DESIGN AND DEVELOPMENT OF AUTOMATED WATER FILLER FOR INDUSTRIAL BOILERS USING PIC MICROCONTROLLER

e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:03/Issue:03/March-2021

Impact Factor- 5.354

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DESIGN AND DEVELOPMENT OF AUTOMATED WATER FILLER FOR INDUSTRIAL BOILERS USING PIC MICROCONTROLLER Dr. P. Jamuna*1, P. Dharman*2, M. Sribharathi*3, S. Suresh*4, K. Thazhaimuthu*5 *1Professor,

*2*3*4*5UG

Department of Electrical and Electronics Engineering, Nandha Engineering college(Autonomous), Erode, Tamil Nadu, India

Scholar, Department of Electrical and Electronics Engineering, Nandha Engineering college(Autonomous), Erode, Tamil Nadu, India

ABSTRACT The Industrial boiler monitoring and control the boiler water level management can play virtual role in the power consumption and water management process. Lead to introduce the design of an electronic system that provides automatic control of water pump motors, which are used to fill the boilers. The water level identify to using The IR sensor detect the maximum and minimum water level of the boiler using water level indication glass. This IR signal sends a signal to the PIC Microcontroller that control the DOL starter. Then it depends on the motor ON/OFF. This maintains water availability in the boiler and helps in building the stream level with needed stream pressure, prevents boiler for changing pressure levels and maintain uniform pressure needed for compression in the industry.

Keywords: Water Management, Energy consumption, Boiler, IR sensors, PIC Microcontroller, Automatic.

I.

INTRODUCTION

Boilers have been at the core of the modern insurgency since the development of the steam motor by James Watt, harking back to the eighteenth century. Basically like a monster tea pot, they are vessels in which water is warmed, blazed to steam, and afterward separated to perform valuable work. In any case, rather than utilizing steam to drive a cylinder, turn a generator, or play out some other sort of mechanical work, a structure's kettle framework utilizes the warmth made by the steam it creates to give heat and a happy with work space for the structure's inhabitants. The boilers themselves need broad support to work appropriately and they need fixes when vital. Note that maintenance and support are not something very similar by any means. Fixes happen suddenly, losing working timetables and bringing about amplified costs down the line. Upkeep, then again, is arranged and proactive, performed at customary spans and for arranged terms to not upset booked activities.

II.

EXISTING METHODS

A. Methods of automatic level detection The manner by which power streams can measure up to a fluid. Fluid moves through a line along these lines that power courses through a conductor.

B. Conductivity probes A test (metal bar) is suspended in the tank, If an electrical voltage is applied and the circuit incorporates an ammeter. With the test inundated in the water, momentum will course through the circuit. In the event that the test is lifted out of the water, momentum won't course through the circuit.

C. Capacitance probes A fundamental capacitor can be built by plunging two equal conductive plates into a dielectric fluid .If the capacitance is estimated as the plates are steadily inundated, it will be seen that the capacitance changes in relation to the profundity by which the plates are submerged into the dielectric fluid.

D. Float control A buoy is mounted in the heater. This might be in an outside chamber, or straightforwardly inside the heater shell. The buoy will go here and there as the water level changes in the evaporator. The following

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e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:03/Issue:03/March-2021

Impact Factor- 5.354

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stage is to screen this development and to utilize it to control either A feedpump (an on/off level control framework) Or A feedwater control valve (a regulating level control framework).

E. Differential pressure cells The differential pressing factor cell is introduced with a consistent head of water on one side. The opposite side is masterminded to have a head which differs with the heater water level.Variable capacitance, strain check or inductive strategies are utilized to quantify the diversion of a stomach, and from this estimation, an electronic level signal is delivered.

III. IR SENSOR-1

IR SENSOR-2

METHODOLOGY

RELAY-1 PIC 16F877A

DOL

MICRO

STARTER

CONTROLLER

PUMP

RELAY-2

Fig 1. Block Diagram The figure 1. explains, The water level indication using the IR sensor. Then its connected to the circuit board .

The circuit board that control the relay via DOL starter. When the water level is drop to the maximum level the DOL starter NC is magnetized .If the water level drop to the minimum level the DOL starter NO is magnetized.

Then the motor is ON. If the water level increase ,when its reach the maximum level the DOL starter NC is demagnetized. The water level maintain in the boiler.

IV.

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MODELING AND ANALYSIS

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e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:03/Issue:03/March-2021

Impact Factor- 5.354

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Fig.2 Circuit Diagram The circuit diagram for the proposed system is given above in the figure 2. The Pic microcontroller has programmed. The pic16f877a input pins are RB0,RB1 and output pins are RB6,RB7 .The IR sensor-1 is used to detect the minimum level of water .When the water level decreased from IR sensor-1,then the photo-diode’s resistance and output voltage change in proportion to the IR light received. Then the output voltage signals to the pic microcontroller RB0 .The pic output pin RB6 its connected to the relay-1. When the output current depends the relay-1 magnetized, then the DOL starter Normally Open is operate. Then the Motor is “ON” .IR sensor-2 is used to detect the maximum level of water . When the water level below the maximum level the IR sensor-2, then the photo-diode’s resistance and output voltage change in proportion to the IR light received.

Then the output voltage signals to the pic microcontroller RB1.The pic output pin RB7 its connected to the relay-2. When the output currents depends the relay-2 magnetized, then the DOL starter Normally Close is operate. If the water level is increase the maximum level the IR sensor-2 is not receive the signal , so the relay-2 is demagnetized. Then the Normally Close is become open, so the Motor will be “OFF”.

V.

RESULTS AND DISCUSSION

In Proposed the human involvement and errors caused are reduced considerably. Thus the efficiency and build the steam is improved. It is low cost and easily available. This system can be used in all types of industries. The controlling water pump using electric water level indication , controlling through some logics which are described above effectively.. All the inherent parts of the circuit performed consistently. The automatic water level of the boiler maintain has been successfully designed and developed.

Table-1: Comparison of Existing System vs Proposed System S. No

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Existing System

Proposed System

1.

The existing system water level detection methods are inbuilt in the boiler or outside gauge glass to human maintain .

The proposed system water level detection methods are outside of the boiler.

2.

Maintain cost high.

Maintain cost low.

3.

Operating not efficiency for long days.

Efficiency for long days.

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e-ISSN: 2582-5208 International Research Journal of Modernization in Engineering Technology and Science Volume:03/Issue:03/March-2021

Impact Factor- 5.354

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Table 2. Comparison of Existing Manual System vs Proposed System 1.

When the boiler water level is below the minimum level, Motor should be ON manually.

When the boiler water level is below the minimum level, Motor should be ON automatically.

2.

When boiler water level reaches the maximum level, Motor should be OFF manually.

When the boiler water level reaches the maximum level, Motor should be OFF automatically.

3.

Manual working, so need human help.

Automatic working, so don’t need human help.

4.

Human error occurred.

Human error reduced.

VI.

CONCLUSION

In this system the boiler water filling method is manual. The water level can be seen in the gauge class . Then the water level monitored manually. Sometime when operated in manual, error occurs, Like the water drop below the constant level and water overflow in the boiler. By which steam pressure level will be varied. By automatic boiler water filling system, The water level is automatically monitored through gauge class .then water drop to the constant level by starting the DOL starter by which Motor is “ON” and when water turns maximum than constant level Motor is “OFF”. In that case the level of pressure in the stream will be maintained. In order to reduce man power and human error, Boiler water level maintained constantly. Its applicable for all type of industries.

VII.

REFERENCES

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