is to convert the manually operated plant to fully
consists of the following operations like filtering, elimination
automated plant for achieving higher accuracy, efficiency and
time saving for the process industries.
of the colloids through the process physical-chemical clotting
and flocculation, treatment to regulate the Ph of the water,
Keywords—Flow, Level, PLC and SCADA biological treatment process, finally decanting and sludge
extraction. The complete sequential process executed with
I. INTRODUCTION automation like PLC/SCADA system, in the system
continuously Monitoring and controlling of process
This present work is implemented in pharmaceutical, parameters like flow rates, level, temperature and various
petrochemical and some of Oil industries suffered fire control valves.
incidents with Flammable Liquid Level overflow of tanks and
carrying Liquid From one place to another place transforming In food, chemical and petrochemical industry, level
with manual operation procedure. So the present system measurement and monitoring of liquid substances products in
proposed to continuous monitor of Liquid Level of tank and tanks and different types of storage places, in this process we
safe transferring Liquid from one place to another place. Any must know the level of the storage tanks. So most of the
manufacturing plant requires continuous monitoring and process industries used PLC/SCADA system to measure and
observation at regular intervals. When it is controlled display of their volume of storage tanks, the process industries
manually, it increases possibilities of errors at measuring level have some of liquids too expensive and flammable so the
of a process. To overcome such problems concept of during the loading and unloading operations, leakage control,
automation came into play. The automation system of oil continuous monitoring of liquid storage tanks
refinery consists of crude oil storage/pre-treatment system,
distillation operations and product storage/dispatch unit in II. SYSTEM IMPLEMENATATION
these operations the system consists of feed pumps, valves,
motors, flow, level, pressure, temperature monitoring
transmitters, unit tanks. The process industries consist of
SCADA used to monitor all these parameter values, to start or
stop operations from GUI (Graphical user interface) like
SCADA and to supervise the unit operations. Control of these
operations are from PLC which is consist of the internal
storage of instructions for implementing functions such as
logic, sequencing, timing, counting and control various types
of machine operations, In the PLC/SACAD based boiler
automation system have various stages involved in measure
and control of water level in storage tank, maintain pressure in
stream line, calculating the flow rate in stream line and
continuous monitoring and controlling of boiler temperature.
The boiler temperature controlled by Variable Frequency
Drive (VFD), for preceding all these operations, water
maintained at least at 50%. For sensing water level PID
controller is used in PLC. If water is not available minimum Fig. 1. Block diagram of Proposed System

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• The operator is assist by computer that recommends

actions to keep the system safety.
• Many types of data can be collected from the PLC; this
creates online the image of the System.

C. Flow Sensor/Transmitter
A Flow sensor/transmitter is a device that they know
exactly how much fluid is passing through a point at any
Liquid flow line. The flow meter is used to measure linear,
non-linear, mass or volumetric flow rate of a liquid or gas.
Many industrial flow meters have to work with fluids which
may be corrosive in nature or may contain foreign matters, but
the equipment may be relatively large and of fixed type. The
Fig. 2. Schematic Diagram choice of a particular flow metering device are the various
performance parameters like range, accuracy, repeatability,
The block diagram consists of the following units
linearity, dynamic response , type of output like analog/digital.
1. PLC The process industries preferred to measure the flow rate of
2. SCADA PC liquid flow line used to vertex-shedding flow meters.
3. Flow sensor The vertex-shedding type flow meters operate on the
4. Level sensor principle that if a bluff body (non-streamlined body) or an
5. Digital Inputs obstruction is placed in a fluid stream, vortices are shed
6. Pump CMDs alternately on each side of the bluff body. The vertex shedding
7. Valves CMDs frequency of the bluff body is a measure of the average flow
8. Monitor velocity of the fluid flow. The output of the flow meter in both
9. Printer cases is electrical and can be suitably processed to either
indicate instantaneous flow or totalized flow.
A. Programable Logic Controller
D. Level Sensor/Transmitter
Programmable Logic Controller (PLC) is a digital
A Level sensor/transmitter is a device used to
computer used for the automation of various
measure and monitoring of the level of liquid within a tank,
electromechanical processes in industries. PLC consists of a
the level measurement can be either continuous or point
microprocessor which is programmed using the computer
values. Continuous level sensors measures the level within a
language. The program is written on a computer and is loaded
specified range and determines the exact amount of substance
into the PLC via communication cable. These loaded
In a certain place, So present process plants proposed to
programs are stored in nonvolatile memory of the PLC.
continuous monitor of Flammable Liquid Level of tank used
During the transition of relay control panels to PLC, the hard
with Differential Pressure Level Transmitter (DPLT) or
wired relay logic was exchanged for the program fed by the
hydrostatic pressure level measurement device(HPLMD).
user. A PLC is an example of a hard real time system since
The hydrostatic pressure created by a liquid is
output result must be produce in response to input condition
directly to the height of the liquid column, a pressure gauge is
within a limited time, otherwise unintended operation will
installed at the bottom or on the side of the tank containing the
result. A visual programming language known as the Ladder
liquid. The rise and fall of the liquid level causes a
Logic Programming (LLP) and Functional Block Diagram
corresponding increase or decrease in the pressure, which is
(FBD) Language has been used to program the PLC.
proportional to the liquid level. The scale of the pressure
B. Supervisory Controland Data Acquistion System gauge is calibrated in the units of level measurement.
SCADA stands for Supervisory Control and Data E. Digital Signalling
Acquisition. As the name indicates, it is not a full control
Digital Input means it is a discreet electrical signal with
system, but rather focuses on the supervisory level, it is used
specified voltage above/below a specific threshold voltage,
to monitor and control plant or equipment. The control may be
normally in process industries designed for different voltage
automatic or initiated by operator commands. The data
levels like 0-5Vdc, 0-12Vdc or 0-24Vdc as depends upon the
acquisition is accomplished firstly by the PLC scanning
process requirements. This Digital Inputs indicates status and
through field inputs connected to the PLC. SCADA provides
position of the process instruments like solenoid Valves status
several unique features that make it a particularly good choice
open or close position.
for many control problems. The features are as follows
A solenoid valve is an electromechanical actuated valve
• The computer control primary equipment, record an store they have a simple form of an electromagnet consisting of a
a very large amount of data from process. coil of insulated copper wire. A solenoid valve is an
• The operator can incorporate real data simulations into the electromechanical valve frequently used to control the flow of
system. liquid or gas. A 2-way solenoid valve have 2 ports; if the

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valve is open, then the two ports are connected and fluid may • Click on Auto button from SCADA screen to keep the
flow between the ports; if the valve is closed, then ports are system in Auto mode.
isolated. If the valve is open when the solenoid is not
energized, then the valve is termed normally open (N.O.). • Then select the Transferring button for transferring
Similarly, if the valve is closed when the solenoid is not liquid/Solvent
energized, then the valve is termed normally closed • There is a face plate related to transferring operations
appears on SCADA screen
III. SOFTWARE IMPLEMENATATION
• Select the destination where liquid/solvent is to b
Ladder Logic Programming (LLP) and Functional Block transferred.
Diagram (FBD) Language has been used to program the PLC.
For this purpose Unity pro XL Simulation Software (PLC) • Enter the set quantity that much of liquid transferred into
and vijeo citect SCADA has been used as simulator. The selected destination.
programming logic has been set according to the process flow • Click on confirm button.
and Tantalizer (TOT) has been used in the program to
tantalize the cumulative liquid Quantity while liquid flows • If all the interlocks satisfied then operations will
through the Flow meter. confirmed otherwise doesn’t confirmed.
• If operation confirmed then click on Start button.
IV. ALGORITHM
The Algorithm of entire system is presented below as • Observe destination, dispensing, suction solenoid valves
shown in the Fig 3. are opened followed by pump starts running to transfer the
liquid/solvent from source tank to destination.
• If Level in source tank decreases and flow sensor in line
senses the liquid/solvent flow then operation remains
continues otherwise operation will be paused
automatically. That means all the opened valves are closed
and pump stops.
• After transferring the liquid/solvent by the set quantity
given then operation completed automatically and opened
valves are closed and pump stops.(Or)While liquid/solvent
pumping, when flow sensor totalizes the flow rate
equivalent to the given set quantity then operation
completed automatically and opened valves are closed and
pump stops.
A solenoid valve is an electromechanical on/off valve
operates with 12v dc power supply. The solenoid valves
operating from SCADA system then arrange the feedbacks for
valve position status and commands for valve opening and
closing in remote mode. The program written into process
consideration, suppose the two feedbacks i.e., open feedback
signal, closed feedback signal and open command signal of a
solenoid on/off valve from field will be connected with PLC
configured in software. The basic concept of operation of
solenoid valve communicates with PLC under Supervisory of
SCADA system. Following are the list of required PLC digital
input and digital output channels.
• %I0.4.2 (ST09_XV01_OFB) is the Digital input signal
from open feedback of valve.
• %I0.4.2 (ST09_XV01_OFB) is the Digital input signal
from closed feedback of valve.
• %Q0.9.1 (ST09_XV01_CMD) is the Digital output signal
to open command of valves.
Following figure represents that PLC Hardware Configuration
and channels.

Fig. 3. Software Algorithm

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affected by the mode of operations and interlocks explained in

following table.
B. Pump/Motor Block in SCADA screen

Fig. 7. Pump/Motor Indication

Tag - This field will represent tag of Pump.

Mode - This field will represent pump Operating Mode.
The motor states are follows as below figure.

TABLE I. PUMP/MOTOR STATUS

Fig. 4. PLC Hardware Configuration

The above address are configured for the ST09_XV01

solenoid valve, the valve in normally closed condition
ST09_XV01_CFBtag address is %I0.4.2 High(ONE) in PLC
System. If the valve in normally open condition
ST09_XV01_OFB tag address is %I0.4.3 High (ONE). When
in operator need to open the valve simply high the
ST09_XV01_CMD tag address %Q0.9.1 need to High (ONE)
from PLC, then solenoid valve normally open and %I0.4.2
address LOW(ZERO) and %I0.4.3 high(ONE) until %Q0.9.1
is high. Finally the PLC memory address linked with the
C. Flow Monitoring Block in SCADA screen
SCADS memory address, when changes in the PLC address
location then automatically changed in SCADA address A Flow Meter is a device used to measure the instant
locations as depend upon the software configuration following flow rate or quantity of a solvent, liquid or gas passing
figure. through a pipeline. Flow Transmitter is the upgrade of flow
meter where transmit the flow value data to monitoring system
A. Solenoid Valve Indication in SCADA screen (SCADA). Flow data from Flow Transmitter in the form of 4–
20 mA (mille amps) currents.

Fig. 5. Solenoid valve Indication

Mode - This field will represent valve Operating Mode.

Tag - This field will represent tag of Valve.
Following are the different types of valve position status and Fig. 8. Flow Monitoring
significant colors represented.
Flow transmitter is the device used to transmit data from a
flow sensor over the two-wire 4-20 mA current loop. The
transmitter converts the physical signal such as flow rate into
the necessary electrical signal in the form of 4 to 20mA
current loop. The scaling of loop current is adjusted by the
transmitter to be proportional to the actual input physical
signal. The transmitter typically uses 4mA output to represent
Fig. 6. Solenoid valve Status/Control. the calibrated zero input or 0%, and 20mA output to represent
a calibrated full-scale input signal or 100%. The relationship
By click on off valve symbol on SCADA graphics by user, between the output current value and transmitter converts the
using “display popup” as event of button the below popup will physical process value is set by calibration of the transmitter,
be displayed as a child screen of main screen. There is a which assigns a different range of engineering units to the
facility to close the popup after controlling on off valve in that span between 4 and 20 mA. The transmitter signals are
popup. The three buttons in the below popup is executes their connected to 4-20mA loop powered isolator is typically used
respected functions. These buttons are enable or disable to provide an isolated 4- 20mA current loop from any existing

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4-20mA loop. This isolated 4-20mA can then be connected to Flow Monitoring Block in SCADA screen as follows.
any input stage without affecting other signals connected to
the system. Alternatively the isolator can be used to isolate
signals from non-isolated transmitters or as a noise reduction
device.

Typical analog flow signal from isolator is connected to AI

Module. Analog input signals are current or voltage. Analog Fig. 9. Flow Indication
input modules convert analogy signals to digital words as
following table. The I/Os are connected through a program TAG - This field represents Flow transmitter tag.
called as Software configuration, as there is no direct-physical PV - This field represents Flow Rate in pipe line.
relation between input and outputs. The program is written UNITS - This field represents Process variable Units of FT
into process consideration. Flow signal from field will be output.
connected with PLC based on communication protocol,
V. PROCEDURE OF TRANSFERRING OPERATION
configured in software as follows.
The process of transferring a fixed quantity of fluid
• %IW0.1.1 is the Analog input signal from flow from a source of storage tank to destination which could
sensor/transmitter. be receiver tank or container is known as “Transferring”.
The Flow Based transferring of liquids from storage
TABLE II. ANALOG DATA PROCESSING Tanks to Receiver tanks process flow chart can be
described as follows. All the following process can be
Analog Data Signed data by Scaling range done through SCADA graphics by operator.
S.No.
in AI Module the Processor in SCADA
1 4 mA 0 0 LPM
2 8 mA 2500 50 LPM
3 12 mA 5000 100 LPM
4 16 mA 7500 150 LPM
5 20 mA 10000 200 LPM

MONITORING SCREEN

Fig. 10. Manual Mode Screen

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First keep the process in auto mode by click on Auto button from SCADA screen.

Fig. 11. Auto Mode Screen

Select the operation needed to be performed i.e. transferring. Click on Confirm button for transferring from source tank to
Then select the destination which could be a defined destination, before confirming the process following are the
destination. Enter the quantity as a set point which needed to Safety interlocks or pre check conditions for dispensing.
transfer from source storage tank to destination. • On/Off valves, pumps, & level switches status indication
should be provided with red color animations in
operating SCADA screen.

Fig. 12. Interlock warning Screen

• Level in the storage tank should be maintained. Entered set The system will have all the above pre check conditions and
quantity of the solvent should available in the selected any one of interlock is not satisfied then operation does not
source Tank. confirmed. The enabled interlock displayed on SCADA
operating screen, operator has to check and confirm the
• Continuous level monitor from level transmitters of operation. Interlock enabled then screen appears as follows.
storage tanks is required.
• Continuous flow monitor on pipe line is required.

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If operation confirmed then screen appears as follows.

Fig. 13. If operation confirmed then screen appears as follows

After confirm click on Start button to transfer operation. source tank to destination. SCADA system will have Flow
Destination, transferring, suction solenoid valves are opened animation of solvent, on off valves and pump status with
followed by pump starts running to transfer the liquid from color indication during dispensing.

Fig. 14. Liquid dispensing operation screen

If any one of the following deviation occurs in the middle of • If there is no change in the storage tank level and if there is
the process then the process will be paused. no change in the line flow.

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• If pump dry run or tripped or failed. • During dispensing of the solvent if any one of other valve
is opened manually from field (override).
• If any one of the dispensing valves open feedback is not
received to PLC or valve fails. • If liquid level/Level switch in the storage tank goes low.

Fig. 15. Interlock enabled then pause screen.

The enabled interlock displayed on SCADA operating Completed automatically pump turns off and
screen. It must be corrected or instrument need to be corresponding valves are closed. Then the process
trouble shoot. Then user comes back and process start complete successfully. Stop is provided in SCADA
again by click on start button. screens, which stops transferring operations if necessarily.
While liquid pumping, when flow sensor totalizes the flow
rate equivalent to the given set quantity then operation

Fig. 16. Liquid dispensing completed screen result

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[12] Li, Jiangye & Xiong, L & Peng, N & Dong, Bob & Wang, P & Q.
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