Endothermic Process Monitoring and Control using IIOT
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This document describes a system to monitor carbon monoxide (CO) levels in endothermic industrial processes in real-time using the Industrial Internet of Things (IIoT). A CO sensor will detect CO levels which an ARM microcontroller will process into parts per million. An ESP32 will transmit the data via MQTT protocol to a server or cloud for remote monitoring. The system aims to warn of toxic gas leaks, detect equipment issues, and allow for energy savings through real-time visibility of process parameters. It could be applied to industries like furnaces, forging, and oil and gas to help ensure worker safety and process efficiency.
![International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 09 Issue: 04 | Apr 2022 www.irjet.net p-ISSN: 2395-0072
© 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 3860
• Dashboard: A dashboardis a data visualizationtool
that tracks, analyzes,anddisplaysKPIs,metrics,and
critical data points. Dashboards empower both
technical and non-technical users to understand
and leverage business intelligence to make more
informed decisions.
HARDWARE REQUIREMENT
TM4C1294NCPDT
ESP32
MQ7 Sensor
SOFTWARE REQUIREMENT
Code composer studio V7.3.0
Arduino V 1.8.19
Teraterm
ADVANTAGES
Avoid fatal health issues or even death of a worker
by monitoring and controlling CO.
Energy saving by timely Alarming Customer about
the energy wastage.
Reducing CO by increasing ventilation.
Smartness added due to Industrial IOT.
Applications
It can be used in Furnaces to monitor and
controlling CO.
Can be modified to use in many endothermic
processes like, forging industries, or oil & natural
gas industries for monitoring critical gases.
3. FLOW CHART
1. Application
2. Communication
4. CONCLUSIONS
We conclude that by using this we can measure CO valuesof
atmosphere .Getting satisfactory CO valuesinPPMandsame
can be viewed remotely using IIOT.
ACKNOWLEDGEMENT
We would also like to thank our guide Prof .JayashriPalkar
head of the department Prof. R. A. Barapate forinspiring us
and providing us all lab facilities with internet,whichhelped
us with the project work.
REFERENCES
[1]Ahmed Abdullah Ibrahim , Carbon Dioxide and Carbon
Monoxide Level Detector.
https://ieeexplore.ieee.org/document/8631933
[2]M. Mello, Carbon-monoxide (CO) Real Time Monitoring
in Combustion Engines by an Optical Detection System.
https://ieeexplore.ieee.org/document/1689987
[3]Emmanuel Estrada, Low Cost CO Detector Integrated
with IoT. https://ieeexplore.ieee.org/document/8920567
Initialization
Connect to WIFI
Connect to MQTT Broker
Loop
Check if data available on SPI lines
If data received on SPI, Give feedback to TM4C129
Publish data to topic on MQTT Broker
Initialization
Read EEPROM
While loop
Read data from ADC and process it
Calculate PPM
Transfer data to ESP 32 using SPI protocol
Check feedback from ESP32](https://image.slidesharecdn.com/irjet-v9i4565-220928075207-eb041fd8/85/Endothermic-Process-Monitoring-and-Control-using-IIOT-2-320.jpg)
Endothermic Process Monitoring and Control using IIOT
- 1. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 04 | Apr 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 3859 Endothermic Process Monitoring and Control using IIOT Satheesh kumar Ponnuswamy1, Faiz Anis Patel2 1 UG Student, dept. of Electronics and Telecommunication Engineering, KSE Pune, India 2UG Student, dept. of Electronics and Telecommunication Engineering, KSE Pune, India 3Prof Jayashri Palkar, dept. of Electronics and Telecommunication Engineering, KSE Pune, India ---------------------------------------------------------------------***--------------------------------------------------------------------- Abstract - In industries using Endothermic processes it is essential to monitor the levels of toxic gases as there are high chances of leakage of toxic gases .In such processes there is a significant contribution of CO (Carbon Monoxide).Thisproject will perform real time monitoring of CO levels and escalate warnings if it reaches alarming level and also take control actions to reduce the effect of toxic conditions. It will also inform about energy wastage and some fault/malfunction in the machinery as increased CO levels indicate inefficient burning of fuel. We are making this process smart and Industry 4.0 compatible by integrating IIOT. Key Words: Endothermic process, Carbon Monoxide, Sensors, ARM controller, IIOT 1. INTRODUCTION Industrial Internet of Things, also known asIndustrial IoTor IIoT, is the application of connected sensors, and other devices to machinery and processes in industry. The Industrial IOT applications can give the plant manager’s, supervisor or any other responsibleperson,a Real timeview of the critical Parameter’s that they need to monitor. An endothermic process is any process with an increase in the enthalpy H of the system. In such a process, a closed system usually absorbs thermal energy from its surroundings, which is heat transfer into the system. By using this system in Endothermic process industry, it gives the organisation a real-time visibility of critical parameters, and avoiding any Hazardous conditions. 1.1 Objectives To make a healthy environment for workers. Energy saving, to make scaled data available on, on-premises server or cloud for remote monitoring. 1.2 Scope The parameters like CO will be detected by the sensors and processed by the controller which will give output in PPM, This data will further will be sent through the used protocol on the IOT network to the server were it can be viewed by the organization or responsible persons in the industry. 2. BLOCKDIAGRAM • CO Sensor:- It is a electrochemical sensor and need external supply of 5V • Signal conditional circuit :- Scale Sensorsignalsin to 0.25V to2.5V for ADC to accept this • SAR ADC:- This is 12bit internal Successive approximation analog to digital converter inside ARM controller. It will convert analog voltage into digital counts to process it in microcontroller • ARM microcontroller: This is one of the advanced Arm controller available in the market. It is 32bit controller with 1mb Flash and256BbRAM.Speedis 150DMIPS and works with 120Mhz clock. • EEPROM: This is 6Kb internal EEPROM insideARM controller with more than 10Lac write cycle. This is used to store calibration and configuration data. • ESP32 : It is a feature-rich MCU with integrated Wi- Fi and Bluetooth connectivity for a wide-range of applications, At its heart, there's a dual-core Tensilica Xtensa LX6 microprocessor with a clock rate of up to 240 MHz, its performance is upto 600 DMIPS. • MQTT Broker: An MQTT broker is a server that receives all messages from the clients and then routes the messages to the appropriate destination clients. • Data bridge: Bridge between Broker and database. • Database: This will be used to store all the data sensed by the sensor.
- 2. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 04 | Apr 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 3860 • Dashboard: A dashboardis a data visualizationtool that tracks, analyzes,anddisplaysKPIs,metrics,and critical data points. Dashboards empower both technical and non-technical users to understand and leverage business intelligence to make more informed decisions. HARDWARE REQUIREMENT TM4C1294NCPDT ESP32 MQ7 Sensor SOFTWARE REQUIREMENT Code composer studio V7.3.0 Arduino V 1.8.19 Teraterm ADVANTAGES Avoid fatal health issues or even death of a worker by monitoring and controlling CO. Energy saving by timely Alarming Customer about the energy wastage. Reducing CO by increasing ventilation. Smartness added due to Industrial IOT. Applications It can be used in Furnaces to monitor and controlling CO. Can be modified to use in many endothermic processes like, forging industries, or oil & natural gas industries for monitoring critical gases. 3. FLOW CHART 1. Application 2. Communication 4. CONCLUSIONS We conclude that by using this we can measure CO valuesof atmosphere .Getting satisfactory CO valuesinPPMandsame can be viewed remotely using IIOT. ACKNOWLEDGEMENT We would also like to thank our guide Prof .JayashriPalkar head of the department Prof. R. A. Barapate forinspiring us and providing us all lab facilities with internet,whichhelped us with the project work. REFERENCES [1]Ahmed Abdullah Ibrahim , Carbon Dioxide and Carbon Monoxide Level Detector. https://ieeexplore.ieee.org/document/8631933 [2]M. Mello, Carbon-monoxide (CO) Real Time Monitoring in Combustion Engines by an Optical Detection System. https://ieeexplore.ieee.org/document/1689987 [3]Emmanuel Estrada, Low Cost CO Detector Integrated with IoT. https://ieeexplore.ieee.org/document/8920567 Initialization Connect to WIFI Connect to MQTT Broker Loop Check if data available on SPI lines If data received on SPI, Give feedback to TM4C129 Publish data to topic on MQTT Broker Initialization Read EEPROM While loop Read data from ADC and process it Calculate PPM Transfer data to ESP 32 using SPI protocol Check feedback from ESP32
- 3. International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056 Volume: 09 Issue: 04 | Apr 2022 www.irjet.net p-ISSN: 2395-0072 © 2022, IRJET | Impact Factor value: 7.529 | ISO 9001:2008 Certified Journal | Page 3861 BIOGRAPHIES Satheesh kumar Ponnuswamy, Student of Keystone school of engineering,Pune Faiz Patel, Student of Keystone School of Engineering Pune. or Photo