DEVELOPMENT OF AUTOMATIC WATER LEVEL CONTROL

AND IT’S MONITORING SYSTEM

MOHD SYARAFI BIN MUDA

A report submitted in partial fulfillment of the requirements for the

Bachelor of Electrical Engineering (Control, Instrumentation and Automation)

Faculty of Electrical Engineering

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

2009
“I hereby declared that I have read through this report entitled “Automatic Water Level
Control and Its Monitoring System” and found that it has comply the partial fulfillment for
awarding the degree of Bachelor of Electrical Engineering (Control, Instrumentation, and
Automation)”

Signature : ……………………………

Supervisor’s Name : PN. AZRITA BINTI ALIAS

Date : 22 APRIL 2009

I hereby declared that this report entitle “Automatic Water Level Control and Its Monitoring
System” is the result of my own research except for the excerpts that have been cited clearly in
the references. The report has not been accepted for any degree and it is not concurrently
submitted in candidature of any other degree.

Signature : …………………………………

Name : MOHD SYARAFI BIN MUDA

Date : 22 APRIL 2009

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ACKNOWLEDGEMENTS

In the name of Allah, Most Gracious, Most Merciful who has given me strength and
patience to complete this final year project and deliver it. It will not be successful without the
contribution and perseverance support of numerous people.

First of all, I would like to express my deepest gratitude to my project supervisor

Madam Azrita binti Alias for her valuable advices, guidance and assistance. Her excellent
supervision had been the key factor for the success of the Final Year Project II (PSMII).

Indirectly, I would like to express my appreciation to all participants who had

volunteered in this study. Without their contribution, there would not have any project testing
conducted. I wish to thanks for their participation and patient throughout the testing
procedures. Thanks a lot to my friends and all BEKC members for their additional support and
encouragement that I need in my way to complete this thesis.

Finally, special tribute goes to my parent Mr. Muda Mamat and Madam Maznah Ngah
who had taught me the good things that really matter in the life and thanks for the love that
never less.
 iii

ABSTRACT

Nowadays robotic and automation system has been introduced to facilitate humankind from
doing everyday chores to the high scale manufacturing. A control and automation system is
very important for country to generate economy throughput optimization and better product.
Therefore, it needs the modern and exceptional automation system. Based on that requirement,
an “Automation Water Level Control and Its Monitoring System” have been developed. The
water levels in tank automatically control by the pump. It also can monitor the system on the
personal computer PC with the interfacing system. Visual Basic software is used as software
tool to produce a graphic user interface (GUI). An electronic sensor circuit was detecting the
water level and give signal to the Programmable Logic Controller PLC. The PLC control the
pumping system to allow the amount of water that will be flow into the tank. The whole
processed will be connected by parallel port to the personal computer and monitor the water
level using Visual Basic 6 software programming.
 iv

ABSTRAK

Hampir kesemua pekerjaan dalam kehidupan manusia seharian masakini telah di permudahkan
oleh penggunaan robot dan sistem automasi. Ia meliputi kerja harian biasa sehinggalah kepada
penghasilan produk yang banyak dan berkualiti. Memandangkan sektor kawalan dan automasi
adalah amat penting untuk menjana ekonomi negara melalui produk yang lebih optimum dan
berkualiti tinggi, maka satu sistem kawalan yang moden dan cekap adalah perlu. Berdasarkan
keperluan ini, projek ” Sistem Automasi Kawalan Paras Air serta Pengawasan ” dibangunkan.
Projek ini mengawal takat air di dalam tangki simpanan secara automatik menggunakan pam.
Ia juga dipantau oleh sistem kawalan melalui paparan pada komputer. Perisian Visual Basic
digunakan bagi membina pengantaramuka grafik pengguna. Pengesan jarak mengesan takat air
dan menghantar isyarat yang diterima kepada Pengawal Logik Aturcara (Programmable Logic
Controller-PLC). PLC mengawal sistem pengepam air bagi membolehkan sejumlah air masuk
ke dalam tangki simpanan. Isyarat yang dikawal dari PLC akan dihantar ke komputer melalui
pengkalan selari dan dipaparkan menggunakan perisian Visual Basic 6.0.
 v

TABLE OF CONTENT

CHAPTER CONTENT PAGE

ACKNOWLEDGEMENT ii

ABSTRACT iii

ABSTRAK iv

TABLE OF CONTENTS v

LIST OF TABLES x

LIST OF FIGURES xi

LIST OF ABBREVIATIONS xiv

LIST OF APPENDICES xv

I INTRODUCTION

1.1 Overview 1
1.2 Objective of project 1
1.3 Scope of project 2
1.4 Problem Statement 2
 vi

CHAPTER CONTENT PAGE

II LITERATURE REVIEW

2.1 Overview 3

2.2 Literature Review 4

2.2.1 Water Level Control System 4

2.2.2 Liquid Level Monitoring Systems 6
2.2.3 Application of Water Level Control System 11
2.2.3.1 Monitor Water Level in sand tank 11
2.2.3.2 Monitor Water Level in Brunei River 12
2.2.3.2 Water Pumping System 13
2.2.4 Types of Water Level 15
2.2.4.1 Float Switch 16
2.2.4.2 Ultrasonic Sensor 17
2.2.4.3 Magnetic Level Gauges 18
2.2.4.4 Capacitive Transmitter 19

2.3 Project Background 20

2.3.1 Water Level Sensor Circuit 20
2.3.1.1 Dual Water Level Sensor Circuit 20
2.3.1.2 Water Level Detector Circuit 23
2.3.2 Programmable Logic Controller 26
2.3.2.1 Parts of PLC 28
2.3.3 Two Way Valve 30
2.3.4 Pump 32
2.3.5 Interfacing System 34
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CHAPTER CONTENT PAGE

III METHODOLOGY

3.1 Overview 36
3.2 Project Methodology 38
3.2.1 Research and Study 38
3.2.2 Design Water Level Sensor Circuit 38
3.2.3 Design PLC 40
3.2.3.1 CX-Programmer 41
3.2.4 Design and wiring hardware 44
3.2.4.1 Components Water Level Circuit 44
3.2.4.2 Hardware Implementation 49
3.2.5 Design Visual Basic 53
3.2.5.1 Visual Basic 6 53
3.2.5.2 Starting Visual Basic 53
3.2.5.3 Properties Window 55
3.2.5.4 Toolbox 56
3.2.6 Interfacing with Parallel Port 57
3.2.7 Analysis 59
3.2.8 Conclusion 59
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CHAPTER CONTENT PAGE

IV RESULT AND DISCUSION

4.1 Overview 60
4.2 Hardware Implementation 60
4.2.1 Water Level Sensor Circuit 60
4.2.1.1 Circuit’s Analysis 61
4.2.1.2 Circuit Simulation 62
4.2.1.3 Simulation Result 65
4.2.1.4 Circuit Implementation 67
4.3 Software Implementation 68
4.3.1 PLC 68
4.3.1.1 I/O Assignments 68
4.3.1.2 PLC’s Analysis 71
4.3.2 Visual Basic 72
4.3.2.1 Codes Programme 72
4.3.2.1 Main Control System 74
4.3.3 Interfacing Parallel Port 78
4.4 Project Implementation 80
4.5 Financial Costing 83
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CHAPTER CONTENT PAGE

V CONCLUSION AND RECOMMENDATION

5.1 Conclusion 84
5.2 Problem Encountered 85
5.2.1 Electronic 85
5.2.2 Mechanical 86
5.2.3 Software Programming 86
5.3 Recommendation 87

REFERENCES 88
APPENDICES 89
Appendix A 89
Appendix B 90
Appendix C 91
Appendix D 92
Appendix E 95
 x

LIST OF TABLES

TABLE TITLE PAGE

2.1 Parts of Valve 31

4.1 Input I/O Assignment 69
4.2 Output I/O Assignment 70
4.3 Internal Relay Assignment 70
4.4 Financial Costing 83
 xi

LIST OF FIGURES

FIGURES TITLE PAGE

2.1 LEVEL MASTER Water Level Control System 4

2.2 Monitoring System of Water Level 5
2.3 Type of Sensor 5
2.4 Water Level Sensor 6
2.5 Typical Water Supply System 7
2.6 Water Level Control System 8
2.7 Field Water Supply 8
2.8 Sump Pump 9
2.9 Automatic Water Level Control 10
2.10 Acoustic Wave Sensor 11
2.11 Water level control in Brunei River 12
2.12 Water Pumping System 13
2.13 Microcontroller Architecture 14
2.14 Example types of Water Level Sensor 15
2.15 Example of Float Switch 16
2.16 Application Float Switch 16
2.17 Example of Ultrasonic Sensor 17
2.18 Application Ultrasonic Sensor 17
2.19 Example of Magnetic Level Gauges 18
2.20 Application of Magnetic Level Gauges 18
2.21 Example of Capacitance Transmitters 19
2.22 Application of Capacitance Transmitter 19
2.23 Sensor setup 22
2.24 Illustrates the complete circuit 22
2.25 Water Level Sensor Circuit 25
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FIGURES TITLE PAGE

2.26 PLC Block Diagram 7

2.27 Example of PLC Block Diagram 28
2.28 I/O Assignments Types 29
2.29 Ladder Diagram 29
2.30 Valve Diagram 31
2.31 Pump Principle 32
2.32 Pump wiring 33
2.33 Pump Motor 33
2.34 Parallel Port 34
2.35 Parallel Port Pin 34
2.36 Wiring of Parallel port 35
3.1 Project Flowchart 37
3.2 Water Level Sensor Circuit 39
3.3 Multisim 9 Software 40
3.4 Multisim 9 Display 40
3.5 CX-Programmer 41
3.6 CX-Programmer Display 42
3.7 Chosen Type of PLC 42
3.8 PLC Flowchart 43
3.9 List of Components 45
3.10 IC-CD4066 46
3.11 Diagram of IC-CD4066 46
3.12 Electronic Level Detector 47
3.13 LED 47
3.14 Alarm Buzzer 48
3.15 Switch ON/OFF 48
3.16 Water Level Detector Circuit 49
3.17 Panel Board 49
3.18 Hardware 50
3.19 Pump 50
3.20 2-way valve 51
3.21 I/O Panel Board 52
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FIGURES TITLE PAGE

3.22 Control Panel Board 52

3.23 Water Level Detector 53
3.24 Icon Visual basic 54
3.25 Layout Visual basic 55
3.26 Form Properties 56
3.27 Toolbox 56
3.28 Parallel Port View 57
3.29 Female pin 57
3.30 Printer Port properties 58
4.1 Water Level Detector Circuit 61
4.2 Simulation Progress 63
4.3 Measure Current Value 64
4.4 Parameter Circuit 64
4.5 Simulation Result 66
4.6 Electronic Water Level Circuit 67
4.7 Panel Box of Electronic Circuit 68
4.8 Isolating Transformer 68
4.9 Mnemonic Code Diagram 70
4.10 PLC Ladder Diagram 71
4.11 Modules Codes of Parallel Port 73
4.12 Visual basic Module 74
4.13 Codes of Programming 78
4.14 Main display of Monitoring 78
4.15 Interfacing Circuit 79
4.16 Parallel Port Circuit 79
4.17 Parallel Port 80
4.18 Main Hardware 81
4.19 Main Control Panel 81
4.20 Parts of Water Detector 82
4.21 I/O Assignment 82
 xiv

LIST OF ABBREVIATIONS

PLC - Programmable Logic Controller

VB - Visual Basic
PC - Personal Computer
RAM - Random Access Memory
I/O - Input/Output
AC - Alternate Current
DC - Direct Current
IC - Integrated Circuit
LED - Light Emitting Diode
GUI - Graphical User Interface
USB - Universal Circuit Bus
 xv

LIST OF APPENDICIES

APPENDIX TITLE PAGE

A Simulation Result of Water Level Circuit

B PLC Ladder Diagram

C Mnemonics List (Ladder Diagram)

D Visual Basic Codes Programming

E Gantt Chart
 CHAPTER 1

INTRODUCTION

1.1 Overview

Control engineering is among the most theoretical and difficult to understand. The
utilizing of control and automation systems is very important in optimization production,
quality and productivity furthermore reduces cost. In industries, application of water level
control system is widely use especially in chemical industries. This project is about design and
develops of an automatic water level control system and its monitoring system. In this project,
the system uses an electronic sensor circuit to detect the water level in a tank. It will be use a
Programmable Logic Controller (PLC) to control the pump for automatic incoming and
outgoing of water. The monitoring system using Visual Basic software programming will be
interface by parallel port between hardware and Personal Computer (PC).

1.2 Objective of Project

The main objectives for this project are to develop the automatic water level control
and its monitoring system where the water level automatically detects by the electronic sensor
circuit. There are also to program the automatic control pumping system using the
Programmable Logic Controller (PLC). Beside that, a Personal Computer (PC) monitoring
system will be developed using Visual Basic software to monitor the water level.
 2

1.3 Scope of Project

The scope of this project is to develop user friendly integrated system for water level
control purpose. The automatic water level control and its monitoring system will help to
overview the overall process of water level control. It has a sensor that will be detect the water
level, and it will generate a signal to control by the PLC. The PLC will be control the motor
pump to allow the amount of water that will be flow into the tank. When the water is reaches
at a high level the sensor will be sent a signal to PLC to stop the pump. The overall system
will be monitor from the personal computer PC using Visual Basic software programming.
Then the interfacing system using the parallel port will display the water level on the tank.

1.4 Problem Statement

Various types of water level system that use in industries nowadays, but to keep the
quality of the product, there are an automatic pumping system which is needs to control the
automation of water level. Otherwise, water level detector also requirements in control the
level of water in a tank such as float switch, ultrasonic and radar sensor. The water level
detector needs to be successfully incorporated in all appliances where water levels are critical,
such as chillers, boilers, and radiators. For those industries that must constantly monitor
solvents and mixtures for their levels, the high quality of water level detector such as
ultrasonic and radar sensor can replace monitoring personnel. In addition the system also has a
Personal Computer, PC to monitor level of the water. The PC monitoring system will control
the incoming and outgoing water and also help user to monitor the water level system.
 CHAPTER 2

LITERATURE REVIEW AND PROJECT BACKGROUND

2.1 Overview

This chapter will be stressed on the literature review and project background of water
level control system. The main purpose of this chapter is to analyze, identify and make
conclusion based on the research. A literature review means a collecting related data, analyzed
business process, identify underlying patterns and create the conclusion (Strauss & Corbin
1990). Another description of the project background is a systematic, explicit and reproducible
method to identifying, evaluating and synthesizing the existing body of completed and
recorded work produced by researcher, scholars and practitioners (Fink, 2005).

In order to develop a successful project, the current systems are identified. The system
of conventional water level control system and its connection have been analyzed. Studies of
these systems are significant to develop a valid, reliable and efficient upgrade project. The
literature review and project background part acts as a mean to discover which methodology
should be chosen in developing this system.
 4

2.2 Literature Review

2.2.1 Water Level Control System

The Level Master of water level control system had been designed by Milwaukee, WI
in January 2006 for fire tube boiler and water tube boiler which is constructed with enhanced
safety diagnostic capabilities.

Figure 2.1: LEVEL MASTER Water Level Control System

The Level Master water level control system as shown in figure 2.1 was designed to be
a low water cutoff controller with enhanced safety features. The Level Master’s capabilities
ensure the boiler’s water level remains at safe operating level. While monitoring the boiler's
water level, the self-checking features verify the control is operating as designed. The system
can also verify the operation of the auxiliary low water cutoff control. The Cleaver-Brooks
Level Master was built with security as a major objective. The operating parameters are
password protect-ed to eliminate the chances of tampering with preset levels. The Level
Master offers easy accessibility to its time stamped alarm and blow down history. As a final
touch to promote peace of mind, the Level Master includes multiple alarms and a visual water
level indicator. [4]
 5

Figure 2.2: Monitoring System of Water Level

The water column chambers have been engineered to easily replace limited, single
purpose controls with state-of-the-art electronic level sensing and monitoring. Figure 2.2
shows the monitoring system which is display the percentages for output value of water level
and display user configurable for on-off or modulating water level control. The design also
makes the system adaptable to both new and existing boilers. The specially engineered design
of the Level Master was built to accommodate your boiler room specifications. Depending on
your boiler application, the control’s sensitivity may be selected in the field.

Figure 2.3: Type of Sensor

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In figure 2.3, this type of sensor employs the magnetostrictive principle, a non-contact,
non-wearing, long-life technology. Designed specifically for boiler applications, it will
withstand working temperatures to 400°F at 250 PSIG. It includes a 2” diameter titanium float
with a captive magnet. The sensor electronics enclosure meets NEMA 4 standards with a
working environment of 130°F.

2.2.2 Liquid Level Monitoring and Automatic Control Systems.

Active Control Systems have become very popular with consultants, designing Water
Supply and Disposal Schemes in Industry. The main reason is that unlike normal conductivity
types, these are unaffected by water corrosion. This has helped reduce the constant manual
checking, and bring about extremely high Functional Reliability. Most of the clients are from
professional maintenance/ project engineers and consultants. For the example, Oberoi Group
of Hotels is consistently using the systems, both in Projects and Maintenance. So is the case
with Le Meridien, Delhi, Mother Dairy, CDIL etc. This company is specializing in Liquid
Level Monitoring and Automatic Control Systems which are based on Magnetic Level
sensing.

STAINLESS STEEL TUBE

SENSORS INSIDE

ACTUATING FLOAT

MAGNETIC SENSOR INSIDE

Figure 2.4: Water Level Sensor

 7

The level sensing is done by means of a probe unit as shown in figure 2.4. It is made of
stainless Steel. A number of sensors suitably spaced, depending of functional requirements are
enclosed inside the Probe Unit. An Actuating Float, made from Stainless Steel or PP is used to
actuate these sensors.

This Float has a Ring Magnet of specific polarity for correct operation of the Control
System. The control unit will receives signal from sensors as liquid reaches their level. This
signal then operates the Controller or Indicator System. The Control Systems are designed as
‘stand alone’ units and are specific to the capacity and system of operation of Pumps.

Otherwise, type of Pumps or Valves which is can be used is any type or capacity for
the example single phase mono-block pumps, jet pumps, single or three phase submersible
pumps, or other heavy capacity pumps or pumps related to chemical or process or dozing etc.

Figure 2.5: Typical Water Supply System

Figure 2.5 shows the typical of water supply system. This is a standard arrangement
where water is drawn from a tube well (submersible pump) and pumped directly to the
overhead tank. A variation to this is a sump tank where water is received from a tube well or
municipal water supply and then pumped to the overhead tank. The automation system for this