Tubewell Automation

• Shubham Banwal

• September 2024

Tubewell Automation System using PLC, Contactor Control & IoT Monitoring

Problem:

Manual operation of tubewell systems leads to inefficient water usage, delayed response, and lack of visibility into system status, increasing operational cost and risk of equipment misuse.

Approach:

Designed and implemented an automated tubewell control system integrating PLC logic, contactor-based switching, and IoT-enabled monitoring to enable reliable, remote, and data-driven operation.

System Design:

• PLC-based control logic for automated operation and sequencing
• Contactor-driven motor control for pump activation/deactivation
• Microcontroller layer for IoT connectivity and data transmission
• Sensor inputs (water level, flow, or status signals) for system feedback
• Remote monitoring interface for real-time visibility

Key Contributions:

• Developed PLC logic to automate tubewell operation based on predefined conditions and inputs
• Integrated contactor-based motor control ensuring safe and reliable switching
• Built an IoT-enabled layer using microcontrollers for remote monitoring and control
• Designed system workflows for efficient water management and operational reliability
• Enabled real-time system visibility, reducing dependency on manual supervision
• Conducted testing and validation to ensure stable performance in field conditions

Constraints & Tradeoffs:

• Electrical safety and reliability requirements for motor control systems
• Integration challenges between PLC, microcontroller, and IoT layers
• Network dependency affecting remote monitoring reliability
• Need for robust operation in harsh environmental conditions