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Mobile Based Industrial Protection

Abstract:

The Project "Mobile Based Industrial Protection" is meant for Monitoring & Controlling
industrial devices using GSM mobiles.

For any Industry to work perfectly there will be some parameters like Room temperature,
atmospheric pressure. for example if the working temperature of a certain device in an industry is
45'c, if the room temperature exceeds 45'c, then the device may get damaged & doesn’t work
properly. so in order to avoid such situations in Industries we are using this project which is
based on the latest mobiles technology.
Block Diagram of Project:

Transmitter:

CELL
PHONE

Receiver:

LCD DISPLAY

FAN
89S52
MICRO-
CONTROL
GSM MA LER
ANTENNA MODULE X 232
RELAY

HEATER

LM35 MCP3201
Components Description:
Project’s main aim is to control & monitor industrial parameters using GSM mobiles.
The circuit diagram mainly consists of a micro controller, LCD display, power -section; GSM
module is connected to micro controller, relay circuit, heater, Max 232, Lm35.

• LCD display to show the temperature of the heater which is variable.


• Micro-controller AT89s52 is used because it has in built 8K bytes of Programmable
flash memory. The AT89S52 is a low-power, high-performance CMOS 8-bit
microcontroller with 8K bytes of in system Programmable Flash memory. The device is
manufactured using Atmel’s high-density nonvolatile Memory technology and is
compatible with the industry-standard 80C51 instruction set and pin out.The on-chip
Flash allows the program memory to be reprogrammed in-system or by a conventional
Nonvolatile memory pro-grammar.
• GSM module which consists of a SIM card is used to send & receive messages.
Temperature readings are send to the number which is dumped in the micro-controller.
Analogic GSM Smart Modem is a multi-functional, ready to use, rugged unit that can be
embedded or plugged into any application. The Smart Modem can be controlled and
customized to various levels by using the standard AT commands. The modem is fully
type-approved, it can speed up the operational time with full range of Voice, Data, Fax
and Short Messages (Point to Point and Cell Broadcast).
• Max 232 cable is used as a level shifter.
• Lm35 is a temperature sensor whose output voltage is linearly proportional to
temperature.
• MCP 3201 is a A/D convertor which converts the analog voltage o/p from lm35 to digital
as i/p to the micro-controller. The o/p from micro-controller is send to LCD to display
temperature.
• Relay circuit is used to supply more power than that of micro-controller can supply.
Project Operation:

• Micro controller continuously reads the data from the temperature sensor and displays
whenever the temperature exceeds the set point.
• The temperature is send to the mobile through the GSM.
• If the temperature exceeds the cut-off temperature then a sms is send to the our mobile by
micro controller, indicating the situation so that we can take action or automatically it can
switch-off the machine and switches ON the coolers to get control over the situation.
Thus the damage of machines is prevented. Using the above procedure we can control &
monitor the Industrial devices from any place using mobiles.
• If the user wants to know the temperature at present condition, the user has to send the
message to the mobile number present in GSM module as “#” .
• If the user wants to change the set point, then the user has to send the new reference
temperature.

TRANSMITTER:

The transmitter used in this project is standard GSM mobile.

The operating frequency of GSM mobile is 900/1800 MHz’s. This frequency is used to receive
and send voice, data calls.

In this project the use of mobile is to read the temperature when ever required just by sending
sms as ” #” and to set the cut-off temperature.

Receiver:
The receiver consists of a micro controller, LCD display, power -section , GSM module is
connected to micro controller, relay circuit, heater, max 232,Lm35.

Yagi Omni panel antenna is used to receive & send message signals. This antenna is
connected to GSM module. Max 232 cable is used as a level shifter. It gives o/p voltage in
terms of 3v to 5v. LCD display is used to show the temperature of the heater which is
variable. On the LCD screen the set point temperature will be displayed.
Through GSM module sending & receiving messages is done, by inserting a SIM card in it.
This GSM Module is interfaced with micro-controller. The user who wants to know the
status of the temperature has to send SMS to the number present in GSM.

A mobile number is dumped in to the micro-controller using Kiel software, so that whenever
a message is received to the number present in GSM module, a reply message is send to the
user.GSM (GLOBAL SYSTEM FOR MOBILE COMMUNICATION) modem is connected
to the micro controller through a max 232 which is a TTL level converter.

Temperature sensor is one that gives the voltage in the form of temperature. The need of lm
35 temperature sensor is that reduces the signal conditioner at its output; because it gives
direct mill volts. This voltage is converted to the digital form by using mcp3201 Analog to
Digital converter.

Cost of the Project:

All the components of project cost approximately Rs.6000.The implementation the project costs
approximately Rs.500. So project could be successfully implemented at a cost of Rs.6500.
Application in Thermal Power Plant:
Thermal Power Plants are equipped with number of machines, motors, pumps, MCCs, PLCs etc.
Many of the processes are automated. In order to run the automated processes continuously, Air
Conditioning is compulsory for the MCC and PLC rooms which are the Control Centers for the
running equipments. The Main Plant is Centrally Air Conditioned. One Junior Plant Attendant
looks after the Central Air Conditioning System. All other remote areas are equipped with
Packaged Air Conditioners (PACs). These are designed to produce 25 plus or minus 1 degree
centigrade room temperature. If the temperature exceeds 30 degrees Centigrade the Control
Centers do not work. Due to this the processes stop and the total project may trip. This cause
generation loss in Crores.

Though the Air Conditioners work in auto mode sometimes they may break down because of the
following reasons.
• The refrigerant gas R-22(FREON) may escapes through some crack developed in the
copper tubes or at some joints.
• Due to failure of some relays.
• As the suction filters are choked up with dust, ice forms in the chiller due to insufficient
air circulation.
• Burn out of motors.
• The invisible worn out bearings may break suddenly.
• The inlet cooling water pressure drops below 4 kg/Sq. Cm. due to leak in the pipe line
somewhere or the cooling water pump is trouble.
• Due to failure of thermostats etc.
Though the maintenance operations are carried out regularly by the Maintenance Engineers the
PACs may trip at any time due to the above reasons. At some locations there will be no standby
PAC. Even if standby is there it is to be started manually after observing all start permissives.
The start permissives steps are as follows.
Start Permissives:
• Close the dampers and valves of tripped PAC

• Open the dampers of and valves standby PAC.


• Observe whether the inlet cooling water pressure is above 4 kg/Sq. Cm.

The rectifying operation must be done within 1 hour. Otherwise the Control Centers trip if the
room temperature exceeds 30 degrees. In order to look after all the remote areas no. of operators
are required. This is not economical. At night times it is very difficult to monitor these hourly by
walking such long distances. By providing these sensors we can recognize where the problem is
and attend immediately.
Advantages:
• The main advantage of this project lies in its simplicity.
• By providing these sensors, Shift operator can go to the location immediately whenever
the problem occurs and switch on the standby.
• This also enables the Maintenance Engineers can know the exact location immediately
and attend the problem. If there is refrigerant leakage we may save about 1 lakh by
pumping down the remaining gas into the Condenser.
• If we put the set point as 27 degrees we can recognize the problem prior to TRIP and
rectify to avoid tripping.
• As there are no of PACs, sometimes it may not be possible for Maintenance Engineers to
look every unit due to busy schedule. Then he can know the problematic unit directly and
give priority to attend its problem.
• The salary of one operator is Rs.15000; to look after the entire plant many operators are
required. There work is to monitor the plant if anything goes wrong immediately switch
on standby and report to the Assistant Engineer (AE). Then AE will go and solve the
problem.
• Management can reduce the number of operators by implementing this project where
ever necessary. By doing this management can save the salaries paid to these operators
and even these sensors provide right information to the right person at right time.
• By implementing this in the plant Packaged Air Conditioners (PACs) work continuously
without interrupting the operations of the Thermal Power Plant.

Conclusion:
Now a day’s Businesses are very competitive and to survive in the market Company or
Industry should take many measures in manufacturing process of products to meet the
demand in right time. This Project will surely help in remote monitoring and even controlling
of temperatures in manufacturing process, which is very necessary. The project is very
simple and can be implemented in any Industry with a less cost. Since mobile phones have
become as a part of our living, the communication and control can be done easily from any
place.

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