PLC-Assisted Smart Water Distribution with Rapid Leakage Detection and Isolation

Abstract

Water loss due to undetected leakages in distribution networks remains a critical issue in urban infrastructure, leading to resource wastage, operational inefficiencies, and increased costs. Traditional manual inspection methods and cloud-dependent monitoring systems often suffer from delays, making them unsuitable for real-time isolation and control. This study presents a PLC-assisted smart water distribution system designed for rapid leakage detection and automated isolation, utilizing real-time sensor data processing and industrial-grade automation logic. The system architecture incorporates flow and pressure sensors, strategically placed at critical pipeline junctions to continuously monitor water conditions. A programmable logic controller (PLC)—Siemens S7-1200—acts as the central control unit, analyzing sensor inputs and executing control logic for leakage detection. Upon identifying anomalies such as sudden pressure drops or unbalanced flow rates, the PLC triggers solenoid valves to isolate the leaking section, thereby minimizing water loss and maintaining distribution continuity in unaffected areas. An integrated human-machine ınterface (HMI) provides real-time visualization of system status and leakage alerts, along with manual override capabilities. Optional ethernet-based SCADA or IoT connectivity enables remote monitoring and logging for maintenance planning.

The prototype demonstrates effective detection within <2 seconds, resulting in an average 15% reduction in water wastage compared to manual methods. The system’s modular, scalable design and low-latency operation make it a promising solution for smart city water management and critical utility infrastructure.