Basic
20 min

Lift Station — Alternating Pumps

pumpswateralternationalarmthermal

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Lift Station — Alternating Pumps scenario preview

Briefing

A wet-well lift station uses two submersible pumps in alternating duty. When the wet well rises to the HIGH level, the duty pump starts; it stops when the well drains to LOW. After each completed cycle the duty assignment swaps so both pumps accumulate equal runtime. A thermal trip on the duty pump hands control to the standby pump. If both thermals trip simultaneously, or the well overflows (above HIGH for too long without draining), the ALARM_HORN and ALARM_LAMP activate.

Objectives

  • WET_WELL_HIGH starts the duty pump; WET_WELL_LOW stops it
  • Duty alternates after each completed pump cycle (HIGH → LOW)
  • PUMP1_THERMAL trips Pump 1 — standby Pump 2 takes over immediately
  • PUMP2_THERMAL trips Pump 2 — standby Pump 1 takes over immediately
  • Both thermals tripped simultaneously triggers ALARM_LAMP and ALARM_HORN
  • Tank overflow (level stays at HIGH with no working pump) triggers ALARM_LAMP and ALARM_HORN

Hints

  • Latch the pumping demand: SET a PUMP_DEMAND bit on WET_WELL_HIGH, RESET it on WET_WELL_LOW — gating on WET_WELL_HIGH alone chatters at the high float
  • Use a DUTY_IS_2 latch bit that toggles on each rising edge of WET_WELL_LOW (pump-down complete)
  • PUMP1_RUN := PUMP_DEMAND AND (NOT DUTY_IS_2 OR PUMP2_THERMAL) AND NOT PUMP1_THERMAL
  • PUMP2_RUN := PUMP_DEMAND AND (DUTY_IS_2 OR PUMP1_THERMAL) AND NOT PUMP2_THERMAL
  • ALARM := (PUMP1_THERMAL AND PUMP2_THERMAL) OR OVERFLOW_BIT
  • ALARM_LAMP := ALARM; ALARM_HORN := ALARM

I/O Table

Inputs

WET_WELL_HIGH

High level float switch (>90%)

BOOL · %I0.0

WET_WELL_LOW

Low level float switch (<20%)

BOOL · %I0.1

PUMP1_THERMAL

Pump 1 thermal overload trip

BOOL · %I0.2

PUMP2_THERMAL

Pump 2 thermal overload trip

BOOL · %I0.3

Outputs

PUMP1_RUN

Pump 1 run contactor

BOOL · %Q0.0

PUMP2_RUN

Pump 2 run contactor

BOOL · %Q0.1

ALARM_LAMP

Alarm indicator lamp

BOOL · %Q0.2

ALARM_HORN

Alarm horn / sounder

BOOL · %Q0.3

Your program will be tested against:

All test cases run automatically when you submit. Assertions are hidden until you pass.

  1. #1Pump 1 (duty) starts on WET_WELL_HIGH

    With no thermals tripped, Pump 1 starts when level rises to HIGH

  2. #2Duty pump stops on WET_WELL_LOW

    Pump 1 stops when level drains to LOW

  3. #3Duty alternates after each fill cycle

    After one complete cycle Pump 2 becomes duty

  4. #4Pump 1 thermal trip hands off to Pump 2

    PUMP1_THERMAL while Pump 1 is duty causes Pump 2 to start

  5. #5Both thermal trips activate alarm

    PUMP1_THERMAL AND PUMP2_THERMAL triggers ALARM_LAMP and ALARM_HORN

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Runnable simulator field guide

Lift-station PLC scenario: test checklist

Direct answer

The learner can define every level transition and pump response and prove normal, failed-pump, stuck-sensor and power-return cases without uncontrolled cycling.

Written for pLC and water-process learners implementing level demand, lead-lag pumps, run feedback, high-level alarms, failover and deliberate restart.

a browser PLC workstation connected to a guarded pump, level and conveyor training rig for repeatable control cases while studying lift-station level, pump, alarm and failover control
System map / 02

NODE 01observable

Scenario setup

Wet-well levels, hysteresis, pump availability, lead and lag policy, alternation, run feedback, minimum timing, high-high alarm, failover, manual mode and restart.

NODE 02observable

I/O and state map

Level sensors through demand state and pump-selection logic to starter or drive commands, flow, changing level, run feedback and alarms.

NODE 03observable

Normal run

Repeated inflow cycles maintain level within the declared band and alternate available pump duty.

NODE 04observable

Boundary run

Failed lead, unavailable lag, stuck high or low sensor, rapid cycling, no-flow feedback, high-high level, manual override and power return.

NODE 05observable

Injected fault

A level, threshold, hysteresis, selection, command, starter, pump, hydraulic, feedback, alarm or restart mismatch.

NODE 06observable

Target check

The sequence and alarm response verified with target PLC, actual instruments, pumps and approved operational procedures.

Answer surface / 07

What does a lift-station PLC control?

It commonly monitors wet-well level, starts and alternates pumps, stages demand, checks feedback and generates alarms for abnormal conditions.

How can pump short cycling be prevented?

Use appropriate level separation or hysteresis, minimum run and stop policies and correct hydraulic design, then test sensor and inflow boundaries.