PLC Based Tank Level and Temperature Control System

Abstract: The increasing adoption of automation in industrial processes has created a need for practical training systems that demonstrate real-time process control concepts. This paper presents the development of a Mini Process Control Plant based on an Allen-Bradley Micro820 Programmable Logic Controller (PLC) and Human Machine Interface (HMI). The developed setup integrates three important process variables, namely temperature, level, and flow, into a single educational platform. Temperature regulation is achieved using a heating element controlled through a Solid State Relay (SSR), while level control is performed using a water tank, pump, and level sensing arrangement. Flow measurement is carried out using a flow sensor interfaced with the PLC. The system supports both manual and automatic operating modes and provides real-time monitoring, alarm handling, and operator interaction through the HMI dashboard. Experimental observations demonstrate satisfactory control performance and reliable system operation. The proposed setup offers a cost-effective alternative to commercial training systems and serves as a useful platform for learning industrial automation and process control principles.

Keywords: PLC, HMI, Process Control, Micro820 PLC, Temperature Control, Level Control, Flow Control, Industrial Automation, Educational Trainer.