International Journal of Computational Intelligence and Information Security, December 2011 Vol. 2, No.

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LPG Plant Control using Multidrop Network Bus Topology with GSM Technology
Mr. P.A. Patil1 Prof. Sanjay S. Chopade2 Prof. S. A. Naveed3 Jawaharlal Nehru Engineering College, Aurangabad, Maharashtra, India E-mail ID: [email protected] Associate Professor Department of Electronics and Telecommunication Engineering Sandip Institute of Technology and Research Centre, Nashik, Maharashtra, India Email_ID: [email protected] Professor, Department of Electronics and Telecommunication Engineering Jawaharlal Nehru Engineering College, Aurangabad, Maharashtra, India. E-mail ID: [email protected]

ABSTRACT
Gas leak detection methods became a concern after the effects of harmful gases on human health were discovered. Before modern electronic sensors, early detection methods relied on less precise detectors. Presently available gas leakage alarms do not provide any PC interface. They also do not provide any automatic control on gas leakage. If there is nobody at home, then chances of alarm being heard by outsiders become less, when there is a gas leakage. In the proposed paper, we have provided automatic control and PC interface to the sensor. Each sensor will be placed at an appropriate place where there is chance of leakage. For example each sensor will be placed in the kitchen of different flats or bungalows. The PC located in cabin of watchman will continuously monitor status of each sensor. If there is no gas leakage, then OK status will be displayed on PC. If there is gas leakage then FAIL status will be displayed on PC. It is my sincere effort to design a system to control gas leakage at the same time massage will be given to control room mobile. Keywords: GSM, LPG, TGS-2610

1. Introduction
Accidents due to leakage of LPG can be very dangerous. With a small mistake they may take lives of our loved ones. Consequences might be much more severe if such an incident takes place in an apartment system. Our paper is a solution to this problem. In our paper we are basically going to sense, monitor and control leakage of LPG. Presently available gas leakage alarms do not provide any PC interface. They also do not provide any automatic control on gas leakage. If there is nobody at home, then chances of alarm being heard by outsiders become less, when there is a gas leakage. In our paper we are going to provide PC interface to the sensor and also we are going to provide automatic control. Each sensor will be placed at an appropriate place where there is chance of leakage. The PC located in cabin of watchman will continuously monitor status of each sensor. If there is no gas leakage, then OK status will be displayed on PC. If there is gas leakage then FAIL status will be displayed on PC.

2. Literature Review
Gas leak detection methods became a concern after the effects of harmful gases on human health were discovered. Before modern electronic sensors, early detection methods relied on less precise detectors.[1][2] Through the 19th and early 20th centuries, coal miners would bring canaries down to the tunnels with them as an early detection system against life threatening gases such as carbon monoxide, methane, propane and butane. The canary, normally a very songful bird, would stop singing and eventually die in the presence of these gases, signaling the miners to exit the mine quickly. Before the development of electronic household carbon monoxide detectors and LPG in the 1980s and 90s, carbon monoxide presence was detected with a chemically infused paper that turned brown when exposed to the gas. Since then, many technologies and devices have been developed to detect, monitor, and alert the leakage of a wide array of gases. Basic Methods of LPG Leak Detection are Gas Leak Detection Fluid using soap and water solution, Manometer. Todays Advanced Trends of LPG Leak Detection are Gas Sensor[8], Gas sensing technologies: Metal Oxide Based Gas Sensors, Capacitance Based Gas Sensors, Acoustic Wave Based Gas Sensors, Calorimetric Gas Sensors, Optical gas sensors[9], Electrochemical gas sensors[10]. Our proposed method of gas leakage detection is using gas sensor with master slave multidrop network bus topology. This topology provides high speed communication with 32 number of nodes. Data speed rate is optimum with nodes connected.[4][5]

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3. Proposed Block Diagram of the System

proposed block diagram is shown in figure 1

Figure 1: Proposed Block Diagram of the System Here a microcontroller acts as Master of the network. The microcontrollers with sensor interface act as slaves of the network. Sensors are interfaced to slave microcontrollers through respective signal conditioning circuits.[3] Communication between Master and Slaves is carried out by polling method. The Master initiates a communication request to a Slave Node by addressing that unit. The Slave addressed by the Master will respond by checking the status of sensor. Here a Personal Computer is also connected to this multidropping network through a RS485 to RS232 converter. This PC is used to monitor and display status of each sensor. The output of sensor is also given to solenoid valve which closes gas flow at the same time the massage will be given to the plant manager on his mobile through the GSM module. Following are the basic building block of the proposed system. Gas sensor analysis Signal Condition circuit Network Bus Topology Communication Protocol

3.1 Gas Sensor Analysis

The sensor used for sensing gas leakage is TGS-2610. It is housed in T0-5 Metal Can package. It consists of a sensing chip made up of Metal Oxide Semiconductor formed on Alumina substrate. It also consists of an Integrated Heater, which is used to keep sensing chip at a specific temperature, which is optimal for sensing. Some important features of this sensor are as follows: 1. Low power consumption. 2. High sensitivity to LP Gas and its components like Propane and Butane. 3. Low sensitivity to alcohol vapors. 4. Uses simple electrical circuit for sensing. The sensor requires two input voltages. 1. Circuit voltage (Vc) 2. Heater voltage (VH) The Heater voltage (VH) is applied to integrated heater. Circuit voltage (Vc) is applied to get voltage drop across load resistor (RL), which is connected in series with sensor resistance (Rs). When there is no gas leakage conducting of sensing chip is less so drop across sensor resistance is more and drop across load resistor is less. When there is gas leakage, conducting of sensing chip increases so drop across sensor resistance decreases and drop across load resistor increases. Thus by using simple electrical circuit conductivity is converted into output signal.

3.2 Signal Conditioning Circuit

Signal conditioning circuit is basically detect change in the gas sensor output which is applied to the comparator which compares it with the reference voltage. The output of comparator generates appropriate signal for microcontroller. Sensitivity can be adjusted by the signal conditioning circuit. The output of the circuit is made compatible with microcontroller circuit.

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3.3. Network Method (Bus Topology)

Figure 2 Networking Method. Figure 2 shows Bus Topology. In Bus Topology all nodes are connected using common communication line. Any node can be programmed as a host at any given time. All nodes see all data so communication is public from host to node. Bus Topology is a good choice when number of nodes is large and physical distance from host to node is also large. There are many cables available meeting the recommendations of RS-422 and RS-485, made specifically for that application. Another choice is the same cable commonly used in the twisted pair Ethernet cabling. This cable, commonly referred to as Category 5 cable, is defined by the EIA/TIA/ANSI 568 specification. The extremely high volume of Category 5 cable used makes it widely available and very inexpensive, often less than half the price of specialty RS422/485 cabling. The cable has a maximum capacitance of 17 pF/ft (14.5 pF typical) and characteristic impedance of 100 ohms. When choosing a transmission line for RS-485, it is necessary to examine the required distance of the cable and the data rate of the system. Losses in a transmission line are a combination of ac losses (skin effect), dc conductor loss, leakage, and ac losses in the dielectric. In high quality cable, the conductor losses and the dielectric losses are on the same order of magnitude Category 5 cable is available as shielded twisted pair (STP) as well as unshielded twisted pair (UTP).

3.4. Communication Protocol

Protocol is a set of rules defined and which are to be obeyed for proper communication between two nodes. In the proposed system design a Master-slave protocol is implemented using RS485 logic. This is the simplest Protocol. In this Protocol Polling method is used. Master and Slaves are connected through a common bus. The Master initiates a communication request to Slave by addressing that unit. The Slave addressed by the Master will respond by checking the status of sensor. In this protocol direct communication between two Slaves is not possible. 3.4.1 Algorithm for Master Microcontroller: The master microcontroller polls the slaves, to find out if there is any data from the slaves. Algorithm is given below: 1. 2. 3. 4. 5. Select GSM using analog switch(4053) Initialize GSM Switch to RS485 in RX mode Wait for gas sensor (P1.0) Low or Alarm from RS485 If Alarm switch to GSM. If Self alarm send self Address else sent slave address to GSM

3.4.2 Algorithm for Slave Microcontroller: The slave microcontroller responds to the requests front the master microcontroller.[7] Algorithm is given below : 1. Wait for gas alarm 2. If alarm(P1.0) low, solenoid ON, Send slave address to RS485

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The master controller polls both the slaves alternately. The slave responds to the request by understanding the command is for itself and sets the P3.0. P3.0 is set to avoid the contention problem, by making enable of 75176 high. After the response the bit is cleared for the next poll.

3.4.3 Implementation Master Slave algorithm using RS485 Transmission RS485 is a specialized interface that would not be considered standard equipment on today's home PC but is very common in the data acquisition world. RS232 is the most common interface used to communicate serially but it has its limitations. RS485 will support 32 drivers and 32 receivers (we are talking about bi-directional - half duplex - multi-drop communications over a single or dual twisted pair cable!!). An RS-485 network can be connected in a 2 or 4 wire mode (fig. Reference 3). Maximum cable length can be as much as 4000 feet because of the differential voltage transmission system used[1]. The typical use for RS485 is a single PC connected to several addressable devices that share the same cable. You can think of RS485 as a "party-lined" communications system (the addressing is handled by the Remote Computer unit). The RS232 may be converted to RS485 with a simple interface converter - it can have optical isolation and surge suppression. Electronic data communications between elements will generally fall into two broad categories: single-ended and differential. RS232 (singleended) was introduced in 1962, and despite rumors for its early demise, has remained widely used through the industry. The specification allows for data transmission from one transmitter to one receiver at relatively slow data rates (up to 20K bits/second) and short distances (up to 50Ft. @ the maximum data rate). When communicating at high data rates, or over long distances in real world environments, single-ended methods are often inadequate. Differential data transmission (balanced differential signal) offers superior performance in most applications. Differential signals can help nullify the effects of ground shifts and induced noise signals that can appear as common mode voltages on a network.[7] RS485 meets the requirements for a truly multi-point communications network, and the standard specifies up to 32 drivers and 32 receivers on a single (2-wire) bus. With the introduction of "automatic" repeaters and high-impedance drivers / receivers this "limitation" can be extended to hundreds (or even thousands) of nodes on a network. RS485 extends the common mode range for both drivers and receivers in the "tri-state" mode and with power off. Also, RS485 drivers are able to withstand "data collisions" (bus contention) problems and bus fault conditions.

Figure 3: Logic Diagram of 75176

4. Implementation of Proposed System 4.1 Gas Sensor design

The sensor used for sensing gas leakage is TGS-2610. It is housed in T0-5 metal can package. It consists of a sensing chip made up of metal oxide semiconductor formed on Alumina substrate. It also consists of an integrated heater, which is used to keep sensing chip at a specific temperature, which is optimal for sensing.

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Figure 4: Gas Sensor implementation Table 1:Specification of Gas sensor Technical Remark condition VC Circuit voltage AC OR DC 5V0.1 VH Heating Voltage AC OR DC 5V0.1 RL Load resistance 20K RH Heater resistance 335% Room Temp PH Heating Less than consumption 750mw The sensor requires two input voltages. Circuit voltage (VC) Heater voltage (VH). The Heater voltage (VH) is applied to integrated heater. Circuit voltage (Vc) is applied to get voltage drop across load resistor (RL), which is connected in series with sensor resistance (Rs). When there is no gas leakage conducting of sensing chip is less so drop across sensor resistance is more and drop across load resistor is less. When there is gas leakage, conducting of sensing chip increases so drop across sensor resistance decreases and drop across load resistor increases. Thus by using simple electrical circuit conductivity is converted into output signal. Symbol Parameter name

4.2 Signal conditioning Circuit Design

Figure 5: Signal Conditioning Circuit With reference to Figure 5, the output of gas sensor is connected to the comparator. The out put of comparator is given to the slave Microcontroller 89S52. If there is no gas leakage then output of comparator is logic 1. If there is gas leakage then output of comparator is logic 0. When Slave reads logic 1, it sends OK signal and when it reads logic 0, it sends FAIL signal whenever Master demands it.

4.3 Network Topology used

The implemented network topology using Master slave protocol is shown in figure 6. The portion shown by green block has been implemented. Such 32 slaves can be implemented with same data speed. The reading and result has been shown in the result chapter.

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Figure 6: Implemented System Following section shows the implementation of protocol.

4.4 Protocol Implementation

4.4.1 Asynchronous communication In Asynchronous communication the sender and receiver decide a data rate before communication. They decide upon signaling used for start & stop of data transmission. Both sender & receiver use a precise timing reference internally to divide serial received data into bits. In the asynchronous method, each character is placed in between start and stop bits as shown in figure 7. This is called as Framing. In data framing for asynchronous communication, the data such as ASCII characters are packed in between a start bit and stop bit. In this case transmission begins with start bit (0) followed by LSB then the rest of bits until the MSB, and finally one stop bit (1) indicating the end of the character is sent out. In some system in order to maintain data integrity, parity bit of the character byte is included in the data frame. This parity bit is useful for error detection.

Figure 7 : Asynchronous Communication Waveform RS 485 Protocol uses balanced lines.[6][7] Each signal requires one twisted pair with voltage on one of the Twisted Pair wires equal to negative or complement of the voltage of the other. The two lines in differential pair are designated as A and B. At the driver when TTL input is logic high, line A is more positive than line B. When TTL input is logic low, line B is more positive than line A. At the receiver if line A is more positive than line B, the TTL output is logic high. If line B is more positive than line A, then TTL output is logic low. Balanced lines are more immune to noise because if noise is present it is present more or less equally on both wires. It gets cancelled by opposite voltage on the other. SN75176: The SN75176 differential bus transceivers are monolithic integrated circuits designed for bi-directional data communication on multipoint bus transmission lines. They are designed for balanced transmission lines and meet ANSI Standards TIA/EIA-422-B and TIA/EIA-485-A and ITU Recommendations V.11 and X.27.[6][7] The SN75176 combine a 3-state differential line driver and a differential input line receiver, both of which operate from a single 5-V power supply. The driver and receiver have active-high and active-low enables, respectively, that can be connected together externally to function as a direction control. The driver differential outputs and the receiver differential inputs are connected internally to form differential input/output (I/O) bus ports that are designed to offer minimum loading to the bus when the driver is disabled or DE= 0. These ports feature wide positive and negative common-mode voltage ranges, making the device suitable for party-line applications. The driver is designed for up to 60 mA of sink or source current. The driver features positive and negative current limiting and thermal shutdown for protection from line-fault conditions. The receiver features a minimum input impedance of 12 k an , input sensitivity of 200 mV, and a typical input hysteresis of 50 mV.

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International Journal of Computational Intelligence and Information Security, December 2011 Vol. 2, No. 12 Table 2: Function table for SN75176

4.4.2 Interfacing Microcontroller with RS 485 Interface Interfacing of microcontroller is shown in figure 8.[3] The MAX75176 is converter from RS485 to RS232 logic level compatible.[5]

Figure 8: Interfacing of Microcontroller with RS 485 Interface

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International Journal of Computational Intelligence and Information Security, December 2011 Vol. 2, No. 12 4.4.3 Flow Chart of the System

Figure 9: Flow chart for Master

Figure 10: Flow chart for SS

Figure 11: Flow chart for ISR

Figure 12: Flow chart for G

Figure 13: Flow chart for S

Figure 14: Flow chart for Slave

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International Journal of Computational Intelligence and Information Security, December 2011 Vol. 2, No. 12 Master controller algorithm is implemented using figure 9 flow chart and Slave controller algorithm is implemented using figure 14 flow chart. Figure 10 is the flow chart for SMS to be sent through the GSM module to the factory manager mobile phone. The alarm will be ON which is implemented in the figure 13 flow chart. Figure 11 and figure 12 are the subroutines implemented for the initialization of ISR( interrupt subroutine) and GSM module.[5][7]

5. Results
The Emergency Gas leakage Message from Master Microcontroller(Node55) is shown in figure 15.

Figure 15: Emergency Gas leakage Message from Master Microcontroller(Node55) The Emergency Gas leakage Message from slave Microcontroller(Node33) is shown in figure 16.

Figure 16: Emergency Gas leakage Message from Slave Microcontroller(Node33) Emergency Gas leakage Message to Mobile Phone is shown in figure 17

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Figure 17: Emergency Gas leakage Message to Mobile Phone

6. Conclusion and future scope

When communicating at high data rates, or over long distances in real world environments, single-ended methods are often inadequate. Differential data transmission (balanced differential signal) offers superior performance in most applications. Differential signals can help nullify the effects of ground shifts and induced noise signals that can appear as common mode voltages on a network. So above system is useful for commercial as well as industrial application with very less development time and cost effective ness. In the future modification the distance between Master and Slave can be increased using telephone line for communication. Here we require two external modems one at the Slave end and other at the master end, If sensor and Slave unit are located in some remote area, we can use RF wireless communication. Here we require two wireless modems, one at Slave site and other at Master site. If we want to send SMS to the owner indicating gas leakage we have to place a mobile handset at sensor site. The status of sensor will be given to that mobile handset through its infrared port. By using Ethernet interface for embedded systems we can watch status of sensor in any part of world using LAN and WAN.

7. References
[1] Peng Zhang, Data Communications in Distributed Control System, Industrial Control Technology 2008, Pages 675-774 [2] Wu, C., and Zhu, J., (2007), Analysis of Biometric Systems for Banking Applications, Journal of Information and Communication Technology, Vol. 5, No. 2, pp. 112-123. [3] A.H.G Al-Dhaher, Integrating hardware and software for the development of microcontroller-based systems , Microprocessors and Microsystems, Volume 25, Issue 7, 15 October 2001, Pages 317-328 [4]Hamit Erdem, Implementation of software-based sensor linearization algorithms on low-cost microcontrollers Original Research Article ISA Transactions, Volume 49, Issue 4, October 2010, Pages 552-558 [5] Jan Axelson, Serial Port Complete Programming And Circuits For Rs-232 And Rs-485 Links And Networks Penram International Publishing (India) Pvt.Ltd. [6] Kenneth J.Ayala, The 8051 Microcontroller Architecture, Programming And Applications Second Edition By, Penram International Publishing (India) Pvt.Ltd. [7]Muhammad Ali Mazidi And Janice Gillispie Mazidi, The 8051 Microcontroller And Embedded Systems, Pearson Education (Singapore) Pte.Ltd. [8] Muda, R. (2009). Simulation and measurement of carbon dioxide exhaust emissions using an optical-fibre-based midinfrared point sensor. Journal of Optics A: Pure and Applied Optics, 11(1) [9]Vitz, E. (1995). Semiconductor Gas Sensors as GC detectors and Breathalyzers. Journal of Chemical Education, 72(920) [10]Breuer, W, Becker, W, Deprez, J, Drope, E, Schmauch, H . (1979) United States Patent 4141800: Electrochemical gas detector and method of using same.

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Mr. Pankaj A Patil is perusing ME from Jawaharlal Neharu Engineering College, Aurangabad, India. He is graduate in BE Industrial Electronics. He is having Teaching experience of 14 years. He is working as Assistant Professor in MET, Bhujbal Knowledge City, Nasik in the university of Pune, Pune since 2008. His working area is Microcontroller, Power Electronics, audio/video Engineering, Computer Network.

Mr. Sanjay S Chopade is perusing Ph.D from Rajasthan University, Jaipur, India. He is graduate in BE Electronics and Telecommunication Engineering in 1996 from Government College of Engineering, Amaravati. Amravati University. He has completed his M.Tech from Centre of Electronics Design and Technology of India Aurangabad, India presently know as DOEACC, Aurangabad. He is having Teaching experience of 14 years. He is working as Associate professor at Sandip Institute of Technology and Research Centre, Nasik in the university of Pune, Pune since 2009. His working area is Microcontroller, Microprocessor Power Electronics, VLSI Design.

Prof. S. A. Naveed is Ph.D in Power Electronics, He is having Teaching experience of 10 years, Presently working as Professor in the Department of Electronics and Telecommunication Engineering Jawaharlal Nehru Engineering College, Aurangabad, Maharashtra, India.

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