Smart Monitoring and controlling of Industrial air compressor

Project Title

Smart Monitoring and controlling of Industrial air compressor

Project Area of Specialization Electrical/Electronic EngineeringProject Summary

Project Summary:

Manipulating a compressed air in industry is strenuous for engineers. In most industries compressed air is used for running a simple air tool or for complicated task such as pneumatic control. One of the big problem is associated with this system is the monitoring and controlling of pressure fluctuations and its other parameters. These fluctuations cause many serious problems like the safety of equipment and worker. As we know increased in pressure or temperature may damage the transmission lines or storage tank. To maintain these parameters, companies have to employ the workers at every station. Thus, to overcome the drawbacks of the previous system as manual we are using automatic system. We will design a system which will maintain these parameters Temperature, Pressure, Consumption of Compressed Air, Flow of Compressed Air and input electrical power to compressor machine with GUI and IoT. There is an increasing demand in substations for smart control and remote monitoring system, where devices can be controlled using latest technologies. This system allows users to control their whole setup at a single control room and in a single hand of supervisor.

Project Objectives

Objectives/Deliverables:

In many industries, the compressed air system is so vital that the industry cannot operate without it. In today's world everyone wants to get maximum advantage from the current technology so, we will built that setup for the industry which will give benefit to them in certain ways like

1. To detect leakage point and make our system more efficient. It will also increase per-unit output by providing essential air to every plant.
2. Perform practically compressed air leakage calculations.
3. To monitor and control compressed air parameters using modern technologies.
4. To make our system more safe and secure for workers and machines.
5. To save heat losses of our system and use them in other applications.
6. Perform practically heat recovery calculations.
7. To increase overall efficiency of input electrical power.

Project Implementation Method

Methodology for Implementation of Project:

Methodology for the implementation of this project is described below,

• Hardware Setup:

We will collect compressed air from compressor into a main headline. This headline is connected to a storage tank, to store compressed air and make it reliable for our system. Main distribution line is directly connected to the storage tank. Primary and secondary distribution lines are connected to main line and they supply air to different units.

• Instrumentation:

To measure temperature, pressure and flow of this compressed air, we have to connect different instruments at the different stages. To monitor every compressor, we have to monitor every compressor’s parameters individually. When this compressed air reach in headline, tank, distribution lines,we have to monitor temperature, flow and pressure of all of them.

• Controlling:

After the installation of these instruments, we have to collect the output of these sensors. We decided to use raspberry pi and Arduino controller for this purpose. For programming we will use C++ and Python languages. We will use an LCD to make a GUI of our system. and will be installed in main control room where an operator will present.

Mechanical valves and relays will be operated by the controller at set points and will shut down when limit will exceed. By this controlling, our system will more secure and safe for worker and machines.

We will offer to our user a system in which he can monitor and control the system wirelessly through IOT. Every trusted person can login and monitor/control it all the world through IOT.

• Leakage Detection:

Leaks can be a significant source of wasted energy in an industrial compressed air system, sometimes wasting 20–50% of a compressor’s output. An unmaintained plant will likely have a leak rate equal to 20% of total compressed air production capacity. To compensate these losses, we will implement a system by which our controller will detect the leakage point. There are two methods for this purpose i-e, ultrasonic Method, difference Method. The second one can detect automatically. It will compare the sending and receiving parameters of air. If there will be difference other than rated, it will generate an alarm.

• Heat Loss:

Approximately 94% of the electrical energy used by an Industrial Air Compressor is converted into heat and loss through radiation in the compression process. The remaining 6% is converted into actual mechanical work.

• Heat recovery:

There is huge potential to harness the waste energy and convert them to more meaningful use for making a greener earth.

We will design a heat recovery system that can recover anywhere from 45-55% of the available thermal energy to generate warm water. This warm water can be used as a driving energy source for air conditioning(Adsorption Chillers) or to warm buildings. This will save huge Electrical Energy being used for cooling applications and help in reducing emissions.

Benefits of the Project

Beneficiaries:

The industry is the targeted-audience of our project and it will beneficial for different industries like,

• Apparel

Conveying, clamping, tool powering, controls and actuators, automated equipment

• Automotive

Tool powering, stamping, controls and actuators, forming, conveying

• Chemicals

Conveying, controls and actuators

• Food

Dehydration, bottling, controls and actuators, conveying, spraying coatings, cleaning, vacuum packing

• Furniture

Air piston powering, tool powering, clamping, spraying, controls and actuators

• General Manufacturing

Clamping, stamping, tool powering and cleaning, controls and actuators

• Lumber and Wood

Sawing, hoisting, clamping, pressure treatment, controls and actuators

• Metals Fabrication

            Assembly station powering, tool powering, controls and actuators, injection molding, spraying

• Petroleum

Process gas compressing, controls and actuators

• Primary Metals

Vacuum melting, controls and actuators, hoisting

• Pulp and Paper

Conveying, controls and actuators

• Rubber and Plastics

Tool powering, clamping, controls and actuators, forming, mold press powering, injection molding

• Stone, Clay and Glass

Conveying, blending, mixing, controls and actuators, glass blowing and molding, cooling

• Textiles

            Agitating liquids, clamping, conveying, automated equipment, controls and actuators, loom jet weaving, spinning, texturizing

• Agriculture

Farm equipment, materials handling, spraying of crops, dairy machines

• Mining

Pneumatic tools, hoists, pumps, controls and actuators

• Power Generation

Starting gas turbines, automatic control, emissions controls

• Service Industries

Pneumatic tools, hoists, air brake systems, garment pressing machines, hospital respiration systems, climate control

• Transportation

Pneumatic tools, hoists, air brake systems

• Wastewater Treatment

Vacuum filters, conveying

Technical Details of Final Deliverable

Technical Details of Final Deliverable:

To monitor the different parameters i-e, input electrical power, temperature, pressure and air flow etc. of this compressed air, we have to connect different instruments and sensors at the different stages. To monitor every compressor, we have to monitor every compressor’s parameters individually. When this compressed air reach in headline, we have to monitor temperature and pressure of headline. We will follow this air at every point and monitor it like main storage tank, distribution lines, at receiving end etc. For this purpose, we have to install different instruments and sensors.

We will collect pressure and temperature output which is analog at the analog pins of Arduino. To calculate flow of air we are using hall effect flow meter and its output is digital. It will connect to the digital pins of Arduino. For the sake of compressor machine electrical power, we will use CT-PT and connect them on the analog pins of Arduino because of their analog output. For the controlling of compressed air, we will use electrically operated valves. Available valves for our project are 220V-AC operated and we will use them with relays and relays will operated by the digital output of Arduino. As we will program Arduino for these IOs, Arduino will connect to the raspberry pi. Here raspberry pi is used as a processor and for an operating system. An LCD(user defined size) will be connect to raspberry pi. We decided to install Raspbian operating system in the raspberry pi. After the upgradation of OS, necessary libraries will be installed. Arduino IDE will also install in RPi to connect Arduino.

Arduino input data will process. Compressor machine rated output will be standard to compare other parameters. There will be temperature, pressure and flow sensors will be connected to the output of compressor(main headline), storage tank and at the different distribution lines. RPi will process this data and make different decisions. Our programming algorithim will check whether headline parameters are equal to the rated sum of compressor machines. In next block it will check whether all of our air reached in tank or not. In negative case it will generate a leakage beep. It will check it also for next distribution lines till to the output.

Data will store into the spreadsheets. A GUI is for the user convenience. Supervisor of firm can monitor this data from every where through a login in the android app in his smart phone. He can turn ON/OFF the machines, valves or tank through his mobile.

As we have discussed, compressors produced much heat and we will use this heat by a heat recovery system. We will pass water from the body compressor through special bank of steel tubes. Compressor will transfer its heat to the water and this heated water can be used for different purposes.

Final Deliverable of the Project HW/SW integrated systemCore Industry ManufacturingOther Industries Petroleum , Food , Health Core Technology Internet of Things (IoT)Other TechnologiesSustainable Development Goals Affordable and Clean Energy, Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	64270
Air Compressor	Equipment	1	17000	17000
Pressure Transducer	Equipment	4	1850	7400
Temprature Sensor	Equipment	6	300	1800
Flow meter	Equipment	4	650	2600
Elecric Valves 1/4	Equipment	4	650	2600
Raspberry pi 3b+	Equipment	1	6200	6200
Arduino Mega	Equipment	1	1220	1220
LCD display 19 inch	Equipment	1	2800	2800
Keyboard Mouse	Equipment	1	600	600
Lines 3/4 inch(dia) 6 inch(length) piecs	Equipment	32	85	2720
Line Brushes 3/4	Equipment	32	30	960
Line Brushes 1/2	Equipment	8	40	320
Brass manual Valve 3/4 inch	Equipment	5	420	2100
Ellbow T's inch	Equipment	32	50	1600
CT	Equipment	1	900	900
PT	Equipment	1	460	460
Power Supply	Equipment	2	450	900
Project Mechanical Stand	Equipment	1	4000	4000
Line Sockets 3/4 inch	Equipment	16	55	880
Air Filter for dust 3/4 inch	Equipment	1	2150	2150
Project Purposal Printing	Miscellaneous	2	120	240
1st Evaluation Report	Miscellaneous	2	110	220
Travelling to buy Sensors	Miscellaneous	2	1160	2320
Relays 5V DC	Equipment	7	40	280
Magnetic Contactor	Equipment	1	550	550
SD card for Raspberry pi	Equipment	1	1450	1450