A Systematic Approach to Develop PLC Program for Automation of a
Backwash Water Treatment Plant
Aamir Hanif, Muhammad Ahmad Choudhry Member IEEE and Tahir Mehmood
Department of Electrical Engineering, University of Engineering and Technology, Taxila.
E-mail: aamirhanif@uettaxila.edu.pk
Abstract
Programmable logic controllers (PLCs) are type of
process control computers, which are small but
relatively inexpensive, environmentally hardened, and
easy to program, operate, maintain and repair. The
process control computers primarily control devices
such as motors, solenoids, pumps, valves, lights and
heaters etc. These computers, which number in
millions, are the control elements in the virtually all
modern factory operations.
The programmability of PLC allows for fast and
easy changes in relay ladder logic to meet the
changing needs of the process or driven equipment
without the need for expensive and time consuming
rewiring.
In this paper a target to develop, simulate and
implement PLC software for automation of a water
treatment plant is achieved. The algorithm developed
in this paper may be used to develop PLC based
software for any control process.
1. Introduction
PLCs are similar to conventional computers in terms
of hardware technology, however the specific features
suite to industrial control [1].
The main features that suit industrial environment
include:
1. Rugged, noise immune equipment.
2. Modular plug-in construction.
3. Standard input/output connection and signal
levels.
4. Easily understood programming languages.
5. Ease of programming and reprogramming the
PLC as per requirement.
These features make programmable controllers
highly desirable in a wide variety of industrial
situations.
Unfortunately the lack of standardization coupled
with continually changing technology has made PLC
common nightmare of incompatible protocols and
physical networks [2]. During 1980s an attempt was
made to standardize communications with General
Motors manufacturing automotive protocol. It was a
time for reducing the size of PLC and making them
programmable through symbolic programming on
personal computers, instead of dedicated programming
terminals.
IEC has recently standardized programmable
controllers and their associated peripherals to facilitate
automation industry. The commission has developed a
series of standards (IEC-61131 series, [7]-[12]) to
address salient issues and problems confronting the
automation industry. It also provides guidelines for the
implementation of programming languages in
programmable controller and their programming
support environment.
2. Purpose of research work
In Pakistan, the Karachi Development Authority has
to supplement its resources for drinking water from
two new projects. These projects are located at Hub
and Pepri near Karachi. This research work is related
to one of many applications of Programmable Logic
Controllers (PLCs) for the water treatment plants in
these locations. PLC based software for backwash
water treatment process used for the above mentioned
projects is developed.
3. Concept of controlling a plant
The concept of controlling a plant is a simplistic in
nature. It involves a systematic approach. The
algorithm involves the following steps.
3.1 Determine the sequence of operation
We have to identify the equipment or the system to
be controlled. The ultimate purpose of the
programmable controller will be to control an external
system. The system to be controlled may be machine,
equipment, or process to be controlled [4].
The movement of the controlled system is monitored
in real time by the input devices. It gives a specified
condition and sends a signal to the programmable
controller. The programmable controller outputs a
signal to the external output devices which actually
controls the movement of the controlled system as
specified and thus achieves the extended control action
[3]. In simple, one needs to determine the sequence of
operation in steps form for onward development of
flow chart by completely understanding the system
detailed operation.
3.2 Assignment of Inputs and Outputs
All external input and output devices to be
connected to the programmable controllers must be
determined. The input devices are the various switches,
sensors and timers. The output devices are the
solenoids, electromagnetic valves, motor indicators and
likewise.
After identifying all the INPUT and OUTPUT
devices, the numbers corresponding to the INPUT and
OUTPUT of the particular programmable controller
will be assigned. The actual wiring will follow the
numbers of the programmable controller.
The assigning of INPUT and OUTPUT numbers
must be carried out before writing the ladder diagram
because the number dictate what is the precise meaning
of the contacts in the ladder diagram.
3.3 Develop timing diagram
Timing diagram is developed to show the length
of occurrence of signals (I/O signals) of control
process.
3.4 Develop flow chart
Flow chart is drawn considering the sequence of
operation of control process.
3.5 Writing of the program
Write the ladder program by following the control
system sequence of operation as determined by step
3.1.
In terms of design methodology, ladder
programming is no different from conventional
computer programming. Thus, considerable attention
was given to:
• Task definition/specification.
• Software design techniques.
• Documentation.
• Program testing.
4. Software design procedure
A programmable controller has the following
software design procedure.
1. The process is described.
2. Input, Outputs (I/Os) are defined for control
process.
3. This description by considering I/Os is
translated into a flow chart or function
diagram.
4. Finally this flowchart is converted into
ladder logic format and then programmed into
the PLC.
The verbal or written description of an automatic
process is usually long and difficult to follow. The
complete process is more easily understood when
divided into a number of self-contained sub-units or
sub-processes. Each sub-unit can then be constructed
from sequences and interlocks to create the required
function.
Several options exists e.g. relay logic diagrams,
logic schematics, flowcharts and function charts.
Choice of a particular method depends mainly on
previous experience and the nature of the application
[6].
5. Sequence of operation for backwash
water treatment plant
After fulfilling the pre-requisites for automatic
operation and the start up sequence, we converted
detailed theoretical description of sequence of
operation for backwashing a filter in steps, so that flow
chart and hence software can be easily developed.
5.1 Initiation of a backwash
Three methods for initiating backwashing sequence
will be available.
1) Timed wash/automatic initiation: The filter
will be washed in sequence by a timer, which will be
adjusted from 12 to 36 hours.
 2) Manual initiation: it will be initiated from the Inlet penstock closed
key operated pushbuttons on the front of the filter Outlet valve closed
consoles. Wash water outlet penstock opened
3) Semi-Automatic initiation: This method is Air scour inlet valve opened
explained in Figure 3. Air dump valve closed
Duty air scour blowers running
5.2 Filter backwash sequence Timer Expired
End of Step 6.
The wash sequence will consists of the following Similarly our sequence of operation will be defined
steps as described below. The condition which must be until Step 18 arises which is
met before jumping from one step to next is listed in Step 18. Signal the filter outlet valve to open and open
each step. it in incremental step and confirm that it has
opened. This will take about 15 – 30 minutes
Step 1. i) Signal the appropriate “filter washing” and allows for a slow start.
lamp on the filter console. Inlet penstock closed
ii) Signal the inlet penstock (V202/X) Outlet valve closed
to close and confirmed. Wash water outlet penstock closed
iii) Start the filter drain down period, which Air scour inlet valve closed
is 30 minute from closing the filter inlet Backwash water inlet valve closed
penstock. End of Step 18.
Inlet penstock closed Step 19. i) Remove the signal “filter washing” lamp on
End of Step 1. the filter console.
Step 2. Signal the filter outlet valve (V-204/X) to ii) Initiate the “time since last wash” timer for
close and confirm. that filter.
Inlet penstock closed
Outlet valve closed Any failure in the backwash sequence will initiate
End of step 2. the “backwash sequence fail” lamp on the front of the
Step 3. Signal the wash water outlet penstock (V- filter control consoles (FCC). It will also initiate a
203/X) to open and confirm. common kalaxon located in the filter building.
Inlet penstock closed
Outlet valve closed 6. Software development
Wash water outlet penstock opened
End of Step 3. After defining the backwash water treatment
Step 4. i) Signal the air scour inlet valve (V-207/X) process, we determined the inputs and outputs from the
to open and confirm. sequence of operation for backwash water treatment
ii) Signal the air dump valve (V-228) to open plant. These are for the CQM1 PLC (Master PLC in
and confirmed. our control process) and the CPM2 PLCs (Slave PLCs
Inlet penstock closed in our control process). I/O tables for slave CPM2
Outlet valve closed PLCs are shown in Table 1 and Table 2.
Wash water outlet penstock opened Corresponding PLC address numbers for each input
Air scour inlet valve opened and output for these PLCs were also given. Timing
Air dump valve opened diagram for filter backwash sequence was developed as
End of Step 4. shown in Figure 1. Flow chart was made by
Step 5. Signal the two duty air blower (B200/X & considering the sequence of operation for backwash
B200/X) to run in sequence. And confirm water treatment plant. The block diagram of the control
they are running. process is shown in Figure 2. After it, ladder program
Inlet penstock closed was written by following the steps of control system
Outlet valve closed sequence of operation as written in section 5, I/O tables
Wash water outlet penstock opened defined and developed flowchart.
Air scour inlet valve opened Now we applied power to the programmable
Air dump valve opened controller. Depending on the type of programmable
Duty air scour blowers running controller, an I/O generation to prepare the system
End of Step 5. configuration was done. After that, we entered our
Step 6. Signal the air dump valve to close and program in the memory by computer aided ladder
confirm it is closed. software tool i.e. OMRON CX-programmer and
checked for any coding errors by means OMRON CX-
Simulator software. PLCs self diagnostic functions
enabled for us easy and fast troubleshooting of the
system.
Before the start push-button was pressed, thoroughly
we ensured that the input and output wiring were
correctly connected according to the I/O assignment.
Once confirmed, the actual operations of the PLCs
were started. We debugged along the way and fine
tuned the control system. Test run was done
thoroughly until it was safe to operate by anyone.
7. Discussions and recommendations
The goal of this research was to develop PLC based
software for controlling a backwash water treatment
plant. The reason of developing PLC based software
for control process was that PLC can be easily
programmed to produce its control function instead of
having to be laboriously hardwired as required in relay
logic control system. The algorithm developed in this
software may be used to develop PLC based software
for any control process.
The main contribution to this research is to
demonstrate how the PLC based software’s can be
developed for automatic control process; because PLC
can control from a simple pick and place system to a
much complex servo positioning system.
We simulated the Software developed by latest
OMRON CX-Simulator software and errors were
removed and finally program was run by giving i/ps
and examining o/ps to yield required results.
Before this simulation software it was very difficult
to test developed software. The difficulty was, because
if developed PLC software uses more than 50 I/Os,
than we need large size PLC (in terms of I/Os) to check
our developed software. With the help of this
simulation software, ladder programmed developed for
upto 5000 I/Os can be simulated.
Although the developed software for backwash
water treatment plant yield the required results, but
this software can be further improved /shortened by
different control logical techniques/strategies using
PLC instruction set and different functions depending
upon the PLC programmer experience and logical
approach.
Also we noted that for a large complex control
system where software developed is very long, the
processing speed of the PLC reduces and even some
times the processing time is much greater. Thus along
with flexibility to handle data acquisition, speed has
become another important development in PLC and
Input, Output technology. Therefore there is need to
improve the performance of the PLCs for large
complex control systems.
Programming a PLC is not difficult, but time must
be spent to become familiar with the programming
device, the software, and the programming techniques
used by various PLC manufacturers.

TIMING CHART FOR FILTER BACK WASHING SEQUENCE

FILTER BACKWASHING SEQUENCE LENGTH OF OCCURANCE OF DIFFERENT PROCESS SIGNALS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

1. FILTER WASHING LAMP ON THE FCC

2. FOR INLET PENSTOCK TO CLOSE

3. TIMER T1 FOR FILTER DRA IN

DOWN PERIOD
4. FILTER WATER OUTLET VALVE CLOSED

5. WASHWATER OUTLET PENSTOCK

TO OPEN
6. AIR SCOUR INLET VALVE OPEN

7. AIR DUMP VALVE OPEN

8. 1ST DUTY AIR BLOWER TO RUN

9. TIMER T2 FOR AIR BLOWERS RUNNING (Adujstable timer)

10. 2ND DUTY AIR BLOWER TO RUN

11. BACKWASH INLET VALVE TO OPEN

12. 1ST DUTY BACK WASH PUMP TO RUN

13. TIMER T3 FOR RUNNING OF AIR (Adjustable timer)

SCOUR BLOWER.
14. 2ND DUTY BACKWASH PUMP TO RUN

15. TIMER T4 FOR BACKWASH PUMP (Adjustable timer)

RUNNING TOGETHER.
16. "Time since last wash" FOR THAT FILTER

Figure 1. Timing chart for filter backwashing

 8. References
[1]Alan J Crispin, “Programmable logic controllers and their
Engineering applications”, 2nd edition, The McGraw-Hill
Companies.
[2]Ian G.Warnak, “Programmable Controller Operation and
Application”, Prentice Hall International (U.K) Ltd. 1998.
[3]Yohansson, G, “Programmable Controller-An
introduction”.
[4]“A beginner’s guide to PLC”, OMRON Asia Pacific PTE.
LTD. 1996.
[5] “Programmable Controllers,” OMRON Asia Pacific PTE.
LTD. 1999.
[6]Richard A. Cox, “Technicians Guide to Programmable
Logic Controllers,”4th edition, Delmar Thomson Learning,
Inc. 2001.
[7]Programmable controllers–part 1: General Information,
International Electro technical Commission, and IEC 61131-
1, 2003.
[8]Programmable controllers–part 2: Equipment
requirements and tests, International Electro technical
Commission, IEC 61131-2, 2003.
[9]Corrigendum 1-Programmable controllers–part 2:
Equipment requirements and tests, International Electro
technical Commission, IEC 61131-2, 2004.
[10]Programmable controllers–part 3: Programming
languages, International Electro technical Commission,
IEC 61131-3, 2003.
[11]Programmable controllers–part 4: User guidelines,
International Electro technical Commission, IEC 61131-4,
2004.
[12]Programmable controllers–part 5: Communications,
International Electro technical Commission, IEC 61131-5,
2000.

Figure 2. Block diagram for backwash water

treatment control process
 Table 1. Slave PLC/X all input detail
S.NO WIRE WIRE# PLC VOLTAGE INPUT FORM
COLOUR ADDRESS
01 BLUE SXN00 0000 24VDC S/S KEY OPERATED POSITION 1 (AUTO)
02 BLUE SXN01 0001 24VDC S/S KEY OPERATED POSITION 2 (SEMI AUTOMAIC)
03 BLUE SXNO2 0002 24VDC S/SKEY PERATED POSITION 3 (MANUAL)
04 BLUE SXNO3 0004 24VDC COLSE CONFIRMATION OF PENSTOCK V-202/X
05 BLUE SXN04 0005 24VDC OPEN CONFIRMATION OF PENSTOCK V-203/X
06 BLUE SXN05 0006 24VDC OPEN CONFIRMATION OF PENSTOCK V-203/X
07 BLUE SXNO6 0010 24VDC CLOSE CONFIRMATION OF VALVE V-204/X
08 BLUE SXN07 0008 24VDC OPEN CONFIRMATION OF VALVE V-204/X
09 BLUE SXN08 00011 24VDC CLOSE CONFIRMATION OF VALVE V-206/X
10 BLUE SXN09 00100 24VDC OPEN CONFIRMATION OF VALVE V-206/X
11 BLUE SXN10 00101 24VDC CLOSE CONFIRMATION OF VALVE V-207/X
12 BLUE SXN11 00102 24VDC OPEN COFIRMATION OF VALVE V-207
13 BLUE SXN12 0013 24VDC AUTO(LOOP INPUT)FOR ALL VALVES & PENSTOCK
14 BLUE SXN13 0014 24VDC REMOTE CONTROL FOR ALL VALVES & PENSTOCKS
15 BLUE SXN14 0015 24VDC START KEY OPERATED PUSH BUTTEN
16 BLUE SXN14 00103 24VDC RESTART
17 BLUE SXN15 00104 24VDC V-202/X FAULT INDICATION
18 BLUE SXN16 00105 24VDC V-203/X FAULT INDICATION
19 BLUE SXN17 00106 24VDC V-204/X FAULT INDICATION
20 BLUE SXN18 00107 24VDC V-206/X FAULT INDICATION
21 BLUE SXN19 00108 24VDC V-207/X FAULT INDICATION
22 BLUE SXN20 00109 24VDC SPARE
23 BLUE SXN21 00110 24VDC SRARE
24 BLUE SXN22 00111 24VDC SPARE
25 BLUE SXN23 01200 24VDC SPARE
26 BLUE SXN24 01201 24VDC SPARE
27 BLUE SXN25 01202 24VDC SPARE
28 BLUE SXN26 01203 24VDC SPARE
29 BLUE SXN27 01204 24VDC SPARE
30 BLUE SXN28 01205 24VDC SPARE
31 BLUE SXN29 01206 24VDC SPARE
32 BLUE SXN30 01207 24VDC SPARE
33 BLUE SXN31 01208 24VDC SPARE
35 BLUE SXN32 01209 24VDC SPARE
36 BLUE SXN33 01210 24VDC SPARE
N=SLAVE#1 TO SLAVE #20
V- ♦♦♦ /X WHERE ♦=1------------20 (FILTER NUMBER)
X= VALVES & PENSTOCK NUMBER.
Table 2. Slave PLC/X all output detail
S.NO WIRE COLOURE WIRE# PLC ADDRESS VOLTAGE OUT PUT TO
01 BROWN SYN00 01000 110VAC FILTER WASHING LAMP AT FCC/X& MIMICS
02 BROWN SYN01 01001 110VAC FILTER IN SERVICE LAMP AT FCC/X & MIMICS
03 BROWN SYN02 01002 110VAC V-202/X (CLOSE)
04 BROWN SYN03 O1003 110VAC V- 202/X( OPEN )
05 BROWN SYN04 01004 110VAC V-203 /X( CLOSE )
06 BROWN SYN05 01005 110VAC V-203/X( OPEN)
07 BROWN SYN06 01006 110VAC V-204 /X (CLOSE )
08 BROWN SYN07 01007 110VAC V-204/X (OPEN)
09 BROWN SYN08 01100 110VAC V-206/X (CLOSE)
10 BROWN SYN09 01101 110VAC V-206 /X (OPEN)
11 BROWN SYN10 01102 110VAC V-207/X (CLOSE)
12 BROWN SYN11 01103 110VAC V-207/X (OPEN)
13 BROWN SYN12 01104 110VAC BACK WASH FALIURE INDICATIN
14 BROWN SYN13 01105 110VAC FILTER OUT OF SERVICE OF FCC/X TO MIMICS
15 BROWN SYN14 01106 110VAC KALAXOL ACTIVATE
16 BROWN SYN15 01107 110VAC SIGNAL 1ST AIR BLOWER TO RUN IN SEQUENCE
17 BROWN SYN16 01200 110VAC SIGNAL TO 2ND DUTY AIR BLOWER TO RUN
18 BROWN SYN17 01201 110VAC SIGNAL THE 1ST DUTY BACKWASH PUMP TO RUN
19 BROWN SYN18 01202 110VAC V-228(OPEN)
20 BROWN SYN19 01203 110VAC V-228(CLOSED)
21 BROWN SYN20 01204 110VAC SIGNAL 2ND DUTY BACKWASH TO RUN
22 BROWN SYN21 01205 110VAC SPARE
23 BROWN SYN22 01206 110VAC SPARE
24 BROWN SYN23 01207 110VAC SPARE