Chapter 1

Introduction and Literature

Review

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 Chapter 1

Introduction and Literature Review

1.1 Introduction

Automation plays an increasingly important role in the global economy and in daily experience.
It improves the performance and also reduces human efforts. The main objective behind
selecting this project is to improve the performance of water distribution system with minimum
human efforts.

Cities are getting smarter and smarter now a day’s using new different technologies, so living
in smart cities makes people reduce the work load and provide the security as well as living
comfort. A city can be called smart by the way of people’s living and culture in it, where every
problem of environment can be controlled and everything should be automated. This system
of water supply can be implemented in cities by using technologies like PLC and SCADA with
the help of government taking efforts to initiate it. This whole water supply system can be
accessed by users through online portal made for this project. The main goal of this system is
to take water from source and supply it to overall areas and generate the records as per the
saved values for future reviews.

1.2 A brief history of water distribution technology [1]

The practice of transporting water for human consumption has been around for several
millennia. From the first pipes in Crete some 3,500 years ago, to today’s complex hydraulic
models, the history of water distribution technology is quite a story. The following highlights
some of the key historical events that have shaped the field since its beginnings.

1500 B.C. — First water distribution pipes used in Crete. The Minoan civilization flourishes on
the island of Crete. The City of Knossos develops an aqueduct system that uses tubular
conduits to convey water. Other ancient civilizations have had surface water canals, but these
are probably the first pipes.

250 B.C. — Archimedes principle developed. Archimedes, best known for his discovery of π
and for devising exponents, develops one of the earliest laws of fluids when he notices that
any object in water displaces its own volume. Using this principle, he proves that a crown
belonging to King Hiero of Syracuse is not made of gold. A legend will develop that he

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discovered this principle while bathing and became so excited that he ran naked through the
streets shouting “Eureka” (I’ve found it).

100 A.D. — Roman aqueducts. The Romans bring water from great distances to their cities
through aqueducts. Brief History of Water Distribution Technology ground, there are also
enclosed conduits to supply public fountains and baths. Sextus Julius Frontinus, water
commissioner of Rome, writes two books on the Roman water supply.

1455 — First cast iron pipe. Casting of iron for pipe becomes practical, and the first installation
of cast iron pipe, manufactured in Siegerland, Germany, occurs at Dillenburg Castle.

1652 — Piped water in Boston. The first water pipes in the U.S. are laid in Boston to bring
water from springs to what is now the Quincy Market area.

1664 — Palace of Versailles. King Louis XIV of France orders the construction of a 15-mile
cast iron water main from Marly-on-Seine to the Palace of Versailles. This is the longest
pipeline of its kind at this time, and portions of it remain in service into the 21st century. A
section of the line, after being taken out of service, was shipped in the 1960s from France to
the United States

1732 — Pitot invents a velocity-measuring device. Henri Pitot is tasked with measuring the
velocity of water in the Seine River. He finds that by placing an L-shaped tube into the flow,
water rises in the tube proportionally to the velocity squared, and the Pitot tube is born.

1738 — Bernoulli publishes Hydrodynamica. The Swiss Bernoulli family extends the early
mathematics and physics discoveries of Newton and Leibniz to fluid systems. Daniel Bernoulli
publishes Hydrodynamica while in St. Petersburg and Strasbourg, but there is a rivalry with
his father Johann regarding who actually developed some of the principles presented in the
book. These principles will become the key to energy principles used in hydraulic models and
the basis for numerous devices such as the Venturi meter and, most notably, the airplane wing

1754 — First U.S. water systems built. The earliest water distribution systems in the United
States are constructed in Pennsylvania. The Moravian community in Bethlehem, Pennsylvania
claims to have the first water system, and it is followed quickly by systems in Schaeffer’s town
and Philadelphia, Pennsylvania. Horses drive the pumps in the Philadelphia system, and the
pipes are made of bored logs. They will later be replaced with wood stave pipes made with
iron hoops to withstand higher pressures. The first steam driven pumps will be used in
Bethlehem ten years later.

1770 — Chezy develops head loss relationship. While previous investigators realized that
energy was lost in moving water, it is Antoine Chezy who realizes that V2 / RS is reasonably
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constant for certain situations. This relationship will serve as the basis for head loss equations
to be used for centuries.

1785 — Bell and spigot joint developed. The Chelsea Water Company in London begins using
the first bell and spigot joints. The joint is first packed with yarn or hemp and is then sealed
with lead. Sir Thomas Simpson is credited with inventing this joint, which replaced the crude
flanged joints used previously.

1839 — Hagen-Poiseuille equation developed. Gotthilf Hagen and Jean Louis Poiseuille
independently develop the head loss equations for laminar flow in small tubes. Their work is
experimental, and it is not until 1856 that Franz Neuman and Eduard Hagenbach will
theoretically derive the Hagen-Poiseuille equation.

1843 — St. Venant develops equations of motion. Several researchers, including Louis Navier,
George Stokes, Augustin de Cauchy, and Simeon Poisson, work toward the development of
the fundamental differential equations describing the motion of fluids. They become known as
the “Navier-Stokes equations.” Jean-Claude Barre de Saint Venant develops the most general
form of these equations, but the term St. Venant equations will be used to refer to the vertically
and laterally averaged (that is, one-dimensional flow) form of equations.

1845 — Darcy-Weisbach head loss equation developed. Julius Weisbach publishes a three-
volume set on engineering mechanics that includes the results of his experiments. The Darcy-
Weisbach equation comes from this work, which is essentially an extension of Chezy’s work,
as Chezy’s C is related to Darcy-Weisbach’s by C2 =8g/f. Darcy’s name is also associated
with Darcy’s law for flow through porous media, widely used in groundwater analysis.

1878 — First automatic sprinklers used. The first Par melee sprinklers are installed. These are
the first automatic sprinklers for fire protection.

1879 — Lamb’s Hydrodynamics published. Sir Horace Lamb publishes his Treatise on the
Mathematical Theory of the Motion of Fluids. Subsequent editions will be published under the
title Hydrodynamics, with the last edition published in 1932.

1881 — The 22 original members create the American Water Works Association. The first
president is Jacob Foster from Illinois.

1883 — Laminar/turbulent flow distinction explained. While earlier engineers such as Hagen
observed the differences between laminar and turbulent flow, Osborne Reynolds is the first to
conduct the experiments that clearly define the two flow regimes. He identifies the
dimensionless number, later referred to as the Reynolds number, for quantifying the conditions
under which each type of flow exists. He publishes “An Experimental Investigation of the
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circumstances which determine whether the Motion of Water shall be Direct or Sinuous and
the Law of Resistance in Parallel Channels.” 1896 — Cole invents Pitot tube for pressure pipe.
Although numerous attempts were made to extend Henri Pitot’s velocity measuring device to
pressure pipes, Edward Cole develops the first practical apparatus using a Pitot tube with two
tips connected to a manometer. The Cole Pitometer will be widely used for years to come, and
Cole’s company, Pitometer Associates, will perform flow measurement studies (among many
other services) into the 21st century.

1906 — Hazen-Williams equation developed. A. Hazen and G.S. Williams develop an

empirical formula for head loss in water pipes. Although not as general or precise in rough,
turbulent flow as the Darcy-Weisbach equation, the Hazen-Williams equation proves easy to
use and will be widely applied in North America. 1900 to 1930 Boundary Layer Theory
developed. The interactions between fluids and solids are studied extensively by a series of
German scientists lead by Ludwig Prandtl and his students Theodor von Karman, Johan
Nikuradse.

1914 — First U.S. drinking water standards established. The U.S. Public Health Service
publishes the first drinking water standards, which will continually evolve. The U.S.
Environmental Protection Agency (U.S. EPA) will eventually assume the role of setting the
water quality standards in the United States.

1920s — Cement-mortar lining of water mains. Cement mortar lining of water mains is used
to minimize corrosion and tuberculation. Procedures for cleaning and lining existing pipes in
place will be developed by the 1930s.

1921 — First Hydraulic Institute Standards published. The first edition of Trade Standards in
the Pump Industry is published as a 19-page pamphlet. These standards become the primary
reference for pump nomenclature, testing, and rating.

1936 — Hardy Cross method developed. Hardy Cross, a structural engineering professor at
the University of Illinois, publishes the Hardy Cross method for solving head loss equations in
complex networks. This method is widely used for manual calculations and will serve as the
basis for early digital computer programs for pipe network analysis. 1938 — Colebrook-White
equation developed. Cyril Colebrook and Cedric White of Imperial College in London build
upon the work of Prandtl and his students to develop the Colebrook-White equation for
determining the Darcy-Weisbach f in commercial pipes.

1940 — Hunter curves published. During the 1920s and ’30s, Roy Hunter of the National
Bureau of Standards conducts research on water use in a variety of buildings. His “fixture unit

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method” will become the basis for estimating building water use, even though plumbing
fixtures will change over the years. His probabilistic analysis captured the mathematics of the
concept that the more fixtures in a building, the less likely they are to be used simultaneously.
1944 — Moody diagram published. Lewis Moody of Princeton University publishes the Moody
diagram, which is essentially a graphical representation of the Colebrook White equation in
the turbulent flow range and the Hagen-Poisseuille equation in the laminar range. This
diagram is especially useful because, at the time, no explicit solution exists for the Colebrook-
White equation. Stanton had developed a similar chart 30 years earlier.

1950 — McIlroy network analyser developed. The McIlroy network analyser, an electrical
analogue computer, is developed to simulate the behaviour of water distribution systems using
electricity instead of water. The analyser uses special elements called “fluistors” to reproduce
head loss in pipes, because in the Hazen-Williams equation, head loss varies with flow raised
to the 1.85 power, while normal resistors comply with Ohm’s law, in which voltage drop varies
linearly with current.

1950s — Earliest digital computers developed. The Electronic Numerical Integrator and
Computer (ENIAC) is assembled at the University of Pennsylvania. It contains approximately
18,000 vacuum tubes and fills a 30 x 50-foot (9 x 15 m) room. Digital computers such as the
ENIAC and Univac show that computers can carry out numerical calculations quickly, opening
the door for programs to solve complex hydraulic problems.

1956 — Push-on joint developed. The push-on pipe joint using a rubber gasket is developed.
This type of assembly helps speed the construction of piping. 1960s and ’70s — Earliest pipe
network digital models created. With the coming of age of digital computers and the
establishment of the FORTRAN programming 15 language, researchers at universities begin
to develop pipe network models and make them available to practicing engineers. Don Wood
at the University of Kentucky, Al Fowler at the University of British Columbia, Roland Jepson
of Utah State University, Chuck Howard and Uri Shamir at MIT, and Simsek Sarikelle at the
University of Akron all write pipe network models. A computer punch card 1963 — First U.S.
PVC pipe standards. The National Bureau of Standards accepts CS256-63 “Commercial
Standard for PVC Plastic Pipes (SDR-PR and Class T),” which is the first U.S. standard for
polyvinyl chloride (PVC) water pipe.

1963 —. The Urban and Regional Information Systems Association is founded by Dr Edgar
Horwood. URISA becomes the premier organization for the use and integration of spatial
information technology to improve the quality of life in urban and regional environments.

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1960s and ’70s — Water system contamination. Chemicals that can result in health problems
when ingested or inhaled are dumped on the ground or stored in leaky ponds because of lack
of awareness of their environmental impacts. Over the years, these chemicals will make their
way into water distribution systems and lead to alleged contamination of water systems in
places like Woburn, Massachusetts; Phoenix/Scottsdale, Arizona; and Dover Township, New
Jersey. Water quality models of distribution systems will be used to attempt to recreate the
dosages of chemicals received by customers. These situations lead to popular movies like A
Civil Action and Erin Brockovich.

1970s — Early attempts to optimize water distribution design. Dennis Lai and John Schaake
at MIT develop the first approach to optimize water system design. Numerous papers will
follow by researchers such as Arun Deb, Ian Goulter, Uri Shamir, Downey Brill, Larry Mays,
and Kevin Lansey. 1970s — Models become more powerful. Although the earliest pipe
network models could only solve steady-state equations for simple systems, the ’70s bring
modelling features such as pressure regulating valves and extended-period simulations.

1975 — Data files replace input cards. Modelers are able to remotely create data files on time-
share terminals instead of using punched cards. 1975 — AWWA C-900 approved. The AWWA
approves its first standard for PVC water distribution piping. C900 pipe is made to match old
cast iron pipe outer diameters.

1976 — Swamee-Jain equation published. Dozens of approximations to the Colebrook-White

equations have been published in an attempt to arrive at an explicit equation that would give
the same results without the need for an iterative solution. Indian engineers P. K. Swamee
and Akalnank Jain publish the most popular form of these approximations. The use of an
explicit equation results in faster numerical solutions of pipe network problems. 1976 —
Jeppson publishes Analysis of Flow in Pipe Networks. Roland Jeppson authors the book
Analysis of Flow in Pipe Networks, which presents a summary of the numerical techniques
used to solve network problems.

1980 — Personal computers introduced. Early personal computers make it possible to move
hydraulic analysis to desktop systems. Initially, these desktop models are slow, but their power
will grow exponentially over the next two decades. Time-share terminal Early 1980s Water
Quality Modelling First Developed. The concept of modelling water quality in distribution
systems is first developed, and steady state formulations are proposed by Don Wood at the
University of Kentucky and USEPA researchers in Cincinnati, Ohio.

1985 — “Battle of the Network Models.” A series of sessions is held at the ASCE Water
Resources Planning and Management Division Conference in Buffalo, New York, where
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researchers are given a realistic system called “Anytown” and are asked to optimize the design
of that network. Comparison of results shows the strengths and weaknesses of the various
models.

1986 — Introduction of Dynamic Water Quality Models. At the AWWA Distribution System
Symposium, three groups independently introduce dynamic water quality models of
distribution systems.

1988 — Gradient Algorithm. Ezio Todini and S. Pilati publish “A Gradient Algorithm for the
Analysis of Pipe Networks,” and R. Salgado, Todini, and P. O’Connell publish “Comparison of
the Gradient Method with some Traditional Methods of the Analysis of Water Supply
Distribution Networks.” The gradient algorithm serves as the basis for the WaterCAD model.

1991 — Water Quality Modeling in Distribution Systems Conference. The USEPA and the
AWWA Research Foundation bring together researchers from around 18 Introduction to Water
Distribution Modeling Chapter 1 the world for a two-day meeting in Cincinnati. This meeting is
a milestone in the establishment of water quality modeling as a recognized tool for
investigators.

1991 — GPS technology becomes affordable. The cost of global positioning systems (GPS)
drops to the point where a GPS can be an economical tool for determining coordinates of
points in hydraulic models. 1993 — Introduction of water quality modelling tool. Water quality
modelling comes of age with the development of EPANET by Lewis Rossman of the USEPA.
Intended as a research tool, EPANET provides the basis for several commercial-grade
models. 1990 through present. Several commercial software developers release water
distribution modelling packages. Each release brings new enhancements for data
management and new abilities to interoperate with other existing computer systems.

2005 — Automated calibration. Automated calibration of distribution models moves from being
a research tool to a standard modelling feature with the use of Genetic Algorithms.

2010 — Security awareness. Water system security increases in importance and utilities
realize the value of water quality modelling as a tool for protecting a water system.

2015 — Integration with PLC & SCADA. Water modelling and SCADA software become highly
integrated.

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1.3 Existing Technology
Traditionally, In PCMC area the water distribution infrastructure is widely spread effectively.
Now-a-days, Water distribution system faces some problems like water leakage & improper
water supply. This leakage causes drastic reduction in pressure of water flowing through
supply line. Due to this, consumer gets less amount of water. Hence, their need to develop
the system to overcome such problems [2].

1.4 Need for PLC

Programmable Logic Controller is the heart of automated water supply system. PLC helps in
controlling pump station motor contactors, stirrer motors, and distributed valves as well as to
measure pressure transmitter of the water. PLC programming is done using Ladder Diagram
Language. Ladder diagram is specialized schematic language commonly used to document
industrial control logic systems [2].

1.5 Proposed System

The conventional method used before in older times, results into problems like empty running,
overflow, leakage. The automation of the process thus helped to overcome these problems
based on level, pressure, flow parameters and it also minimizes human efforts for the same.
If there is any problem in system then using SCADA system we can detect problem easily.

Level Sensor MOV

PLC

Flow Sensor Pumping Section

SCADA

Fig 1.1: Block Diagram of Proposed Model

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1.6 Literature review
Earlier many research paper which are related to the ‘SCADA and PLC based water
distribution system’ has been published. In some paper, to make the system atomized
combination of SCADA and PLC is used while some of them introduce the combination of
microcontroller and GSM. These papers also introduce the concept to use the Flow meter, pH
sensor etc. All these axillaries make the system intelligent as well as automated.

1.6.1 Review on Smart water network

Prashant Palkar et.al [9] Now a day’s there is a rapid development in urban residential area,
whereas in case of water distribution system they are using traditional method, which is not
atomized. The best way to improve the water distribution system is by using industrial PLC.
Which accepts analogue input from all the sensors like flow sensor, GSM modules, pH sensor
etc. Water theft can also be protected with the help of flow meter due variation in flow given
by it. The system includes Remote Terminal Units (RTU), flow transducers and actuators
distributed on a wide geographical area, control and power panels for the pump stations etc.
The reliable instrumentation connected to PLC or RTU assure real time monitoring of the main
technological parameters of large water distribution networks.

Pratiksha Hattikatti et.al [10] Automation in the distribution side provides optimized solution
to all problems of distribution of water system. For controlling and monitoring of whole system
SCADA (Supervisory Control and Data Acquisition) is installed along with this network.
SCADA handles the whole system in case of power failures to maintain continuity of power
supply. There are many problems in distribution side like water leakage & improper water
supply. This paper develop a system which can analyse the pressure from different branches
of distribution network and compare it with fixed benchmark. In this way, system is able to
control & monitor the whole system.

Rohini.P.Onkare et.al [11] Water is basic need of human being. Automation provides
optimized solution to all problems of distribution of water system. This system has features of
SCADA (Supervisory Control and Data Acquisition) system to control and monitor the water
supply and in case of power failures to maintain continuity of power supply. Now-a-days water
distribution system faces some problems like improper water supply and water leakage. This
leakage cause reduction in a pressure of water flowing through the supply line. Due to this
consumer gets less amount of water. By, considering above scenario we are trying to find
solution for the above problem.

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E.Vinothini et.al [12] In this paper, the problems occur when supplied water is in lack of quality
because of leakage in pipelines or by contamination because of harmful organisms. To
overcome those issues proposed system consists of flow monitoring system, quality
assurance system and automated supply system. To perform all the decided tasks the
following system design is formulated by utilizing components such as flow sensors, pH
sensors, microcontroller and analog to digital converters. Water flow in each home unit is
measured and intimated to the main distribution unit. Automated water distribution and
performance monitoring system focuses on various entities such as proper supply, over
consumption alert and water quality assurance. Those factors can be effectively monitored by
employing flow sensors and pH sensors along with communication support provided by
ZigBee protocol.

Harish K M et.al [13] In this author proposed Centralised water distribution monitoring and
controlling system using PLC and SCADA is used to distribute the domestic water
depending on their needs to all the individual houses in an Apartment building or Villas.The
methodology includes the set point is fixed for each house and the water from the storage
tank to individual houses is measured with the help of flow sensors. Solenoid valve is used
to open or close the valve automatically. If the flow rate for a particular house reaches its set
point then a message will be sent to that customer through GSM module and the tariff
applied will be hiked for the extra water. And also PLC gives the signal to the solenoid valve
according to the input from the user through GSM or DTMF module. Here it also creates
awareness about conserving water.

1.7 Conclusion from research paper

After reviewing so many papers the common conclusion is that the combination of SCADA
and PLC is best suited to make the system atomized. The fault detection and the leakage
detection become easier along with this wastage of water can be reduced, supply-demand
balancing can be established and electrical energy can also be saved. By introducing the flow
meter water theft can also be eliminated. Therefore, it is preferred to work with this kind of
system to obtain a better water network.

1.8 Methodology

▪ Simulation using interfacing of SCADA and PLC.

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 ▪ Surveying of existing water system of MANIT campus.
▪ Proposed an intelligent water network for MANIT campus.

1.9 Thesis outline

This report is organized in following manner: Chapter 1 gives an overview about proposed
work, development of water network from ancient time to modern era. Literature survey of
some papers is also included in this chapter. Chapter 2 generates the need of intelligent water
network. It also includes the features and advantages, disadvantages of existing and proposed
system and also compares both the systems on different parameters. Chapter 3 includes the
field survey of conventional system. It also explains the various component used in smart
water network and their need. At last in this chapter there is the description of block diagram
and the flowchart of the intelligent water network. Chapter 4 introduces the SCADA and PLC,
features of these two and interfacing of both. Chapter 5 includes the field survey of Ahmedpur
water pump house (Bhopal) and also gives the overview of Narmada water supply project
and some results of Ahmedpur water pump house. Chapter 6 gives the conclusion of the
report and discusses about the future scope of the project.

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Chapter 2

Need of Smart
Water Network

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 CHAPTER 2
Need of Smart water network

2.1 Conventional Water Network

In traditional drinking water supply system is facing many problems related to filtration,
pumping of water, distribution of water and testing of water. Conventional water supply
department comprises three different sections for water supply. First is the pumping station,
which does the sucking of water from water source. The second section is a filtration
department in which measurement of pH and chlorine is done. Third section is the distribution
section through which water is distributed in all the municipal wards. Currently these three
sections are working independently. The major problems in water supply system are, leakage
or wastage of water and the majority public is using suction motors to suck water from main
supply connection, which results decrease in water pressure.

2.1.1 Salient Features of Conventional System

2.1.1.1 Pipes
• In MANIT campus RCC and Cast Iron Pipes are used for water distribution purpose.
• Concrete cement pipes are expensive but non-corrosive by nature. Their advantage is
that they are extremely strong and durable. However, being bulky and heavy, they are
harder and costlier to handle, install and transport.
• Cast iron pipes are quite stable and well suited for high water pressure. However, cast
iron pipes are heavy, which makes them unsuitable for inaccessible places due to
transportation problems. In addition, due to their weight they generally come in short
lengths increasing costs for layout and jointing.

2.1.1.2 Valve

Water valves are made of iron and are hand operated or key operated. Gate Valve is
exceptionally sturdy, rugged and durable, with a reputation for quality, integrity and long service.
They are designed for tight sealing and ease of operation. The valves are available in a variety
of materials of construction, Gate Valves are of flexible wedge, outside screw-and-yoke and
bolted-bonnet construction. Globe Valves feature a ball-type disc, outside screw-and-yoke and
bolted-bonnet construction. Check Valves are of swing-type and bolted-cover construction.

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2.1.1.3 Motor

There are 3 pumping stations in MANIT to pump water from sump well to overhead water tank.
Induction motors are used as they are very efficient, rugged in construction, suitable for any
kind of environment, cheaper as compared to other motors of same ratings. In each pumping
station 2 motors are installed in which of motor installed as standby unit. Thus 6 induction
motors are installed in 3 pumping stations near the overhead tank. Out of these 6 motors 4
motors are of 60 HP and rest two are of 75 HP.

2.1.2 Disadvantages of Existing System

▪ Existing system is not a reliable system

▪ Fault detection is very difficult it can be detected only by experience

▪ Wastage of Water

▪ Wastage of Electrical Energy

▪ Supply-Demand unbalancing

▪ Required more Man power

▪ Since MANIT Campus is very large so Manual operation of valves at appropriate time
is very difficult.

2.2 Proposed System

This project, smart water supply control system is completely based on PLC and SCADA
technologies. In SCADA model of this system the activities like date, time, flow and volume of
water are recorded in Database system. Database will be shown on the online portal of water
supply control system. User can access the information as well as bills, usage of water as per
the dates and time as well.

In this proposed system, Allen bradly micrologix1400 as a PLC has been used. In this
system, SCADA model has been developed for recording all the activities, activities like time,
date and flow in litres are calculated.

The components that are required for this system are sensors, tanks, motor operated valves,
led lights, switches and wireless Wi-Fi router.

On starting the execution of system, PLC checks the level of sensors whether the city tank is
full or not, if the tank is empty then according to the condition water pump gets started and
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once the city tank gets full then the level sensor indicates that the city tank is full and then
automatically the water pump gets off. This procedure is carried out every time when the city
tank gets empty. Now, here the question arises in mind that what happens when the source
water and city tank both are empty? For this a level sensor is placed we have placed in source
water too, to check the empty condition of the source water and if it is empty then water pump
doesn’t get start.

When the city tank gets full then it is time to proceed further with the water supply in city in a
smart way so PLC checks the tank full condition and opens the motor operated valve
connected to the city pipeline to supply the water to different areas of city. On the same pipe
line, we have connected Flow sensor to generate the records of flow in litres at the time of
water supply to the city. When the values are collected, they are saved in database with the
help of SCADA Connectivity. For the supervision of all these activities there is the requirement
of skilled person. User can access daily usage and own information as well as monthly bills
from database itself.

2.2.1 Salient Features of Smart Water Network

2.2.1.1 SCADA

In touch is world’s leading supervisory control and data acquisition software. The InTouch
software package consists of Tags (Memory + I/O). The software is available in 64, 256,
1000 and 64,000 Tags with the two options.

▪ Development + Runtime + Network (DRN)

▪ Runtime + network (RN).

2.2.1.2 PLC

A programmable logic controller (PLC) is a digital electronic device with a

programmable memory for storing instructions to implement specific functions, such as logic,
sequencing, timing, counting, and arithmetic to control machines and processes.

1. It is digital (uses binary to operate)

2. It can interface with analog devices

3. It is programmable and has memory

4. It stores instructions that are used to implement some function

5. It controls machines and processes

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2.2.1.3 Motor Operated Valve

Motor Operated Valves are often called as On-Off valves as the motors serve the purpose of
fully opening or fully closing valves in pipelines. Motor operated valves can be of various types
e.g. Gate/ Ball/ Butterfly etc. An electric motor is mounted on the valve and geared to the valve
stem so that when the motor operates the valve will open or close.

2.2.1.4 Flow meter and Pressure Sensor

Effective water management involves supplying water according to the real requirement,
and thus measuring water is very essential step in water management systems. Hall Effect
Water Flow Sensor” comes with three wires: Red/VCC (5-24V DC Input), Black/GND (0V)
and Yellow/OUT (Pulse Output). By counting the pulses from the output of the sensor, we
can easily calculate the water flow rate (in litre/hour – L/hr) using a suitable conversion
formula.

2.2.1.5 Water Level Indicator

Water level indicator is equipment used to control the water level in a water tank. The level of
the water is controlled by using a PLC, sensor, motor etc. The PLC produces the control
signals to drive the motor. If there is no water then PLC gives control signal to start the motor
and if there is sufficient water in the tank then the PLC give control signal to stop the motor.

2.2.1.6 HDPE Pipes

HDPE pipes are being used which have following advantages

1. Excellent ID/OD corrosion resistance.

2. Smooth surface reduces friction losses.

3. Very lightweight.

4. The pipes are flexible.

5. The pipes can easy to mould any shape

2.2.2 Advantages of Smart Water Network

▪ Supply- Demand management

▪ Water loss management

▪ Increase distribution efficiency

▪ Near real time monitoring

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 ▪ Energy optimization

▪ System will be fully automated.

▪ Fault detection is easier because of flowmeter and pressure sensor.

▪ Required man power reduces.

▪ System is fully reliable

2.3 Comparison

Table:2.1 Comparison between conventional system and Smart Water Network

Conventional water supply system Smart Water Network

Leakage can’t be detected in the pipes. Leakage can be detected easily by

measuring the pressure of pipe.

Monitoring and controlling is manual so
more man power is required.
Due to use of analogue circuitry installation
cost of this system is low.
Monitoring and controlling is easy due to use
of automation and comparatively negligible
man power is required.
Due to use of various sensors and digital
circuitry this is costlier.

Installation cost is low (Rs.558 per meter). Installation cost is high (Rs.1103 per meter).
This system is not reliable. Highly reliable system.

More maintenance is required. Less maintenance is required.

No need of skilled supervision. Skilled supervision

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Chapter 3

Survey, Components and

Schematic

19
 Chapter 3

Survey, Components and Schematic

3.1 Field survey of MANIT

To replace the existing water network of MANIT with Smart Water Network, the already
implemented system which was implemented in 1960 is studied and survey data and result is
given. The equipment and technology used in that network was the best available at that time.
The current manual system has RCC and cast iron pipes and hand operated valves.

Table:3.1 Components of Existing System

S. No. Components of current network Quantity

1 BMC Sump well 1
2 MANIT Sump well 2
3 Overhead water tank 3
4 8-inch Valves 8
5 6-inch Valves 15
6 3-inch Valves 8
7 Air Valves 5
8 8-inch pipe line (in meters) 3782
9 6-inch pipe line (in meters) 3434
10 3-inch pipe line (in meters) 4021
11 Motor pump set (55 KW) 2
12 Motor pump set (45 KW) 4
13 Auto transformer Starter 2
14 Star-Delta Starter 4

3.1.1 Valve

Water valves are made of iron and are hand operated or key operated. Gate Valve is
exceptionally sturdy, rugged and durable, with a reputation for quality, integrity and long
service. They are designed for tight sealing and ease of operation. The valves are available
with flanged ends or butt-weld ends, in pressure ratings from ASME Class 150 to Class 1500,

20
and in a variety of materials of construction, Gate Valves are of flexible wedge, outside screw-
and-yoke and bolted-bonnet construction. Globe Valves feature a ball-type disc, outside screw
and yoke and bolted-bonnet construction. They conform to BS 1873 and also meet the general
requirements of API 600, including shell wall thickness and stuffing box dimensions. Check
Valves are of swing-type and bolted-cover construction. They conform to BS 1868 and also
meet the general requirements of API 600, including shell wall thickness.

(1) (2)

Fig:3.1 Manual Gate Valve

3.1.2 Pipes

Generally, cast iron and RCC pipes are used. Cast iron pipes are quite stable and well suited
for high water pressure. However, cast iron pipes are heavy, which makes them unsuitable for
inaccessible places due to transportation problems. In addition, due to their weight they
generally come in short lengths increasing costs for layout and jointing.

Fig:3.2 CI pipes Fig:3.3 RCC pipes

21
Concrete cement pipes are expensive but non-corrosive by nature. Their advantage is that
they are extremely strong and durable. However, being bulky and heavy, they are harder and
costlier to handle, install and transport.

3.1.3 Motor

There are three pumping stations in MANIT campus to pump water from sump well to
overhead water tank. Induction motors are used as they are very efficient, rugged in
construction, suitable for any kind of environment, cheaper as compared to other same rating
motors. These six induction motors are installed in three pumping stations near the overhead
tank. Out of these six motors: four motors are of 60 HP and rest two are of 75 HP. In 75 HP
motors auto transformer starters are used and in 60 HP motors star-delta starters are used.

Fig:3.4 Pumping Station (near Hostel-3)

Table:3.2 Motor Specifications

Power output 75 HP
Voltage 415±10%
Current 22 A
Speed 1460 rpm
Efficiency 90%
Starter Star-Delta
Frequency 50 Hz

22
3.2 MANIT Water Network

Fig: 3.5 Water pipe line network

23
Fig:3.6 Water pipe line network with Valves

24
3.3 Cost of Existing network

Table:3.3 Cost of conventional system components

S. Component Rate (Rs) Total (Rs)

No.
1 8-inch CI pipes × 3782 meters 613 Rs/meter 2316160

2 6-inch CI pipes × 3434 meters 547 Rs/meter 1877666

3 3-inch CI pipes × 4021 meters 481 Rs/meter 1934826

4 8-inch manual valve × 8 6500 52000

5 6-inch manual valve × 15 4500 67500

6 3-inch manual valve × 8 2800 22400

Total 6270552

7 Unskilled man power × 7 7000/month/head 49000/month

8 Skilled man power × 1 9000/month/head 9000/month

3.4 Description of components to be used and their specifications

Table:3.4 List of Components

S. No. Component Type Qty.

1 SCADA Intouch Software 1

2 PLC Micrologix1400 9

3 Control Valve Motor Operated 36

4 Motor Induction 6

5 Variable Frequency Drive BT300 6

6 Pipes HDPE -

7 Flow meter & Pressure sensor YF-S201 20

8 Level Indicator 5

25
3.4.1 SCADA [3]

Intouch is world’s leading supervisory control and data acquisition software. The InTouch
software package consist of Tags (Memory + I/O). The package is available in 64, 256, 1000
and 64,000 Tags with the two options

1. Development + Runtime + Network (DRN)

2. Runtime + network (RN).
With DRN package you can develop as well as run the application but in case of RN you
cannot develop/modify the application. The application can be developed by using DRN
package and can be installed on RN package.

Wonderware has a package, Factorysuite, which can be used for monitoring the process. It's
a Runtime software with no control i.e. output from the Factoryfocus software to
hardware/external devices is not possible.

Fig:3.7 SCADA design

3.4.2 Programmable logic controller (PLC)

A programmable logic controller (PLC) is a digital electronic device with a programmable
memory for storing instructions to implement specific functions, such as logic, sequencing,
timing, counting, and arithmetic to control machines and processes. Some features of PLC
are given below:
26
 1. It is digital (uses binary to operate)
2. It can interface with analogue devices
3. It is programmable and has memory
4. It stores instructions that are used to implement some function
5. It controls machines and processes

Fig:3.8 Micrologix1400
3.4.2.1 PLC Advantages
▪ Flexibility
• In the past, each different electronically controlled production machine
required its own controller; 15 machines might require 15 different
controllers.
• Now it is possible to use just one model of a PLC to run any one of the 15
machines.
• Furthermore, you would probably need fewer than 15 controllers, because
one PLC can easily run many machines.
• Each of the 15 machines under PLC control would have its own distinct
program

▪ Implementing Changes and Correcting Errors

• With a wired relay-type panel, any program alterations require time for
rewiring of panels and devices.
• When a PLC program circuit or sequence design change is made, the PLC
program can be changed from a keyboard sequence in a matter of minutes.
• No rewiring is required for a PLC-controlled system.
27
 • Also, if a programming error has to be corrected in a PLC control ladder
diagram, a change can be typed in quickly.

▪ Lower Cost
• Increased technology makes it possible to condense more functions into
smaller and less expensive packages.
• Now you can purchase a PLC with numerous relays, timers, and counters,
a sequencer, and other functions for a few thousand rupees.

▪ Pilot Running
• A PLC programmed circuit can be evaluated in the lab. The program can be
typed in, tested, observed, and modified if needed, saving valuable factory
time.

▪ Visual Observation
• A PLC circuit's operation can be seen during operation directly on a CRT
screen.
• The operation or disoperation of a circuit can be observed as it happens.
• Logic paths light up on the screen as they are energized.
• Troubleshooting can be done more quickly during visual observation.

▪ Ladder or Boolean Programming Method

• The PLC programming can be accomplished in the ladder mode by an
electrician or technician. Alternatively, a PLC programmer who works in digital
or Boolean control systems can also easily perform PLC programming.

▪ Reliability and Maintainability

• Solid-state devices are more reliable, in general, than mechanical systems or
relays and timers. Consequently, the control system maintenance costs are
low and downtime is minimal.

▪ Documentation
• An immediate printout of the true PLC circuit is available in minutes, if
required.
• There is no need to look for the blueprint of the circuit in remote files.

28
 • The PLC prints out the actual circuit in operation at a given moment.
• Often, the file prints for relay panels are not properly kept up to date. A PLC
printout is the circuit at the present time; no wire tracing is needed for
verification.
3.4.3 Motor Operated Valve (MOV)

Motor Operated Valve (MOV) is an important item of Plant & Piping system. These valves are
generally of large size and are used for different applications such as Pump discharge etc.
Motor Operated Valves are often called as On-Off valves as the motors serve the purpose of
fully opening or fully closing valves in pipelines. For example, cooling water lines, process
pipelines where controlling of fluid is not required, motor operated valves can be used to fully
allow or fully stop the fluid flow. These valves are not used for throttling purposes as they serve
mainly On-Off service application.

Fig:3.9 Motor Operated Valve

Motor operated valves can be of various types e.g. Gate/ Ball/ Butterfly etc. with actuator
control. Design of Motors and valves can be different. An electric motor is mounted on the
valve and geared to the valve stem so that when the motor operates the valve will open or
close. For this MOV, motor operated with actuator control from local panel or, from control
room is required. There is a requirement of co-ordination among Piping-Electrical-
Instrumentation-Process engineers and vendor for design and procurement of such motor
operated valves.
29
3.4.3.1 Applications of motor operated valves

• Whenever frequent operation is required.

• Valves located in remote, inaccessible or hazardous places.

Motorised control valve / Motor operated valves are usually for full open and full close
applications. However, there are places where they are used for position control as well.

3.4.3.2 Types of motor operated valves

Motorised control valve can be classified into three types. However, it must be noted that the
main application of motorised valves are for flow control and flow isolation. Open/close valves
used to automate manual open close valves Examples include, pump discharge/suction
valves, boiler feed water isolation valves, drum vent valves, product line valves etc.

3.4.3.3 Key differences between control valves and motor operated on/off valves

• Control valves have a faster response as compared to the motorised valves.

• Control valves usually have an analogue control element, while the motorised
operated valves have a digital control element.
• Control valves can be used for any type of control, pressure control, flow control,
temperature control etc. while motorised valves are usually used for flow control.
• Control valve usually are used in closed loop control, while motorised valves are
predominantly open loop (with the exception of precision flow control valves).
• Control valves are used for precision control. However, motorised valves are not
usually used for precision control.

3.4.4 Motor

Water is filled in the tanks with the help of Induction Motor as these motors are very efficient,
rugged in construction, suitable in any kind of environment, cheaper as compare to other
motors.

Fig:3.10 45 KW Induction motor

30
There are 3 overhead tank in MANIT campus to fulfil the water requirement and each one is
employed with two such motors one as running unit and other one as stand by unit. So, there
are 6 induction motor installed near the overhead tank. Two motors are of 75 HP and
remaining 4 motors are of 60 HP.

Table:3.5 Motor Specifications

Output power 75 HP

Voltage 41510% volt

Current 22 A

Speed 1460 rpm

Efficiency 90%

Starter Star-delta

Frequency 50 Hz

3.4.5 Variable Frequency Drive [4]

Energy efficiency starts with motor speed control. Sixty-five percent of all electrical energy
used in the United States operates flow loads such as pumps, fans, blowers and compressors,
mostly powered by constant speed induction motors. When output flow requirements fluctuate
in such systems, an external means of adjustment is needed.

Fig:3.11 BT300 Variable frequency drive

31
Commonly used methods for flow control include throttling or restrictive devices such as
valves, outlet dampers, inlet vanes and dif-fusers. Mechanical speed changers and
recirculating sys-tems are also sometimes used. However, all these devices waste energy,
dissipate power by friction and diffuse heat. Fixed-speed pumps draw nearly full horsepower
and consume nearly maximum energy full time, regardless of demand. Power requirements
for throttled systems drop only slightly even when flow or volume is reduced significantly.

3.4.5.1 Choices

Variable frequency drives are available from fractional to 1000 HP with a wide range of input
voltages and options. Since they are designed to operate with standard motors, they can easily
be applied to an existing system. However, when choosing a variable frequency drive for a
particular system, it is essential to evaluate the product in terms of:

• Features and functions

• Ease of installation
• Ease of operation and maintenance
• Availability of options
• Expansion or upgrade capability to meet present and future needs
• Comprehensiveness of the vendor's application and service offering

3.4.6 PIPES

3.4.6.1 Advantages of HDPE pipes [5]

Some distinctive advantages of HDPE pipe that provide important benefits for water
applications are listed below:

• HDPE pipe can be heat fused together to form a joint that is as strong or stronger than
the pipe itself and is leak free. This eliminates the potential leak points every 10-20
feet as found with PVC and Ductile Iron bell and spigot connections.
• The Life Cycle Cost of HDPE pipe differs from other pipe materials because the
allowable water leakage is zero rather than typical leakage rates of 10 to 20% for PVC
and Ductile Iron.
• HDPE pipe fused joints are self-restraining and costly thrust restraints or thrust blocks
are not required.
• HDPE pipes fused joints simply do not leak, eliminating infiltration and exfiltration
problems experienced with alternate pipe joints.

32
 • HDPE pipe can be bent to a radius 25 times the nominal pipe diameter (Example: 12”
HDPE can be cold formed in the field to a 25ft radius). This can eliminate many fittings
required for directional changes in a piping system where fittings and thrust blocks or
restraints are required with alternate materials.
• The flexibility of HDPE pressure pipe makes it well suited for dynamic soils including
areas prone to earthquake.
• HDPE pressure pipe can accept repetitive pressure surges that significantly exceed
the static pressure rating of the pipe.
• Polyethylene pipe installations are cost effective and have long term cost advantages
due to its physical properties, leak free joints and reduced maintenance costs.
• HDPE pipe will not corrode, tuberculate or support biological growth.
• HDPE pipe has superb chemical resistance and is the material of choice in harsh
chemical environments
• It is much easier to handle and install HDPE pipe vs. the heavier, rigid metallic or
concrete pipe segments, allowing for huge cost advantages in the construction
process.

Table:3.6 Comparison between different pipes

Pipe material Main Use Advantages Disadvantages

Galvanised Customer 1. Robust 1. Not installed much
iron supply pipe 2. More difficult to anymore
tap into illegally 2. More disruptive and
difficult to lay

Cast iron Not used 1. Cast iron pipe is 1. It is also not

anymore the preferred advisable to use
choice for cast iron pipes in
handling high inaccessible places
pressures and 2. Because of their
loads of water heavy load, these
pipes are made in
shorter lengths.
Ductile iron Distribution 1. Robust 1. Needs to be coated
pipe 2. More difficult to depending on soil
tap into illegally condition to prevent
corrosion.
2. Rubber gasket at
joint can be
damaged when pipe
is jointed.
3. Expensive

33
 High Density Distribution 1. Flexible and 1. Cannot be used
Polyethylene pipe versatile under certain soil
(HDP) 2. Can be bent to a condition such as
point around contaminated with
curves oil, diesel, petrol
3. Good for etc.
directional 2. Need to be joined
drilling. together correct
Medium Customer 1. Flexible and 1. Joints need to be
density supply pipe strong electro fused
polyethylene( 2. Easy to handle 2. Sustainable to oil
MDP) similar to HDPE.

Polyvinyl Distribution 1. Cheapest option 1. Can be damaged by

chloride pipe in use exposure to
(PVC) 2. Easy to lay and sunlight.
join 2. Joints are glued
making them prone
to leakage.
3. Needs to have
proper bedding and
covering
Copper Customer 1. Robust, 1. More expensive
supply pipe 2. Suitable for harsh than MDP.
soil type 2. Needs to be joined
with mechanical or
soldered joints.

3.4.7 Water level Indicator

Water level indicator is equipment used to control the water level in a field. The level of the
water is controlled by using a PLC. Main component are PLC, sensor, motor etc. The sensors
sense the presence of water and give indication to the PLC. The PLC produces the control
signals to drive the motor. If there is no water then PLC gives control signal to start the motor
and if there insufficient water in the field then the PLC give control signal to stop the motor.
And also, the PLC and SCADA enables the display and displayed as “THE MOTOR IS ON”
when the motor starts and disable the display when “THE MOTOR IS OFF”. Hence the level
of water in a field can be automatically controlled. The main components used in this
equipment are PLC, sensor and motor.

3.4.7.1 Sensor

Here the sensor used is the two conductors placed in the field. If there is water then the
conduction occurs between the two conductors, which closes a circuit to the microcontroller
and microcontroller detects the intensity of water in the field. If there is no conduction

34
microcontroller detects that water is in the field. If there is no conduction microcontroller
detects absence of water.

3.4.7.2 Block Diagram

Relay circuit PLC &SCADA LCD

MOTOR

Water tank and

Sensor

Fig:3.12 Block Diagram of Water Level Sensor Circuit

3.4.7.3 Advantages of Water Level Sensor

• Human effort is reduced as the system controls the motor automatically based on
the water level.
• This system consumes less power.
• Simple and more reliable.
• Used in big buildings where the manual monitoring is difficult.
• Used in industries to control the liquid level automatically.

3.4.8 Water Flow Sensor

Flow meters have proven excellent devices for measuring flow in the irrigation fields as it is
required for measuring the water needed in irrigation fields in order to avoid damage of crops
with excess water and even to save the water as it is most precious resource. Flow meter also
serves the purpose of judging the irrigation pipelines as for example lower than normal flow

35
rates may indicate the need for pump repair or leakage of pipelines. Flow can be measured
with contact type or non-contact type of sensor. [6]

3.4.8.1 YF-S201 Hall-Effect Water Flow Sensor

Accurate flow measurement is an essential step both in the terms of qualitative and economic
points of view. Flow meters have proven excellent devices for measuring water flow, and now
it is very easy to build a water management system using the renowned water flow sensor YF-
S201

This sensor sits in line with the water line and contains a pinwheel sensor to measure how
much water has moved through it. There is an integrated magnetic Hall-Effect sensor that
outputs an electrical pulse with every revolution. The “YFS201 Hall Effect Water Flow Sensor”
comes with three wires: Red/VCC (5-24V DC Input), Black/GND (0V) and Yellow/OUT (Pulse
Output). By counting the pulses from the output of the sensor, we can easily calculate the
water flow rate (in litre/hour – L/hr) using a suitable conversion formula.

Q =V x A

where,

Q is flow rate/total flow of water through the pipe

V is average velocity of the flow

A is the cross-sectional area of the pipe

Fig:3.13 Water Flow Meter

36
3.5 System Block Diagram

SCADA System PLC

Database Server
Programmable Water
Logic Tank
Controller Level

MOV 1 MOV 2 MOV 3

Online Portal

Flow Flow Flow

Meter 1 Meter 2 Meter 3

User User User

1 2 3

Fig: 3.14 Block Diagram of Proposed System

3.6 System Design and Implementation

1. SCADA Screen shows all the parameters of motor-pump set (Voltage, Current,
Temperature, Phase sequence), position of motor operated valve (Open or Closed),
reading from flow meter, water level of water tank.
2. SCADA system is connected to all remotely installed PLCs through Modem and PLCs
are connected to motor operated valves and motors through LAN Cable.
3. First level indicator sense the level of water in overhead tank and send data to SCADA,
if tank is empty then user can send a starting signal to pump and vice-versa.
4. If water tank has sufficient water to supply to the consumer, user can operate the motor
operated valve as per the requirement.
5. If there is any leakage in the pipe line or any fault in system it will be detected instantly
and shown on SCADA screen, so that user can take required action.

37
3.7 Flow Chart

start

Motor switch on

No is water
tank empty

yes

Is water Yes
source empty

Motor on

No Is water
tank full

Motor off

Electronic valve switch on

Starts counting water

flow & store in database

end
38
3.8 Cost Estimation

Table: 3.7 Cost Estimation

S. No. Product Name Quantity Price(₹) Total

1 Micrologix1400 PLC 9 22680 204120

2 Water Flow sensor 20 1250 25000

3 Water level Indicator 5 2285 11425

4 Variable Frequency Drive 6 186270 1117620

5 HDPE pipes 3-inch (in meters) 4021 167.31 672753

6 HDPE pipes 6-inch (in meters) 3434 529.57 1818543

7 HDPE pipes 8-inch (in meters) 3782 826.01 3123969

8 MOV 8 inch 8 318955 2551640

9 MOV 6 inch 15 207997 3119968

10 MOV 3 inch 8 138990 1111923

11 SCADA Software 1 14500 14500

12 D-Link Modem 9 1800 16200

Grand Total ₹13787389

39
Chapter 4

PLC and SCADA

40
 Chapter 4

PLC and SCADA

4.1 PLC [6,7]

A programmable logic controller (PLC) is a digital electronic device with a programmable

memory for storing instructions to implement specific functions, such as logic, sequencing,
timing, counting, and arithmetic to control machines and processes.
1. It is digital (uses binary to operate)
2. It can interface with analogue devices
3. It is programmable and has memory
4. It stores instructions that are used to implement some function
5. It controls machines and processes

4.1.1 History of PLC

The Hydromantic Division of the General Motors Corporation specified the design criteria
for the first programmable controller in 1968. Their primary goal to eliminate the high costs
associated with inflexible, relay-controlled systems

• 1968- Programmable concept developed

• 1969- Hardware CPU controller, with logic instructions, 1 K of memory and 128
I/O points
• 1974- Use of several (multi) processors within PLC - timers and counters;
arithmetic Operations; 12 K of memory and 1024 I/O points
• 1976- Remote input/output systems introduced
• 1977- Microprocessors - based PLC introduced
• 1980- Intelligent I/O modules developed Enhanced communication facilities
Enhanced software features (e.g. documentation) Use of personal
microcomputers as programming aids
• 1983- Low - cost small PLC’s introduced
• 1985- Networking of all levels of PLC, computer and machine using SCADA
software.

4.1.2 PLC Hardware

PLC inputs and outputs can be following types

41
 1. Discrete or Analog
Inputs and outputs are sold as either analogue or digital/discrete. Analog inputs
and outputs can vary continuously in steps in the same way that a Digital to
Analog Converter works. Digital or Discrete inputs and outputs are either on
or off.
2. Fixed, Expansion, or Modular
Some PLCs come with a set of “fixed” I/O. They cannot be removed and are
not exchangeable. Some PLCs do not come with fixed I/O and if you want any
you need to purchase “expansion” I/O. Still other PLC modules come with
“fixed” I/O and have room for “expansion” I/O. Many times, the I/O is needed to
be located away from the PLC and a communication cable is placed between
them. This is called “modular” I/O. Many PLCs have the ability to accommodate
all three types.

3. DC or AC
Inputs and outputs are sold as either direct current (DC) compatible or
alternating current (AC) compatible. Some inputs and outputs can handle either
AC or DC. Below is a list of available input and output sets available for the
MicroLogix1400 PLC we have in the lab. The MicroLogix1400 is capable of
handling four I/O expansion modules along with the fixed I/O.

4. Sourcing and Sinking

This one of the most important and overlooked aspect of I/O! From the
MicroLogix1400 User Manual, below is an image of the fixed I/O supplied with
the controller. To wire the inputs as sourcing the DC COM would be wired to
+24Vdc and the inputs would be wired to a switch of some sort. The other side
of the switch would be wired to ground. To wire the inputs as sinking, the switch
is wired to +24Vdc and to an input and the DC COM is wired to ground. We will
use sinking inputs in the lab.

4.1.3 Ladder Logic Symbols

There are three main symbols that are commonly used. These are the Normally Open (NO)
Contact (also called the XIC –Examine if Closed), the Normally Closed (NC) Contact (also
called the XIO – Examine if Open), and the output.

42
 INPUT TERMINAL BLOCK

Not not DC DC
Used used COM 1/0 1/1 1/2 1/3 COM 1/4 1/5 1/6 1/7 1/8 1/9 COM IV1 IV2

[ +12/24 NOT VAC 0/0 VAC 0/1 VAC 0/2 VAC 0/3 VAC 0/4 VAC 0/5 NOT
DC IN ] USED VDC VDC VDC VDC VDC VDC USED

OUTPUT TERMINAL BLOCK

Fig: 4.1 PLC I/O Terminals

1. Normally Open Contact (XIC) Address I: 0.0/0 – input 1

2. Normally Closed Contact (XIO) Address I: 0.0/3 – input 4

3. Output – Address O:0.0/0 – output 0

With these three components, we can create the seal circuit in a ladder logic program. The
first step is to realize that there are no switches inside the PLC, but instead a contact can be
“associated” to an input and the switches can be wired to an input.

4.1.4 Software
RSLinx

RSLogix is used to communicate with the PLC to the emulator. start by running the RSLinx
software under the

START > All Programs > Rockwell Software > RSLinx > RSLinx Classic shortcut.

Follow these steps to set it up:

43
 • Under the Communications menu select Configure Drivers.

• Under the Available Drivers Types select the SLC 500 (DH485) Emulator driver and
click the Add New button.

• A name can be given to driver. For example, EMU500-1.

• Leave the configuration options as Station Number 00 and click OK.

4.2 SCADA
Intouch is world’s leading supervisory control and data acquisition software. The InTouch
software package consist of Tags (Memory + I/O). The package is available in 64, 256, 1000
and 64,000 Tags with the two options

1. Development + Runtime + Network (DRN)

2. Runtime + network (RN).

With DRN package you can develop as well as run the application but in case of RN you
cannot develop/modify the application. The application can be developed by using DRN
package and can be installed on RN package.

Wonderware has a package, Factorysuite, which can be used for monitoring the process. It's
a Runtime software with no control ie output from the factoryfocus software to
hardware/external devices is not possible.

4.2.1 New features in InTouch 7.0

1. Application Explorer

Window Maker's Application Explorer is a hierarchical graphical view of application. It

shows what items user have configured in the application and provides you easy
access to those items. It also provides you with quick access to many of
WindowMaker's most commonly used commands and functions.

2. Applications Run on Windows NT Operating System or Windows 95

The applications you create on the Windows 95 or the Windows NT operating systems
are interchangeable. They can run on either operating system without requiring
conversion.

44
 3. Tagname Cross Referencing
The Tagname Cross Referencing utility allows you to determine both your tagname
and SuperTag usage and, in which window or QuickScript that a specific tagname is
used. For convenience, the Tagname Cross Reference utility can remain open in
WindowMaker while you perform other tasks. It also allows you to view any QuickScript
or QuickFunction where a tagname is found.

4. Instrument Failure Monitoring

Beginning with Version 7.0, InTouch supports three tagname dot fields (.RawValue,
.MinRaw and .MaxRaw) that you can use in InTouch QuickScripts to monitor
instrument values to determine out-of-range, out-of-calibration or, failure.

4.2.2 Installation of SCADA software

Table:4.1 SCADA Installation procedure

Sr. No. Action Result

1 Insert the InTouch installable disk and run Welcome to setup program window
setup

2 Click on Next Button Factory suite 2000 license window

3 Click on Yes button User information window

4 Enter the name and company name of the Registration confirmation window
customer and click NEXT

5 Click yes if the registration information is Installation will start and Installing
correct. If the information is not correct click FS2000 common component
“NO”. Re-enter the information and click “YES”. window will appear.

6 If version conflict message like “A file being Select Intouch destination directory
copied is older than the file currently on your window.
computer------- Do you want to keep 5this file
“appears. Please click on yes .

7 Click on NEXT without changing the default Select component window.

directory.

45
 8 Please select the desired components like Choose configuration option window
Intouch 7.0, Intouch 7.0 SPC, Intouch 7.0
SQL Access, Intouch 7.0 Recipe Manager
and click on Next

9 Select Full development, Runtime only or Question “Add icons to start menu to
Factory Focus as per the requirement and click access manuals from install source?
on to “YES “ “window.

10 Click “YES “ Start copying files window.

11 Click on “NEXT “ Intouch setup window “Please

review the release-------- “

12 Click on “OK “ Setup complete window will appear

13 Restart the PC by clicking on finish Installation complete.

In between the installation, the message will appear for installation of the MSSQL and
Acrobat reader. Please install the software. The MSSQL software is used for
generating reports and acrobat reader software is used for viewing the manuals.

4.2.3 Application Development in Intouch Software

1. Creating New Application

1. Click on InTouch in the factory suite group

InTouch application manager window will appear
2. On the File menu, click New, or click the New tool in the toolbar Create New
Application wizard will appear.
Click on Next
3. Create new application window with default path will appear. By default, the system
will display the path to InTouch directory followed by "NewApp."
4. In the input box, type the path to the directory in which user want the application to
be created or click Browse to locate the directory.
Click Next.
5. If the directory you specify does not exist, a message dialog box will appear asking
if user want to create it.

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 Click OK.
6. Create New Application wizard dialog box will appear. in the Name box, type a
unique name for the new application's icon that appears when the application is
listed in the InTouch Application Manager window.
Click Finish
7. The InTouch Application Manager will reappear displaying an icon with the name
user specified for the new application.

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Chapter 5

Field Survey and Analysis

48
 Chapter 5

Field Survey and Analysis

5.1 Field Survey of Ahmedpur Substation (SCADA Based System)

Intelligent water network system is completely based on the interfacing of SCADA and PLC because
the combination of these gives the optimal solution for different problem like water distribution, water
leakage, water flow, real time monitoring and controlling, pressure sensing etc.

To get the results of implemented intelligent water monitoring system observation of Water
Supply network of Bhopal city has been done. The Operation of Distribution network is manual but
the pumping stations and treatment plants are SCADA based and automated. In this report overview
of the SCADA controlled unit located at Ahmedpur (Bhopal) has been shown. All supply system is
divided into five Zones. Overview of these zones is as follows-

Fig: 5.1 Overview of Narmada water supply project Bhopal (Courtesy- BMC)

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The above shown overview is the complete distribution system for a particular area which is
connected through wireless communication. The connections from water treatment plant and
all pumping stations is shown below.

Fig: 5.2 Water flow From Treatment plant to Substations (Courtesy- BMC)

5.1.1 Hirani

Hirani is the raw water pumping station which takes water from Narmada River. The whole
project is under Narmada Water Supply Project. The capacity of Hirani pumping station is 185
MLD. This substation has 6 pump units to pump water to the treatment plant which is in
Khatpura (Bhopal). Out of these 6 units 3 are in continuous working and other 3 units are
standby. All pumping units has Automatic valves and manual valves. Automatic valves are
PLC and SCADA controlled which provides real time controlling and has response in
milliseconds.

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 Fig: 5.3 Raw water pump house, Hirani (Courtesy- BMC)

5.1.2 Water Treatment Plant, Khatpura

Raw water collected from Hirani is pumped to water treatment plant Khatpura. First of all this
water is passed through Aerator. Aerator brings water and air in close contact in order to
remove dissolved gases (such as carbon dioxide) and oxidizes dissolved metals such as iron,
hydrogen sulphide, and volatile organic chemicals (VOCs). Some key tests are also
performed.

1. PH test- pH is one of the most common water quality tests performed. pH indicates
the sample's acidity but is actually a measurement of the potential activity of hydrogen
ions (H+) in the sample. pH measurements run on a scale from 0 to 14, with 7.0
considered neutral.
2. Turbidity test- Turbidity is the cloudiness or haziness of a fluid caused by large
numbers of individual particles that are generally invisible to the naked eye, similar to
smoke in air. The measurement of turbidity is a key test of water quality.
3. Wrinkle test- Winkler test is used to determine the concentration of dissolved oxygen
in water samples.

After all these test water is passed through chemical house, where all these parameters are
corrected to their normalized value, and at the outlet, all these parameters are again measured
to be assured about water quality.
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 Fig: 5.4 Water treatment plant, Khatpura (Courtesy- BMC)

5.1.3 Water pump house no. 1, khatpura

After the treatment water is stored in two water sump each one of which is connected to 3
motors to forward the water. Two out of three motors work at a time one remains at stand by
unit. Water is forwarded to Dohtaghat from these sump well.

In the below shown SCADA screen red coloured pumps are in ON condition and the green
coloured pump are in OFF condition. Orange colour valve shows that these are not fully
opened. One flow meter and air vessel is also connected in the pipe line. Air vessel is used to
nullify the effect of vacuum.

5.1.4 Break pressure tank, Dohtaghat

The clear water from the Khatpura is pumped to the break pressure tank, Dohtaghat because
Dohtaghat is located at upward slope as compare to Khatpura. The break pressure tank is
constructed not to reduce the pressure of pipe lines. Inlet and outlet flow meter are connected
in the tank so the water flow can be maintained.

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 Fig: 5.5 Water pump house no.1, Khatpura (Courtesy- BMC)

5.1.5 Water pump house no. 2, Ahmedpur

Clear water is forwarded from break pressure tank to Water pump house no.2 without any
pumping efforts, water flows due to gravity because break pressure tank is at height as
compare to water pump house no.2.

Fig: 5.6 Break Pressure Tank, Dohtaghat (Courtesy- BMC)

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 Fig: 5.7 Water sump house no.2, Ahmedpur (Courtesy- BMC)

In this pumping station, some amount of chlorine (1.00 ppm) is mixed with the clean water to
enhance the quality of water to be distributed. As previous pump house this is also divided
into two tank and each tank is connected to 3 motors. 2 out of three runs at a time and one is
installed as standby unit. These motors are feed through 33/6.6 KV substation installed beside
the pumping station. The specification of motors installed at the pumping stations is as follows-

Table: 5.1 Motor Specification

Power 650 KW
Voltage 6.6 KV
Current 68 AMP
Frequency 50 Hz
Power Factor 0.973
Energy (KWH) 703
Starter Soft starter

5.1.6 Master balancing service reservoir, Arera Hills

Clean water stored in water sump no.2 is pumped to the Master balancing reservoir, Arera
hills. As clear from the name master balancing reservoir takes care about Supply-demand

54
balancing. From this reservoir, the water is forwarded to the different distribution overhead
tanks.

Fig: 5.8 Master balancing reservoir, Arera hills (Courtesy- BMC)

5.2 Results of Ahmedpur Substation

SCADA system provides real time data monitoring and data collection. It provides an online
data storage facility which can be used for future analysis. The system provides hourly data
of water discharge, flow rate, chlorine (PPM), pressure, stored water, motor parameters like
voltage, current, power factor and energy consumed along with all these data system also
gives the information about motor parameter like voltage, current, power factor and energy
consumed. Hourly report of 3 different days of different months (11 sept, 6 oct, 26 march) is
attached. There is very small deviation in the quantity of water flows per day.

One monthly report (august 2016) is also attached. Total amount of water discharge in august
month is 4520.4 Million Litres and it remains same for different season. Bar graph of monthly
report is also shown which shows the discharge of water (MLD) on the daily basis.

55
Chapter 6

Conclusion and Future

Scope

56
 Chapter 6

Conclusion and Future scope

6.1 Conclusion

The automation implemented in water distribution system ensures to avoid wastage of water
and reduces time. Due to SCADA it is possible to monitor and control whole system from
headquarters. Distributed system is intelligences it monitoring all time without man power. This
system of water supply can be implemented in cities by using technologies like PLC and
SCADA with the help of government taking efforts to initiate it. This whole water supply system
can be accessed by users through online portal made for this project. This system insures to
avoid wastage of water and reduce the time as well as it also controls and monitor the water
supply Due to SCADA it is possible to monitor and control whole system from main control
units. The displaying data based can be enlarged throughout the year, month and daily report
in central PC.

The whole automatic system involves the process of supplying water to a particular area at
particular time. Water supply will be stopped automatically after reaching fixed value limit.
Over consumption can be intimated by measuring the flow of water to every connection in
water supplying network. This measurement can be done by using flow sensor at every
channel.

This system primarily focused on the water crisis in order to make water distributions more
efficiently by reducing wastage of water and power. This proposal is made considering water
distribution system advanced for both rural and urban areas. This system which insures the
balanced distribution of water throughout the city/area. it monitors, controls and protects all
the water pumps used for water distribution purpose. It monitors all the storage tanks situated
and distributes the water equally to all the areas depending upon the amount of water in the
tank.

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6.2 Future Scope

• In future work this system can be modified as, it will detect the exact location of
pressure drop and this system can also be used in agriculture field to supply the water
properly for required area to meet own conditions effectively. [14]
• By using the pH sensor quality of water can also be improved. [14]
• For water theft prevention, a water meter can also be installed at consumer side.
• A solar panel can also be installed to power PLCs at remote areas.
• Advance water leakage detection technologies such as for metallic pipes signal
generator and for nonmetallic pipes tracer wire and sound wave technology can be
used for instant leakage point detection.

58
References

[1] history of water network (wordpress.com) Authors Haestad Methods Thomas M. Walski,
Donald V. Chase, Dragan A. Savic, Walter Grayman, Stephen Beckwith, Edmundo Koelle.

[2] Automation of Water Distribution Plant (IJREAT International Journal of Research in

Engineering & Advanced Technology, Volume 2, Issue 1, Feb-Mar, 2014).

[3] Intouch SCADA software manual.

[4] Instrumentation and control, Kevin Tory, Hitachi America, Ltd.

[5] AWWA Committee Report “Design and Installation of Polyethylene (PE) Pipe Made in
accordance with AWWA C906,” American Water Works Association, Denver, Colorado
(1998).

[6] Ria Sood, Manjit Kaur, Hemant Lenka (International Journal of Computer Science,
Engineering and Applications (IJCSEA) Vol.3, No.3, June 2013)

[7] A. Daneels, W. water, “Technology survey summary of study report”, CO/98-08-09/ CERN,
Geneva 26 th Aug 1998.

[8] A. Deneels, W. salter, “Selection and Evaluation of commercial SCADA systems for the
controls of the CERN LHC Experiments”,proceeding of the 1999 international conference on
Accelerator and Large Experimental physics control systems , Trieste 1999.

[9] Prashant palkar, Shrinivas Patil, Pooja Belagali, Ashish Chougule. IOSR Journal of
Electronics & Communication Engineering (IOSR-JECE) ISSN: 2278-2834, ISBN : 2278-
8735, PP : 36-38
[10] Pratiksha Hattikatti, Savita Karwande, Poonam S. Rode Mrunalini Bhandarkar, PLC
Controlled Water Distribution System, Vol. 4, Issue 5, May 2015.

[11] Rohini .P Onkare, Sneha Randhir Mane, Pooja Ramchandra Rakshe, Priyanka Suryakant
Waghmare, Water Distribution System Using PLC and SCADA, Vol. 5, Issue 3, March 2017

[12] E.Vinothini, N. Suganya Department of Pervasive Computing Technology, Kings College

of Engineering, Punalkulam, Tamilnadu, Automated Water Distribution and Performance
Monitoring System, International Journal of Engineering and Innovative Technology (IJEIT)
Volume 3, Issue 8, February 2014.

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[13] Harish K M, Chaitra R, Deepika R, Divya K S, Nandini M, CENTRALISED WATER
DISTRIBUTION MONITORING AND CONTROLLING SYSTEM USING PLC AND SCADA,
International Journal of Science, Engineering and Technology Research (IJSETR) Volume 5,
Issue 6, June 2016.

[14] Report submitted by Urban Management Centre to CEPT University, Ahmedabad, Study
Tour to Maharashtra on SCADA and 24x7 Water Supply Initiatives, April 2013.

[15] www.wikipedia.com

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