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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.
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.
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.
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.
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.
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S.No.
Current Rages
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.
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
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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
From these test results, we have analyzed that the error will get minimum as the temperature gets nearer to the 100 mark.
S. No.
State
Error (a-b/a)*100
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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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