REMOTE MONITORING AND CONTROLLING OF GENERATOR

COURSE

EMBEDDED SYSTEMS AND DESIGN

Prepared By
MALIK MUHAMMAD FAIZAN MUHAMMAD ADEEL QADRI SHIREEN QURESHI 4650 4603 4667

Instructor: Dr Hussain Ahmed

College Of Engineering

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ACKNOWLEDGEMENT

Praise to ALLAH ALMIGHTY, the most Gracious and the most Compassionate.

We wish to express our sincere gratitude to Engg. Imran Ghaffar (External Advisor from Byco) for providing us an opportunity to work under his guidance on the Project entitled Remote Monitoring and Controlling of Generator. We are also very grateful to our course instructor Dr. Hussain and internal project advisor Asst. Prof. Mr. M. Abdul Aleem for enlightening us with his great knowledge and vast experience throughout the project work. Finally our sincere thanks to our institute PAF-KIET College of Engineering, for providing us the opportunity and to gave us the strength to undertake this project.

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INDEX

Sno. 1 2 3 4 5 6 7 8 9 10 11

Content Project objective Motivation Objectives of project Methodology Test results and their analysis Process flow Algorithm Block diagram Schematic Mechanical design Conclusion

Page No. 4 4 4 5 6 11 12 13 14 15 16

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Project Objective:
The objective of this project is to design and construct a model for monitoring and controlling of power generators. We have worked on three different parameters of power generators such as fuel level, temperature and load. We have used GSM technology to communicate between substation( where actually the generators will be installed) and the base station or a cell phone.

Motivation:
For the last few decades, technology is getting advance rapidly which has made life more efficient and comfortable. We saw the application of this project at our Internship period to PARCO, where they were heavily relying on the use of generators for power. From there, we get motivated to work on this project for making the process efficient and less time consuming. The project we are designing is an extended approach to automate and controlling different parameters of the generator set manually as well as giving option for remote monitoring and controlling.

Objectives:
To design and construct a low cost industrial based monitoring system model. Monitor different parameters of the generator; temperature, fuel and electric load. To provide Remote and Manual options for Generator Monitoring. Use of GSM (Global System for Mobile Communication) technology for cell phone
monitoring

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METHODOLOGY:
The design and implementation of the project can be divided into following major phases: Analysis of components, designing and selection. Assembling of different design and testing. Simulation development and Verification at the hardware level. Development for future implementation.

Analysis of components, designing and selection:

The very first part to achieve our desired objectives is to analyze the components required and selection of the best available components furthermore the hardware selection is also one of the major part.

Assembling of different Design and testing:

Once all components were selected and all major functional parts were designed, the next step is to assemble all of them together and then to test all the modules simultaneously.
.

Simulation development and Verification at the Hardware Level:

Test results were simulated to achieve the desired goals and then they were verified at the hardware level to get the desired outcome.

Market adaptability
The idea of monitoring the parameters of the generator is not new. There are systems in the market which are used now a day in industry. There are companies having their small generators installed at different locations they have the major issue of monitoring but they cannot afford

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those costly monitoring systems available in market, this project is the solution for many small scale industries.

TEST RESULTS & THEIR ANALYSIS

We have performed different tests for checking the working of different sensors that we are using. Also component as well as module testing has been done before assembling the system to the prototype. The test results and their analysis are given below.

Microcontroller (PIC16F877A)
Microcontroller PIC16F877A has been tested using different Logical Programs and its working correctly. We have also tested its working on our main control board.

Figure 4-1 Microcontroller Module Testing

We have tested our modules of temperature, fuel and overload and all are working properly.

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GSM MODULE

We are using GSM module, Siemens TC-35 which is also tested and its working properly. We are using GSM module for communication between sub station and base station or cell phone.

Figure 4-2 GSM Module

This module has also been tested via micro-controller for sending the commands of the conditions from sub-station to base-station. The delay in sending the SMS is about 40 sec. to 60 sec., while it may also vary depending on the service usage at that particular time.

ELECTRONIC OVER CURRENT RELAY (EOCR)

EOCR electronic over current relay we are using for electric load monitoring. We are using EOCR of current range from 0.5 - 6 A. this also we have tested with load and its working properly.

Figure 4-3 EOCR Testing

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S.No.

Expected Delay Time (a)

Measured Delay Time (b)

Expected Over Time (c)

Measured Over Time (d)

Current Rages

01. 02. 03. 04. 05.

0.2 sec. 05 sec. 10 sec. 20 sec. 30 sec.

01 sec. 06 sec. 10 sec. 21 sec. 31 sec.

0.2 sec. 02 sec. 05 sec. 08 sec. 10 sec.

01 sec. 02 sec. 06 sec. 08 sec. 11 sec.

0.5 6 A 0.5 6 A 0.5 6 A 0.5 6 A 0.5 6 A

Table 4-1 EOCR Working Analysis

EOCR has also been tested with the module and its functioning properly. There has been an error of approx. 10% in over-time and delay time, which is acceptable in our circumstances.

PT-100
PT-100, temperature sensor is also being tested and its working properly. It is also interfaced with microcontroller for verification of temperature sensing.

Temperature Expected Deg. oC Resistance (a)

Measured Resistance (b)

Measured Temperature

Error (a-b/a)*100

0 oC 10 oC 20 oC 30 oC 40 oC 60 oC 80 oC 100 oC 110 oC

100.00 103.90 107.79 111.67 115.54 123.24 130.90 138.51 142.29

98.58 103.20 107.15 110.50 114.93 122.20 129.89 138.10 141.98

0 oC 9.5 oC 19.0 oC 29.0 oC 41.0 oC 61.0 oC 79.0 oC 99.0 oC 108.0 oC

1.42 % 0.67 % 0.59 % 1.05 % 0.53 % 0.84 % 0.77 % 0.30 % 0.22 %

Table 4-2 PT-100 Resistance Table Analysis

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Error Analysis
1.6 1.4 1.2 %age error 1 0.8 0.6 0.4 0.2 0 0 10 20 30 40 60 80 100 110 Temperature (deg Cent.) 0.67 0.59 0.53 0.3 0.22 1.05 0.84 0.77 1.42 Error Analysis

Graph 4-1 b/w Temperature Measured and Tabled (PT-100)

From these test results, we have analyzed that the error will get minimum as the temperature gets nearer to the 100 mark.

FLOATING BALL BASED FUEL SENSOR

Since ultrasonic sensors are too much expensive, therefore, we have worked on floating ball based fuel sensor for our model displaying. The sensor is tested and its working properly.

S. No.

Expected Resistance (a)

Measured Resistance (b)

State

Error (a-b/a)*100

Slow Movement of Arm 1 2 3 Fast Movement of Arm 4 5 6

(0 2.6) K (2.6 5.2) K Above 5.2 K

(0 2.7) K (2.7 5.5) K Above 5.5 K

Low Moderate Full

3.85 7.69 6.25

(0 2.6) K (2.6 5.2) K Above 5.2 K

(0 2.9) K (2.9 6.1) K Above 6.1 K

Low Moderate Full

11.54 23.08 18.75

Table 4-3 Fuel Sensor Analysis

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Error Analysis
25 20 %age error 15 10 7.69 5 0 1 2 3 No. of Reading 4 5 6 3.85 6.25 11.54 23.08 18.75 Error Analysis

Graph 4-2 for errors b/w fast and smooth movement of sensor.

From these test results, we have analyzed that the error will get maximum if the arm of the sensor is moved fast. But in our case it will move slowly, so no danger to use it.

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PROCESS FLOW

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ALGORITHM

1. 2. 3. 4.

Initialize all the circuit. Initialize GSM modem. Send status SMS to the cell phone. Get temperature reading from PT100 and display on LCD and send it to the cell phone through GSM. 5. If temperature in range, go to step 10 if higher than normal range go to step 6. 6. Turn ON the buzzer and send an SMS to cell phone through GSM if temperature goes down go to step 5 else continue. 7. If temperature exceeds from the maximum limit turn OFF the Generator and send an SMS to cell phone. 8. Go to step 18. 9. Get Load reading from Overload relay and display on LCD and send SMS to cell phone. 10. If load is in range go to step 15 if higher than normal continue to next step. 11. Turn ON the buzzer and send an SMS to cell phone, if load decreases go to step 10 else continue. 12. If load exceeded from the maximum limit Turn OFF the generator and send SMS to cell phone. 13. Go to step 18. 14. Get Fuel reading from Fuel sensor and display on LCD also send SMS to cell phone 15. If fuel is enough go to step 5, if lower than defined range continue to next step. 16. Send an SMS of low fuel status to base station 17. If fuel gets lower than the 2nd defined range Turn OFF the generator and send an SMS to cell phone. 18. Wait for SMS from base station or manual restart. 19. If manual restart go to step 1. 20. If restarted from cell phone go to step 3. 21. END

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BLOCK DIAGRAM

CELL PHONE

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SCHEMATIC

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MECHANICAL DESIGN

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CONCLUSION
Initially, it was considered by us a very difficult task to measure different parameters of the generator and then display them on the panel as well as send those indications via GSM to the base station, but Alhamdulillah with hard work and good support from our teachers, we have successfully achieved our aim and all the objectives for the project. Following are the expected results and the results which we have obtained.

Results Expected
Following results are desired and expected for successfully running a project: Parameters must be read correctly from the sensors that are placed. Microcontroller must get the readings from sensors timely and make the indication decisions according to the programmed values.

GSM module must be interfaced with micro controller for cell phone monitoring.

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