Simulation of Water Supply Pump System with

PLC based Control

Sudirman

, I Nyoman Gede Baliarta

, Putu Darmawa

and D. G. Agustriputra

Mechanical Department, Bali State Polytechnic, Jl. Kampus Bukit Jimbaran, Badung-Bali, Indonesia

Keywords: Smart Relay, Input, Output, Ladder Diagram.

Abstract: This paper discusses the simulation of the control of a clean water pump system for supply to the building.

There are several systems in the field, generally using conventional controls. The system uses a contactor and

WLC. The simulation system is made with 3 tanks, namely tower tank, consumption tank and ground tank.

This simulation control system using PLC control. The PLC used is the Zelio SR3PACKBD Smart Relay.

The inputs are stainless steel rod sensors in the tower tank and ground tank. The outputs are 2 pump motors

and a solenoid valve. The PLC program used is Ladder diagram with ZELIO SOFT 2 program. Pumps 1 and

2 will operate from low level to middle level. When middle level to high level only pump 1 operates.

Meanwhile, when the hight level there is no pump operating. The test results show satisfactory results

according to the program made, and the equipment required is very simple compared to conventional controls.

1 INTRODUCTION

The main objective in designing a water supply

system for high-rise buildings is to ensure adequate

water supply at all times, both in terms of required

pressure and discharge for all outlets, fixtures and

equipment. In addition, also to achieve energy saving,

efficient and energy saving. (Rodrigues,

Fernanda.2011).

Bali as a foreign and domestic tourist destination,

must provide adequate accommodation to ensure the

comfort of International and Domestic guests, during

their stay in Bali. Hotels and villas grow moldy

anticipating the arrival of guests. Hotel and Villa

building facilities adjust the status of the Hotel and

Villa. The basic facilities for hotels and villas are the

availability of clean water whenever needed.

Disruption of the clean water supply system in a

hotel will also disrupt the comfort of the guests

staying and will reduce the credibility of the hotel,

which in turn will reduce the hotel occupancy rate.

For this reason, a reliable clean water supply system

is needed to meet the basic needs of guests, so that the

hotel's credibility is maintained.

https://orcid.org/0000-0003-2816-523X

https://orcid.org/0000-0003-3286-2732

https://orcid.org/0000-0001-7621-6420

https://orcid.org/0000-0002-9422-7876

There are many clean supply pump systems

installed in hotels depending on the hotel owner's

request. The supply system uses a tower tank and

distribution by gravity and the supply system uses a

ground tank and distribution uses a pump. Each

system has its advantages and disadvantages. ( Pears,

A., 2002).

Building utilities consist of mechanical and

electrical systems. One of the sub-mechanical

systems is a clean water supply system. Clean water

supply systems installed in hotels mostly use 2 or 3

supply pumps. For hotel or villa locations with flat

locations, most pumps supply directly to the end-user

by using pressure as the on-off control of the pump.

Meanwhile, hotels/villas with high-rise locations use

tower tanks for water distribution to end-users.

(Vinita Chanan, 2013).

The Clean Water Distribution System in Multi-

story Buildings by Wujek, Joseph B. (2012) is

divided into several systems, namely:

Sudirman, ., Nyoman Gede Baliarta, I., Darmawa, P. and Agustriputra, D.

Simulation of Water Supply Pump System with PLC based Control.

DOI: 10.5220/0010947800003260

In Proceedings of the 4th International Conference on Applied Science and Technology on Engineering Science (iCAST-ES 2021), pages 477-483

ISBN: 978-989-758-615-6; ISSN: 2975-8246

 2023 by SCITEPRESS – Science and Technology Publications, Lda. Under CC license (CC BY-NC-ND 4.0)

477

1.1 Up-feed System

In this system, the distribution pipe directly from the

ground tank with the pump is directly connected to

the main pipe for providing clean water to the

building, in this case using the full capacity of the

pump. Due to the limited pressure in the pipe and the

limited size of the branch pipe from the main pipe,

this system is especially applicable for housing and

small low-rise buildings (Alfred, 1984). The

manufacture is relatively cheap but the pump breaks

quickly.

Figure 1: Up Feed System.

The disadvantages of this system are:

a. pump working continuously

b. The height is limited because the strength of

the pipe is limited to anticipate the pressure

of the water inside.

1.2 Down Feed System

In this system, water is first stored in the ground tank,

then pumped to the upper tank which is usually

installed on the roof or on the highest floor of the

building. From here the water is distributed

throughout the building. This roof tank system is

quite efficient to implement because:

a. As long as the water is used, the pressure

changes that occur in the plumbing tool are

insignificant.

b. The pump system that raises water to the top

tank works automatically in a very simple

way so that difficulties can be suppressed.

c. Tank maintenance is very simple compared

to for example a pressure tank.

The advantages of this down feed system are:

a. The pump does not work continuously so it

is more efficient and durable.

b. Clean water is always available at all times.

c. No need for automatic pump.

The disadvantages of this system are :

a. Requires additional costs for the

procurement of additional tanks.

b. Adding weight to the structure of the

building.

c. Increase maintenance costs.

For long-term use, this system is effective and

efficient even though it is expensive to manufacture.

If the number of floors is very large, the water

pressure in the pila is very high, so that the pipe can

burst due to high pressure (every seven meters of

pressure the pipe receives a pressure of 1

atmosphere), then this down feed system is equipped

with: Spillback Tank

Figure 2: Down Feed System.

1.3 Spillback Tank

In the form of auxiliary tanks that are placed on each

particular floor. Each tank is equipped with a pressure

control valve. When the water pressure is high, the

valve will close. The most important thing in this roof

tank system is to determine the location of the tank

whether it is installed in the ceiling, on the roof, or

installed in a special tower. This determination must

be based on the type of plumbing device installed on

the highest floor of the building and which determines

the highest working pressure.

Figure 3: Down Feed System With Spill Back Tank.

The working principle of this system is as follows:

a. Water that has been pumped in a spill back

tank that is on several floors so that the air

inside is compressed.

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b. The water in the tank flows through the

building's distribution system. The pump is

regulated automatically by a relative that

drives the electric motor switch that drives

the pump.

c. The pump stops working when the tank

pressure has reached the maximum set limit

and works again after the tank pressure

reaches a predetermined minimum limit as

well. This area of pressure fluctuation is

usually set between 1.0 -1.5 kg/cm'.

1.4 Presure Reducer Valve (PRV,

Katup Reduksi Tekanan)

On a relatively large number of floors, there is a

possibility that the pressure in the pipe is very high so

it needs to be reduced with a valve. These valves are

placed on certain floors.

Figure 4: Down Feed System With Pressure Reducer Valve.

1.5 Some Systems Applied in Hotels

Surveys to hotels that have been carried out to find

out directly the installation of clean water supply

systems in hotels with regard to this research, namely:

1.5.1 Double-Six.Luxury Hotel Seminyak

The installation of a clean supply system at Double-

Six.Luxury Hotel Seminyak uses 3 pumps. The three

pumps are alternately controlled by the Control Panel.

This installation is without tower tank. From the

pump, water is distributed directly to the user at a

pressure of 3.5 Bar, using a Digital Pressure

Transmitter.

Figure 5: The installation of a clean supply system at

Double-Six.Luxury Hotel Seminyak uses 3 pumps.

Figure 6: Control Panel of the clean water supply system at

Double-Six Luxury Hotel Seminyak.

1.5.2 Estate Villa Four Seasons Resort

Jimbaran

Figure 7: Plumbing installation and control panel of clean

water supply system Estate Villa Four Seasons Resort

Jimbaran.

The clean water supply system at Estate Villa Four

Seasons Resort Jimbaran uses 2 pumps. Switch on

duty pump from pump 1 to pump 2 using a switch

over relay. Water is distributed directly to the end-

user of the pump using a pressure switch for on-off.

1.5.3 Luna 2 Hotel Seminyak

Clean water is pumped from the ground tank to the

tower tank, the pump turns on and off based on the

flow to the end user by gravity. On and off the supply

pump to the tower using WLC based on the water

level in the tower tank

Simulation of Water Supply Pump System with PLC based Control

479

Figure 8: Installation of a clean water supply system and

tower tank at Luna 2 Hotel Seminyak.

Pump control that has been widely applied now is

using PLC, as done by Indra Saputra et al, (2013).

They designed the Water Level Control using an

Omron Sysmac C200H PLC equipped with

Wonderware InTouch 10.5 SCADA Software.

Dendin Supriadi, (2015), made a water level control

system using an ultrasonic sensor based on PLC

(Programmable Logic Controller). For monitoring

and control interfaces on this system, the Omron

NB7W-TW00B HMI is used, so that all events that

occur in the system can be directly controlled and

monitored. in real time. This water level control

system has two controls, namely automatic control

and manual control.

Sri Kusumastuti and Suryono (2015), made a

practical teaching aid for water level control in

reservoirs and tanks using PLC. With an output in the

form of a water pump and a solenoid valve.

Gebremaryam Alem and Dr. Krishnanaik Vankdoth

(2016), designed a water level control using PLC.

With input in the form of electronic sensors in the

form of limit switches and outputs in the form of

pump motors and solenoid valves, and they create

Ladder logic diagram programs using the Softcomfort

Logo.

Paper written by Cosmina Illes et al, (2017), about

water level control system using PLC and wireless

sensors. The aim of the paper is to present the

cheapest cost method for water level control using

wireless.

For this water level control simulation project,

the Schneider Smart Relay Zelio Logic

SR3PACKBD PLC is used.

2 METHODOLOGY

The scheme built in the clean water system simulation

project with PLC is as shown in Figure 8 below.

This Simulation Scheme consists of 3 tanks,

namely;

1. Tower Tank as a water reservoir whose position

is the highest, or its position on the roof of the

building. The tower tank is equipped with probe

A (water level sensor) with 4 sensor rods.

a. Sensor No. Probe A1 as cummon

b. Sensor No. Probe A2 as low level sensor

c. Sensor No. A3 probe as medium level sensor

d. Sensor No. A4 probe as a hight level sensor

2. Consumption Tank is a tank which is a water

storage tank that comes out of the Tower Tank

which is associated as a water consumer in a

building. The consumption tank is connected to

the ground tank by 2 different pipes. The first

pipe is equipped with a solenoid valve, the way

it works is when the ground tank is in a low level

position, the solenoid valve will automatically

open. The second pipe is equipped with a gate

valve 4, which works manually.

Figure 9: Simulation scheme of clean water pump control

using PLC.

3. Ground Tank is a storage tank whose position is

at the bottom of a building. Water reservoirs

from drinking water companies or underground

water reservoirs. The end of the pipe that enters

the ground tank is the pump suction pipe, check

valve 3 is installed whose function is so that the

pump suction pipe always has water. Ground

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tank is equipped with probe B. Which consists of

3 sensor rods,

a. Sensor No. Probe B1 is as cummon

b. Sensor No. Probe B2 as Low level sensor

c. Sensor No. Probe B3 as a hight level sensor.

2.1 Description Sistem

This simulation tool uses 2 pumps, which move water

from the Ground tank to the Tower tank, when the

water is consumed (gate valve 3 is manually opened),

the water is accommodated by the consumption tank.

The consumption tank collects water from the tower

tank and forwards it to the ground tank again. Thus

the water cycle in this simulation tool. Sistem kontrol

akan bekerja jika kondisi level air pada Ground tank

tidak mencapai posisi Low Level (batang Probe B2

tidak menyentuh air) dan kondisi level air di Tower

tank tidak hight level (batang Probe A4 tidak

menyentuh air).

When the Probe B3 ground tank sensor is

submerged in water and Probe A2 is not touched by

the water in the tower tank, Pump 1 and Pump 2 will

turn on pumping the ground tank water to the tower

tank, When the tower tank water level touches the

Probe A3 sensor, pump 2 will turn off and only pump

1 is still alive. When the water level reaches/touches

probe B4 (hight level), pump 1 will also stop.

When gate valve 3 is opened, water flows to fill

the consumption tank. When the water level of the

tower tank decreases and the probe rod A3 does not

touch the water, pump 2 will automatically start

pumping water from the ground tank to fill the tower

tank. When the water consumption is too much, the

tower tank water level continues to decrease and the

water level does not touch the A2 sensor probe, then

pump 1 will run and fill the tower tank.

If the pump is running continuously, and the

condition of the water level in the ground tank

continues to drop until the ground tank water level

does not touch the probe rod B2, then the system will

not work. Because if it is continued, the pump will

work in dry running condition (no water is pumped).

This can cause the pump to fail and this system is

designed to save the pump from being severely

damaged.

In this condition, the solenoid valve will

automatically open, filling water from the

consumption tank, the water flows by gravity.

2.2 Program PLC (Ladder Diagram

Program)

This PLC program is in the form of a Ladder Diagram

Program that will be uploaded/transferred to the PLC.

PLC used is PLC SMART RELAY ZELIO

SR3PACKBD. While the software used is ZELIO

SOFT 2. PLC and its software is a product of

SCHNEIDER.

For PLC programs there are inputs and outputs. The

inputs of the PLC are;

a. Input 1 is the start of the program in the

form of a push button

b. Input 2 is the sensor Probe A2 (low level

tower tank)

c. Input 3 is sensor probe A3 (medium level

tower tank)

d. Input 4 is the sensor probe A4 (hight level

tower tank)

e. Input 5 is sensor probe B2 (low level

ground tank)

f. Input 6 is sensor probe B3 (high level

ground tank).

The output of the PLC is;

a. Output 1 is Pump 1

b. Output 2 is Pump 2

c. Output 3 is the Selenoid Valve.

The Ladder Diagram Program that is made in

accordance with the work system as described above

is as shown in Figure 10.

3 RESULT

Ladder Diagram program created using Zelio Soft 2

program, then uploaded to the Smart Realy PLC using

an SR2USB01 USB cable that is compatible with

Windows 7, 8.1 or 10.

Simulation of Water Supply Pump System with PLC based Control

481

Figure 10: Ladder Diagram Program.

Figure 11: Schneider SR3PACKBD PLC and USB cable

SR2USB01.

After the Ladder diagram is uploaded to the PLC, the

results of the running test simulation of the water

supply control system with the PLC are as follows,

which are shown in Table 1.

Table 1: Matrik Kerja Water Supplay Pump System.

Kondisi Level

air

On Duty

Pompa 1 Pompa 2

Selenoid

Valve

Hight Level

Tower Tank

OFF OFF OFF

Medium Level

Tower Tank

ON OFF OFF

Low Level

Tower Tank

ON ON OFF

Hight Level

Ground Tank

ON ON OFF

Low Level

Ground Tank

OFF OFF ON

Table 1 is the output condition with several input

conditions in the form of the water level in the ground

tank and tower tank.

Pump 1 will work when the tower tank is in low,

medium level and high level ground conditions.

Pump 2 works when the tower tank is in a low level

condition and the ground tank is in a high level

condition.

The solenoid valve will work or open if the

ground tank is in a low level condition, which will

drain water from the consumption tank to the ground

tank.

Figure 12: Simulation of Water Supply Pump System.

4 CONCLUSIONS

The PLC-based Water supply control simulation

system that was made showed very satisfactory

results. The big advantage of PLC based water supply

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482

control is that it has maximum accuracy, also has

higher reliability and small space requirements

compared to conventional controls.

ACKNOWLEDGEMENTS

Our gratitude goes to P3M a Bali State Polytechnic

who has funded this research through DIPA 2021

funds.

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