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Solution for Water Wells and Tank Control System

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 Journal of Electrical Engineering, Electronics, Control and Computer Science
JEEECCS, Volume 2, Issue 4, pages 1-6, 2016

Solution for Water Wells and Tank Control

System
Cristian PÎRVU1, Costin CEPIŞCĂ2
1
Polystart Craiova, Romania
2
POLITEHNICA University of Bucharest, Electrical Engineering Faculty, Romania
[email protected], [email protected]

Abstract - This paper presents the design and - Magelis XBT RT500 – Alphanumeric semi-graphical
implementation of a modern control system for a water unit;
wells network for capturing and collecting raw water. The - PM710 – power monitoring unit;
main components are the programmable logic controllers - MPC – control panel of the Grundfos pumping group.
and interface terminals, designated for small and medium
Interfaces used: Ethernet & optical fiber, RS 485 and
applications. Components such as sensors, actuators or
RS232.
visualization features are connected via digital or analogue
input or output modules or through communication Standards and communication protocols: Modbus RTU,
channels. An essential element of this application is the Modbus TCP/IP, GSM/GPRS.
communication system. The presented system allows all the basic functions of the
pumping station automation: surveillance, control and
Keywords - water well, tank, pump, distributed system, interlocking, sequential automatic management, change of
remote control PLC, HMI, Modbus, Ethernet, RS485. adjustable parameters, alarms and event management, self
diagnosis, communication with other systems.
Schematic and panel drawings presented in Fig.2 have
I. INTRODUCTION
been created in AutoCAD.
The water intake stations are operated by automation The simplified logic diagram shown in Fig. 3 was
systems and, today, remote control and remote operation developed and drawn from initial information obtained
play a significant role in automation. [1], [2], [3]. The from the operational description of a water well.
paper presents a control system implemented for
capturing and collecting raw water, an efficient and
reliable method of information gathering and viewing.
The PLC is suitable for complex solutions in the field of
measurement and control [4], [5]. Programmable Logic
Controller (PLC) devices have different benefits, such as
computing performance or capacity to communicate
using different interfaces: RS232, RS485, and Ethernet.
Complex methods of control can also be treated by a
compact PLC. Another characteristic is a combination of
basic types of control systems, distributed and integrated Figure 1. Block diagram of the system
systems. The advantages of both systems can be
combined.

II. SYSTEM ARCHITECTURE AND FUNCTIONALITY

Four well pumps starters and corresponding water tank,
located approximately 2 km from each other, were
interconnected by a single-mode optical fiber line.
Using Schneider Electric products, it was designed a
flexible structure, easily reconfigurable, with monitoring
and control facilities [6] – [9].
The hardware solution shown in Fig. 1 included:
- Modicon M340 PLC – with I/O extension modules;
- Magelis XBT GT – multifunction graphic terminal off
XBT GT6330 touch screen type; Figure 2. Electrical diagrams
- Twido – programmable logic controllers of TWD
LCDE40DRF type;
 2 Cristian PÎRVU, Costin CEPIŞCĂ

System functions implemented al local level:

- self diagnosis of the automatic system;
- logics for start/stop commands;
- emergency stop;
- display all process information on touch screen;
- secure commands on desktop screens;
- alarming at exceeded periods, previously established
intervals to stop pumping;
- Counting the number of pumping on the day;
- Warning about the communication status between
programmable controllers and HMI terminal;
- selecting manual/automatic mode,
- under local /remote control (software switch).

Figure 4. Automation and electrical panels

The central equipment, a data concentrator, was made

Figure 3. An example of logic diagrams with a Modicon M340 programmable controller that
ensures the functioning of the whole system, depending
For each objective, it has considered the existence of on the water level in the reservoir and water
operating modes such as manual mode or automatic consumption. Furthermore, it provides remote start/stop
mode with local control, useful at commissioning and and setpoint commands for the pumping group equipped
maintenance, other than the normal working regime, the with inverter. It also acts as the communication master
automatic-remote mode, depending on the water level that polls all sites.
and operating permission. System functions implemented:
For electrical parameters monitoring and energy - level measurement;
measurements has provided a Merlin Gerin PM700 - upper and lower limit on the input or output signal
power meter. (setpoint limits, according to operating mode)
There are many sets of sensors: level switches and - software configurable level thresholds;
ultrasonic level transducers, with 4-20 mA analog output, - selecting manual/automatic mode;
to determine the presence of water in wells or degree of - under local /remote control (software switch);
filling of the tank. In addition, there are flow meters, - periodically rotate the switching order to equalize run
pressure gauges with contacts and a pressure transmitter, hours;
disposed on the discharge pipes at the each installation. - emergency stop;
The submersible pumps from the water wells line can - display all process information on touch screen;
operate independently of each other, by implementing the - secure commands on desktop screens;
programmable controllers for command, control, - warning about communication status.
protection and signaling. The whole functioning was first tested in the laboratory,
The PLCs provided in electrical panel (Fig. 4) of the under conditions simulating the real process (Fig. 5).
water wells ensure access to information via HMI while
facilitating remote data transmission to higher-level
control:
- discharged flow;
- circuit breaker / contactor / softstarter faults;
- pump status (on / off);
- water level (minimum / maximum);
- number of starts per day;
- pump operating time;
- monitoring supply voltage range in electrical panel;
- lack of control voltage 24 Vdc;
- unauthorized door opening in well or electric panel; Figure 5. Laboratory for testing and programming
 Solution for Water Wells and Tank Control System 3

III. PLC SOFTWARE PACKAGE instructions that appear like boxes of instructions. The
Starting from automation graphs, the program for Twido program logic is implemented through modes of
PLCs has been implemented in Ladder language through connection between these boxes of instructions.
the editor of the TwidoSuite programming environment The FBD bistable function blocks (SR and RS) consist of
from Telemecanique (Fig. 6). Previously were assigned two stable states controlled by one or more inputs.
input and output PLC variables and internal memory Starting from level 2 GRAPHCET of the application, the
variables, of boolean, integer or real type, delay blocks, programs were made using bistable blocks of RS type,
pulse counters. with reset dominant entry: Q n+1 = R . (S + Q n)
Variables are attached to graph stages, represented by the
outputs of bistable blocks. The entries correspond to the
activation functions of the stages, while the reset inputs
are the steps to be activated when the current stage is
disabled.
Repetitive used basic functions are encapsulated in user
function blocks DFB (Derived Function Block) in IEC
61131-3 language. DFB types are function blocks that
can be programmed by the user ST, IL, LD or FBD. The
application uses a Level DFB (Fig.8), with level limits
and thresholds, and a Flow/Pressure setpoint DFB.

Figure 6. TwidoSuite programming environment

Schneider-Electric Unity Pro is the software environment

for designing and programming of the central
programmable controller. It is an high performance
multitask software, offered for the Modicon M340 and
the Premium or Quantum PLC‘s.
An example of the Unity Pro application in design stage
is presented in Fig. 7.

Figure 8. Function block DFB

Figure 7. Unity Pro software package

IV. COMMUNICATION PROTOCOL
Unity Pro makes the best use of the graphic and context- Communicating via Modbus enables data exchange
sensitive interfaces of Windows operating systems. It between all devices connected to the bus. The RS485 bus
offers five IEC 61131-3 languages as standard. Each consists of one master station and several slave stations.
section of code can be programmed in the language of Only the master station can initiate the exchange (direct
user’s choice, best adapted to each processing operation. communication between slave stations is not possible).
All of the edit, debugging and operation tools are The Modbus protocol is a communication protocol that
accessible whatever language is used. The main benefit is creates a hierarchical structure. A master, in this case the
in a complete set of functions and tools enabling PLC, addresses slave devices individually, the power
modeling of application structure on any machine or monitoring unit and the control panel from the pumping
process structure. The program is split into organized group, then these devices return the reply to the
function blocks by grouping: program sections, animation requests.
tables, operator screens and hyperlinks. The use of serial connection to transmit and receive
FBD (Function Block Diagram) editor is a program that characters through Modbus RTU protocol requires serial
allows viewing of the instructions through logical boxes, port configuration for master and slave devices, related
very similar with logic gates (AND OR NOT XOR, etc.) communication parameters. The BMXNOM0200
in digital electronics. There are no contacts or relays 2-channel serial link module is particularly recommended
found in Ladder editor, but can be found equivalent for this type of use. Physical interfaces:
 4 Cristian PÎRVU, Costin CEPIŞCĂ

- RS 232 port 0: RS 232 8-wire, non-isolated The syntax of the address of device on the bus is of the
- RS 485 port 0 and port 1: RS 485 2-wire, isolated ‘r. m. c. node’ type. The address is made up of the
Another serial link is between PLC and the operator following parameters:
panel. The BMX P34 2020 processors enable r: Rack number of the module
communication via a serial link. This processor has an m: Slot number of the module within the rack
integrated communication channel dedicated to serial c: Channel number of the module
communications. Master device is the Magelis console. node: Number of slave to which the request is being
Modbus protocol has been combined with Ethernet to sent.
form Modbus/TCP, a completely open Ethernet protocol. The following table outlines the various parameters for
The main connection is the Ethernet network, with the READ_VAR function [9]:
architecture consists of four Twido PLCs and the central
PLC, via their integrated Ethernet ports, and is used to Table 1.Parameters description
manage the exchange of remote I/O states on the Parameter Type Description
Ethernet network after a configuration operation, with a ADR ARRAY Address of the destination entity given by
[0..7] the OUT parameter of the ADDM function.
special programming. OF INT
The application variables (tags) are available by Modbus OBJ STRING Type of object to be read. The available
TCP/IP protocol in Ethernet network, at fixed IP types are
addresses. Modicon M340 station can exchange a as follows:
maximum of 100 words for writing and 125 words for %M: internal bit
%MW: internal word
reading. %I: external input bit
When is used as the master processor in a Modbus link, a %IW: external input word
BMX P34 2020 processor supports several services via NUM DINT Address of first object to be read.
the communication functions. Two specific functions are NB INT Number of consecutive objects to be read.
defined for sending and receiving data via a Modbus GEST ARRAY Exchange management table consisting of
[0..3] the following words:
communication channel: OF INT - Rank 1 word: A word managed by the
- READ_VAR: to read variables. system and consisting of two bytes:
- WRITE_VAR: to write variables. - Most significant byte: Exchange number,
The following Modbus requests are addressed to the - Least significant byte: Activity bit (rank
0) and cancel bit (rank 1).
slave device with which you wish to carry out reading or
- Rank 2 word: a word managed by the
writing of variables: system and consisting of two bytes:
Read bits 16#01 or 16#02 READ_VAR - Most significant byte: Operation report,
Read words 16#03 or 16#04 READ_VAR - Least significant byte: Communication
Write bits 16#0F WRITE_VAR report.
Write words 16#10 WRITE_VAR - Rank 3 word: A word managed by the
user which defines the maximum response
time using a time base of 100 ms.
These requests use the READ_VAR and WRITE_VAR - Rank 4 word: A word managed by the
communication functions. system which defines the length of the
exchange.
RECP ARRAY Word table containing the value of the
[n..m] objects reads.
OF INT

The command system is provided with the possibility of

connecting to a higher level of supervision of the plant,
the SCADA system.

V. USER INTERFACE
Magelis operator dialogue terminals communicate with
an automation system equipment.
Figure 9. Communications functions in FBD
Vijeo Designer HMI software [10] is a software tool that
allows the creation of such HMI interface, the screens for
The diagram shown in Fig. 9 represents an example of touch panel TP. The setting for Magelis graphic terminal,
programming of the communication functions in FBD for XBT GT6330 type, with 12” screen, is processed offline.
Modbus/TCP protocol. Use of TP requires the configuration of the controls by
The lines of code below represent an example of assigning of tags and functions that allow TP to interact
programming of the READ_VAR and WRITE_VAR with PLC programs.
communication functions in ST language for The following figures are presented the application
implementing the Modbus RTU: screens. The operator interacts with these screens to
READ_VAR(ADDM('0.4.1.2.MBS'), ’%MW’, 110, 20, supervise. The screens used for process control have been
Management_Table, Receiving_Table);
configured and organized in a hierarchical structure. The
WRITE_VAR(ADDM('0.4.1.2.MBS'), ’%MW’, 150, 10,
Data_to_write, Management_Table);
navigation between screens is achieved through the
function keys arranged in the lower zone.
 Solution for Water Wells and Tank Control System 5

Figure 10. Screen for pumping station

Figure 12. Screen for remote control of the water wells

When is powered, TP has a default screen (Fig. 10). The The list of alarms (Figure 13) displays alarm messages,
main screen allows online monitoring of the pumping but also additional information, date and time when an
group and the reservoir. alarm activated, the time when the alarm was confirmed
Each screen contains one or more controls, which are by the operator and is canceled when the condition of
data indicators, numeric data entry, touch elements. The alarm generation. The messages change color depending
operator uses these elements to control or for on alarm status, active, confirmed or canceled alarm.
parameterization (Fig. 11). Alarm display is done in the chronological order of the
activation.

Figure 11. Numeric keypad (for parameterization) and alphanumeric

keypad (login)

Images were placed on the screen to make a presentation

or animation. We're also defined controls, navigation
buttons, to load and display a separate screen when the Figure 13. List of alarms and events
button is pushed.
The operator monitors the real-time on/off status of the When analyzing the cause of process disturbances, the
pumps, positions for switching elements or changes in comparison of alarm and trend data (Fig. 14), an intuitive
operation (selector switches, contactors, circuit- evolution, can be quite revealing.
breakers), being warned of the occurrence of events or There is a screen (Fig. 15) that allows monitoring of
alarms. The access to commands and settings are enabled electrical parameters: line voltage, phase current, active
only secured, through a password. and reactive power, energy consumption, frequency,
On the screen designated to control the water wells the power factor.
interface elements are grouped into functional units (Fig. This application uses an advanced security system with
12). The commands on/off can be transmitted in manual password protection technology to ensure a safe
mode by the operator or in automatic mode depending on operation. The management of the user groups is
the water level in the tank. performed on-line (Fig. 16).
Communication integrity is extremely important. All
errors are reported.
 6 Cristian PÎRVU, Costin CEPIŞCĂ

Figure 14. Trends Figure 17. Matrix display unit with keypad

VI. CONCLUSION
The article presents the design and programming stages
and methods, both for the components and the entire
system, focusing on the industrial communication system.
The selected programmable controllers and operator
terminals represent an optimal solution for automation of
medium complexity applications. The compact design and
a complex set of instructions make from this automation
system a proper solution to control supplying water
applications.
Presented system is an open system that allows further
Figure 15.Electrical parameters hardware and software development, both at operating
and process stations and at communication system.

ACKNOLEDGEMENT
The work has been partially funded by Grant
no.30_PCCA_2012 of the Romanian National Authority
for Scientific Research CNDI– UEFISCDI.

REFERENCES
[1] Rafferty, K, Specification of Water Wells, ASHRAE Transactions,
Vol. 107, Pt. 2., 2001
Figure 16 . Windows for online management of user groups and for
[2] Paradise:Water System Monitoring and Control, Campbell
login procedure Scientific, See also: https://www.campbellsci.com/paradise-ut-
water
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console to act as a Web Server, providing flexibility in See also: http://www.michigan.gov/documents
accessing the system from remote sites as Web Client [4] Margineanu I., Automate programabile, Ed. Albastra, Cluj-
through a browser, either Internet Explorer or otherwise. Napoca, 2005
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Ed.Electra, 2004, Bucuresti
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[6] Twido programmable controllers, Software Reference Guide,
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address, just a single PC, such as the control room. The [7] Malvoisin,A.- Notice programmation d’automates Schneider
access control is similar as for a console, based on an Modicon, Premium, Quantum sous Unity Pro, See also:
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[10] Vijeo Designer tutorial, Schneider-Electric
RT small panels for controlling local automation systems
(Fig. 17).

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