REPORT ON PLC PROGRAM FOR OIL AND
WATER SEPARATION PROCESS
MECHATRONICS ENGINEERING
PLC PROGRAMMING AND SCADA
(22585)
2024 – 25
UMAIR WAGHU - 2205690492
AVEZ MUKADAM - 2205690491
ABDUR RAHMAAN - 2205690493
Maharashtra State Board of Technical
Education, Mumbai
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
Certificate
This is to certify that of Roll no. of V Semester of Diploma in Mechatronics of
Institute ABDUL RAZZAK KALSEKAR POLYTECHNIC, PANVEL, has completed the Micro Project
satisfactorily in the subject PLC PROGRAMMING AND SCADA(22585) for the Academic Year
2024 – 25 as prescribed in the curriculum.
Place: New Panvel Enrollment No:
Date: / 09 /2024 Exam Seat No: __________
Subject Teacher Head of the Department Principal
PLC Program for Oil and Water Separation Process
1.0 Brief Introduction
PLC programs for oil and water separation automate the process using sensors, pumps,
valves, and the PLC itself. The PLC monitors sensor data, controls pumps and valves, ensures
safety, and can log data or be monitored remotely. Common programming languages include
ladder logic, function block diagrams, and structured text
2.0 Aim of the Micro – Project
● Improve efficiency: By optimizing the flow rates and timing of the separation process.
● Reduce human error: By automating tasks that can be prone to mistakes.
● Enhance safety: By implementing safety interlocks and alarms to prevent accidents.
● Improve data collection: By logging process data for analysis and troubleshooting.
● Enable remote monitoring: By connecting the PLC to a network for remote supervision.
3.0 Action Plan (Sequence and time required for major activities for 8 Weeks)
Sr. Details of Activity Planned Planned Name Of
No Start Finish Responsible
Date Date Team Members
1 Selection of the team 19.08.24 20.08.24 Avez Mukadam
2 Selection of an interesting topic 20.08.24 20.08.24 Umair Waghu
3 Information search/collection 10.09.24 10.09.24 Abdur Rehman
4 Report completion 20.09.24 25.09.24 Umair Waghu
4.0 Resources Required (major resources like raw material, some machining facility, Software)
Sr. No Name Of Remarks
Resource/Material
1 Gemini
2 YouTube
3 Google / Wikipedia
PLC Program for Oil and Water Separation
Process
This is a PLC Program for Oil and Water Separation Process.
Problem Description
Implement programming of Oil and Water separation process in PLC using Ladder Diagram
programming language.
Problem Diagram
Problem Solution
● Due to the gravitational force and different liquid density of Water and Oil,
when water and oil both are present in the liquid, oil always resides on top of
the liquid. By following this theory and making an arrangement shown in the
diagram above, Oil and Water can be separated.
● However, this process does not completely remove water particles but only
less than 10% of water contents are present after passing through this
process.
● Level of the tank is monitored using a level sensor. To control the level of the
system Inlet is controlled.
● To control the temperature of this system, ignition is to be controlled.
Temperature sensor is used and gas supply flow is controlled to control
temperature. Temperature set point here is 50 degrees centigrade.
● Oil outlet is controlled by a control valve which is operated by two level
switches.
Here is PLC program for Oil and Water Separation Process, along with program explanation
and run time test cases.
List of Inputs and Outputs
I:1/14 = Start (Input)
I:1/15 = Stop (Input)
O:2/15 = Master Coil (Output)
I:3 = Level sensor output (Input)
N7:0-N7:2 = Level monitoring and controlling registers
(Registers)
O:3 = Inlet controlling valve (Output)
O:6 = Level Display (Output)
I:1/1 = High level (Oil) (Input)
I:1/0 = Low level (Oil) (Input)
O:2/0 = Oil output valve (Single actuating)
(Output)
I:4 = Temperature output from sensor (Input)
N7:3 to N7:5 = Temperature monitoring and controlling registers
(Registers)
O:5 = Gas supply controlling valve (Output)
O:7 = Temperature Display (Output)
Ladder diagram to monitor and control Oil and Water separation process
● RUNG000 is the master start and stop control rung.
● RUNG001 is for Level Monitoring and control of Oil and Water separation
process tanks.
● I:3 is an input where the Level sensor is connected. Height of the tank is
200cms. And we need to control the level till 100cm. hence output of the
sensor is divided by 327 which means that per cm, input is added with 327.
● This data is further processed and multiplied by 655, because when output is
100cm, we have to throttle the inlet valve to be fully closed. So when output is
100cm in N7:1 register, it is multiplied by 655 and the full throttling is received
at O:3 which is connected to Inlet valve through I-P converter.
● N7:1 stores the level of the tank which is moved to O:6 (Display address)
through Decimal to BCD converter.
● Similarly Temperature monitoring and controlling is done as shown in the
Ladder diagram below.
Ladder diagram to control and monitor Temperature of Oil and Water separation
process
● Let’s say, the temperature to be controlled is 50 degree centigrade. According
to the used sensor RTD PT100, data is processed and required temperature is
controlled through Gas Supply for ignition.
● Here the display output address is O:7.
● RUNG002 is to operate Oil Outlet Valve with address O:2/0.
● When Level low is detected by Low level sensor with address I:1/1, outlet
valve is opened and it is closed when I:1/0 is detected that is high level.
Runtime Test Cases
Inputs Outputs Physical Elements
I:1/1 = 1 O:2/0 = 1 Open oil outlet valve
I:1/0 = 1 O:2/0 = 0 Close oil outlet valve
I:3 = 8000h O:3 = 0000h Close inlet valve fully
I:3 = 4000h O:3 = 7FFFh Inlet Valve 50% open
I:4 = 6018h O:5 = 0000h Gas supply valve fully closed
I:4 = 300Ch O:5 = 8000h Gas supply valve fully closed
Reference :
● https://www.sanfoundry.com/plc-program-oil-water-
separation-process/
● Rockwell Automation:
https://www.rockwellautomation.com/en-us.html
● Siemens: https://www.youtube.com/watch?v=xmSo-
yXu4o8
● Schneider Electric:
https://www.youtube.com/watch?v=irTubjlvYmE
● AutomationDirect:
https://www.automationdirect.com/adc/home/home
Industrial Automation and Process Control:
● ISA (International Society of Automation):
https://www.isa.org/
● ControlGlobal: https://www.controlglobal.com/
ANNEXURE II
Evaluation Sheet for the Micro Project
Academic Year: 2024 – 25 Name of Faculty: MARIA PATHAAN
Course: PLC PROGRAMMING AND SCADA Course Code: 22585 Semester: V
Title of the Project: PLC PROGRAM FOR OIL AND WATER SEPARATION PROCESS
COs addressed by the Micro Project: REPORT FOR OIL AND WATER SEPARATION PROCESS
The main aim : Oil and water separation processes using Programmable Logic Controllers
(PLCs) involve integrating automation and control systems to enhance efficiency, accuracy,
and reliability. PLCs are widely used in industrial settings to automate processes, including oil
and water separation.
Major Learning Outcomes achieved by students by doing the Project:
● Unit Outcomes in Cognitive Domain: TO UNDERSTAND PLC PROGRAMMING.
● Outcome Affective Domain: Worked as a leader/team member&Followed ethical
practices.
Marks out of 6 for Marks out of 4 for
performance in performance in
Roll. Total out of
Student Name group oral/presentation
No activity 10
(D5 Col.9)
(D5 Col.8)
05 AVEZ MUKADAM
06 UMAIR WAGHU
07 ABDUR RAHMAAN
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Subject teacher.
