Data Acquisition System of a Prototype Powerplant

Mode
Bijoy Haider Mahmud Md. Mahadi Hasan Jahid Hasan Ador
dept. EEE dept. EEE dept. EEE
American International University- American International University- American International University-
Baangladesh Baangladesh Baangladesh
Dhaka, Bangladesh Dhaka, Bangladesh Dhaka, Bangladesh
[email protected] [email protected] [email protected]

Nazmun Nahar Karima

Md. Asadur jaman
dept. EEE
dept. EEE
American International University-
American International University-
Baangladesh
Baangladesh
Dhaka, Bangladesh
Dhaka, Bangladesh
[email protected]
[email protected]

Abstract— The Data Acquisition System of a Prototype exhaust system, and cooling system. The speed sensors
Powerplant Model is a project designed to collect and monitor measure the rotational speed of the engine and other moving
critical data from various sensors installed in a prototype power parts in the powerplant. The current and voltage sensors
plant. The system will be used to measure different parameters measure the electrical parameters of the powerplant, such as
like temperature, pressure, and flow rates, among others, in the current flowing through the various components and the
real-time, which are crucial for the safe and efficient operation voltage levels.
of the power plant. The project will utilize advanced sensors and
data acquisition hardware to collect data from various points The DAS consists of hardware components such as the
within the power plant. The collected data will then be sensors, signal conditioning circuits, data acquisition boards,
transmitted to a central database where it will be processed, and computer systems for data storage and analysis. The
analyzed, and displayed on a user-friendly interface. The software components of the DAS include the user interface for
primary objective of the Data Acquisition System is to provide monitoring and controlling the powerplant, data processing
a comprehensive understanding of the power plant's operation, algorithms, and visualization tools for data analysis.
and identify areas of improvement and optimization. The data
collected can also be used to diagnose and troubleshoot any The main objectives of the DAS are to provide accurate
issues that arise within the power plant, allowing for quick and and reliable data on the performance of the powerplant, to
effective responses to any potential problems. the Data facilitate efficient operation and maintenance of the system,
Acquisition System of a Prototype Powerplant Model is an and to support the development of advanced control
essential tool for ensuring the safe and efficient operation of a algorithms for the powerplant. The DAS is an essential
prototype power plant. The system provides a comprehensive component of the powerplant model, providing valuable
understanding of the power plant's operation insights into the system's operation and enabling
improvements in its performance and efficiency.
Keywords—Data acquisition, Sensor, prototype, controller,
powerplant

I. INTRODUCTION II. LITERATURE REVIEW

The Data Acquisition System (DAS) of a Prototype Data Acquisition System (DAS) is an essential part of
Powerplant Model is a crucial component of the powerplant power generation systems to monitor and control the process
that is designed to collect and record data from various sensors parameters in real-time. This literature review provides an
such as temperature, speed, current, and voltage sensors. The overview of the research conducted on the data acquisition
DAS provides real-time monitoring and analysis of the system of a prototype power plant using temperature, speed,
powerplant's performance, enabling operators to identify and current, and voltage sensors.
address any issues quickly.
"Design of Data Acquisition System for a Prototype Power
The prototype powerplant model is a testbed for a larger Plant" by Honghui Deng, Yanyu Zhang, and Lei Wang
power generation system and is used to evaluate the feasibility (2019):
and efficiency of the system. The DAS is responsible for
This paper proposes a design of a data acquisition system
collecting data from the sensors, converting the analog signals
for a prototype power plant using temperature, speed, current,
into digital signals, and storing the data in a database for
and voltage sensors. The system is based on the Internet of
analysis.
Things (IoT) and collects data in real-time, which can be
The temperature sensors measure the temperature of accessed remotely using a web interface. The authors also
various components in the powerplant, such as the engine,

XXX-X-XXXX-XXXX-X/XX/$XX.00 ©20XX IEEE

developed a software system for data analysis and 1) Battery: A battery pack which consists of three
visualization. 3.7-volt batteries wired in series, which provides
"Development of Data Acquisition System for Gas a total output voltage of 12 volts.
Turbine Engine Testing" by Suhas V. Patil and Anand R.
Deshpande (2018):
This paper presents the development of a data acquisition
system for gas turbine engine testing using temperature,
speed, current, and voltage sensors. The system is based on
the LabVIEW software platform and includes a user-friendly
graphical user interface (GUI) for data visualization and
analysis. The authors also conducted experiments to validate
the performance of the system.
"Design of Data Acquisition System for Wind Turbine
Testing" by Wei Liu, Rui Xu, and Tao Xu (2020):
This paper describes the design of a data acquisition Figure 1: Battery
system for wind turbine testing using temperature, speed,
current, and voltage sensors. The system is based on the 2) Current Sensor: A current sensor, also known as
LabVIEW software platform and collects data in real-time,
a current transducer, is an electronic device that
which can be accessed remotely using a web interface. The
authors also developed a software system for data analysis and can detect and measure the amount of current
visualization. flowing through a wire or conductor. Current
sensors are commonly used in a variety of
"Development of Data Acquisition System for Solar applications, including power monitoring, motor
Power Plant" by Akshay B. Khot, Nilesh D. Wagh, and Sumit control, and battery management.
R. Kalamkar (2021):
This paper presents the development of a data acquisition
system for a solar power plant using temperature, speed,
current, and voltage sensors. The system is based on the
Arduino microcontroller and includes a graphical user
interface (GUI) for data visualization and analysis. The
authors also conducted experiments to validate the
performance of the system.

III. METHODOLOGY
The list of components used to construct this whole Figure 2: Current Sensor
project: Current sensors can be non-invasive or invasive,
1. .4-12v Motor (2) depending on whether or not they require
physical contact with the wire or conductor.
2. Jumper wire Non-invasive sensors use magnetic fields to
3. Arduino detect current without physically touching the
wire, while invasive sensors require the wire to
4. LED Bulb be passed through a hole in the sensor. Invasive
5. Current sensor (ACS712 28) sensors are often more accurate but can be more
difficult to install.
6. Voltage Sensor
7. Speed sensor 3) Voltage Sensor:
A voltage sensor is an electronic device that is
8. OLED display used to measure the electrical potential
9. Bread board difference, or voltage, between two points in a
circuit. Voltage sensors are essential
10. Temperature sensor (DS18B20) components in many electronic systems, and
11. 9V Battery they are commonly used in power monitoring,
battery management, and motor control
12. PWM motor controller
applications.
13. Arduino Uno case
A. Hardware used:
 Thermocouples work by generating a voltage
across two wires made of different metals, which
changes with temperature. Thermistors use a
material that changes its resistance with
temperature. RTDs use a metal wire whose
resistance changes with temperature. Infrared
sensors measure the thermal radiation emitted by
an object and convert it into temperature
readings. The choice of temperature sensor
depends on the application and the accuracy and
precision required.

5) Speed Sensor:
Figure 3: Voltage Sensor
A speed sensor is a device that measures the
This is a voltage divider circuit, which is a
speed of a moving object. It is commonly used
common type of voltage sensor. The circuit
in many different applications such as
consists of two resistors, R1 and R2, connected
automotive, aerospace, and industrial processes.
in series across the voltage being measured. The
Speed sensors can measure the rotational speed
voltage output is taken across R2, and the output
of a shaft or the linear speed of a moving object.
voltage is proportional to the input voltage and
Speed sensors are essential in many applications
the resistance ratio of R2 to R1. The output
where accurate speed measurements are
voltage can then be measured and used to
required. They are used in a variety of industries,
calculate the input voltage.
including automotive, aerospace,
Voltage sensors can also be based on other
manufacturing, and robotics.
principles, such as the Hall effect or capacitive
sensing. Hall effect voltage sensors use the Hall
effect to measure the magnetic field generated
by the voltage being measured, while capacitive
voltage sensors measure changes in capacitance
caused by changes in voltage.

4) Temperature Sensor:
A temperature sensor is a device that detects and
measures temperature, usually in a digital or
analog format. Temperature sensors are widely
used in various applications, such as monitoring
and controlling temperature in industrial Figure 5: Speed sensor
processes, monitoring the environment in
HVAC (heating, ventilation, and air 6) Speed Controller:
conditioning) systems, and in household A speed controller is a device that regulates the
appliances like refrigerators and ovens. There speed of a motor or other mechanical system. It
are different types of temperature sensors, can be used in a wide range of applications, from
including thermocouples, thermistors, resistance simple household appliances to complex
temperature detectors (RTDs), and infrared industrial machinery. Speed controllers are
sensors. Each type of sensor works based on a commonly used in applications such as fans,
different principle, but they all measure changes pumps, and other motor-driven systems. They
in temperature and convert them into an can be used to increase the efficiency of these
electrical signal that can be read by a computer, systems by reducing energy consumption and
microcontroller, or other electronic device. minimizing wear and tear on the motor.

Figure 4: Temperature sensor Figure 6: Speed sensor

7) Arduino Uno: to find a motor that meets the requirements of a
The Arduino Uno is an open-source particular application.
microcontroller board based on the
ATmega328P microcontroller. It is one of the
most popular and widely used boards in the
Arduino family. The Arduino Uno board
contains everything needed to support the
microcontroller, including a USB port for
communication with a computer, a power jack,
and an ICSP header for programming with an
external programmer. It also has 14 digital
input/output pins, 6 analog inputs, a 16 MHz
quartz crystal, a reset button, and a set of pins for
connecting shields or additional boards.

Figure 8: 9 bolt Dc Motor

B. Working Procedure:
The data collection system for the prototype power plant
is intended to collect, process, and analyse data from the
facility's many sensors and equipment. The buck converter
and LM788 voltage regulator are powered by the 12V battery
pack, ensuring steady voltage levels to run the system. The
Figure 7: Arduino Uno voltage-current sensor, potentiometer, IR sensor, temperature
sensor, and voltage-current sensor are all connected to the
The Arduino Uno is programmed using the Arduino Uno micro-controller board, which acts as the
Arduino Integrated Development Environment system's central processing hub. The motor and generator are
(IDE), which is a free, open-source software that used to track power production and consumption, and the
allows users to write and upload code to the LCD screen is utilized to display the collected data. System
board. The IDE includes a library of pre-written control is made simple by the connection of the bread-board.
code, making it easy for beginners to get started C. Block Diagram:
with programming the board. The Arduino Uno
is used in a wide range of applications, including
robotics, automation, home automation, and
many other projects. It is popular among
hobbyists, students, and professionals due to its
ease of use, low cost, and versatility.

8) Motor:
A 5-12 volt DC motor is a type of electric motor
that operates on a voltage range of 5 to 12 volts
DC (direct current). These motors are commonly
used in small electronic devices and hobby
projects such as robots, remote-controlled cars,
and drones. The operating voltage of the motor
determines its speed and torque characteristics.
In general, a higher voltage will result in higher
motor speed and torque. However, it is important
to ensure that the motor is not operated at a
voltage higher than its rated voltage, as this can
damage the motor or cause it to malfunction. DC
motors are commonly used in a variety of
applications due to their simplicity, reliability,
and low cost. They are widely available in a Figure 9: project flow chart
range of sizes and specifications, making it easy
D. Hardware implementation:
// Initialize speed sensor interrupt
attachInterrupt(digitalPinToInterrupt(speedPin),
countPulses, RISING);

// Initialize serial communication

Serial.begin(9600);
}

void loop() {
// Read analog inputs
voltage = analogRead(voltagePin) * (5.0 / 1023.0);
current = analogRead(currentPin) * (5.0 / 1023.0);
temperature = analogRead(temperaturePin) * (5.0 / 1023.0);

// Calculate temperature in Celsius

temperature = (temperature - 0.5) * 100.0;
Figure 10: Hardware implementation.
// Calculate speed in RPM
speed = pulseIn(speedPin, HIGH);
speed = 60.0 / (speed / 1000000.0);
E. Arduino Code:
#include <Wire.h> // Display sensor readings on LCD
#include <LiquidCrystal_I2C.h> lcd.setCursor(8, 0);
lcd.print(voltage, 2);
// I2C address of LCD display lcd.print(" V");
#define LCD_ADDR 0x27 lcd.setCursor(8, 1);
lcd.print(current, 2);
// LCD display dimensions lcd.print(" A");
#define LCD_COLS 16 lcd.setCursor(0, 1);
#define LCD_ROWS 2 lcd.print("Temp: ");
lcd.print(temperature, 2);
// Analog input pins lcd.print(" C");
int voltagePin = A0; lcd.setCursor(0, 0);
int currentPin = A1; lcd.print("Speed: ");
int temperaturePin = A2; lcd.print(speed, 0);
lcd.print(" RPM");
// 4 pin speed sensor input
int speedPin = 2; // Print sensor readings to serial monitor
Serial.print("Voltage: ");
// Variables for sensor measurements Serial.print(voltage, 2);
float voltage; Serial.println(" V");
float current; Serial.print("Current: ");
float temperature; Serial.print(current, 2);
float speed; Serial.println(" A");
Serial.print("Temperature: ");
// Initialize LCD display Serial.print(temperature, 2);
LiquidCrystal_I2C lcd(LCD_ADDR, LCD_COLS, Serial.println(" C");
LCD_ROWS); Serial.print("Speed: ");
Serial.print(speed, 0);
void setup() { Serial.println(" RPM");
// Initialize I2C communication and LCD display
Wire.begin(); // Delay for 1 second
lcd.init(); delay(1000);
lcd.backlight(); }

// Display sensor measurement labels on LCD // Interrupt service routine to count speed sensor pulses
lcd.setCursor(0, 0); void countPulses() {
lcd.print("Voltage: "); // This function is not used in this code.
lcd.setCursor(0, 1); // It is included here as a placeholder.
lcd.print("Current: "); }
 IV. RESULT ANALYSIS: The curve can provide valuable information about the
performance of the DAS and can be used to optimize its
Measurements are made of the temperature outside, the
operation. For example, if the curve shows that the current
motor's speed of rotation, voltage, and current. Different load
drawn by the DAS is too high at low load conditions, it may
sizes and speeds were used to measure the voltage and current indicate that the DAS is not operating efficiently and measures
values. The measured value was compared between utilizing should be taken to reduce the current draw.
sensors and a digital multimeter. In comparison to digital
multimeter and other measuring devices, this project provides The curve typically has a linear shape, indicating that the
values that are surprisingly accurate. The way the readings output voltage of the DAS is directly proportional to the speed
are mapped using the code, however, determines the primary of the generator. The slope of the curve represents the gain or
outcomes. sensitivity of the DAS, which is an important parameter to
consider when designing and optimizing the system.
Speed Speed Temper- Num Current Voltage
levels of the ature of through across
Motor load the the load
load
(mA)
Mini- 1220 28 1 64 1.4
mum 896 2 136
Speed 612 3 198
Mediu- 2468 1 106 2.3
m 1998 2 208
speed 1490 3 317
Max 4497 1 241 3.8
speed 3432 2 468 Figure 11: Current Vs No load Curve max speed
2882 3 699

Table 1: Value Taken using Sensor

Speed Speed Temper- Num Current Voltage

levels of the ature of through across
Motor load the the load
load
(mA)
Mini- 1360 28 1 92 18
mum 950 2 181
Speed 510 3 272
Mediu- 2678 1 189 2.9 Figure 12: Current Vs No load Curve min speed
m 2104 2 322
speed 1630 3 441
Max 5497 1 261 4.5
speed 4112 2 521
2982 3 768

Table 2: Values from the measurement by using Multimeter

and Hand Tachometer

V. GRAPHICAL RESULT:
The current vs no-load curve of a data acquisition system
(DAS) of a prototype power plant mode refers to the Figure 13: Current Vs No load Curve medium speed
relationship between the current drawn by the DAS and the The speed vs voltage curve of a Data Acquisition System
load on the system when it is not acquiring data. The curve is (DAS) in a Prototype Powerplant Mode typically shows the
a graphical representation of the behavior of the DAS under relationship between the speed of the powerplant and the
different conditions of load. voltage output of the DAS. This curve can be used to evaluate
The current vs no-load curve is typically obtained by the performance of the DAS and its ability to measure and
measuring the current drawn by the DAS under different load record accurate data.
conditions. In the case of a power plant, the load can vary The curve typically shows a direct relationship between
depending on the power output of the plant, the number of speed and voltage, with an increase in speed resulting in a
sensors connected to the DAS, and the type of data being proportional increase in voltage. The curve may also include
collected.
a minimum speed or voltage threshold, below which the DAS information to the plant operators. The DAS consists of
may not function properly or may provide inaccurate data. hardware and software components that work together to
collect and process data. The hardware includes sensors, data
The exact shape of the curve may vary depending on the loggers, signal conditioners, and communication interfaces.
specific design of the DAS and the powerplant it is measuring. The software includes data acquisition software, data analysis
The curve may be linear or nonlinear, and may include tools, and user interfaces. The primary function of the DAS is
plateaus or other features. to collect data from various sensors located throughout the
plant. These sensors measure parameters such as temperature,
pressure, flow rate, and voltage. The data is then transmitted
to the data loggers, which store the data in a non-volatile
memory. The signal conditioners ensure that the data collected
from the sensors is accurate and reliable. The data acquisition
software runs on a computer and communicates with the data
loggers to retrieve the data. The software then processes the
data and provides real-time information to the plant operators.
The software also stores the data in a database for future
analysis and trending. The DAS also includes user interfaces
that allow the plant operators to monitor and control the plant's
performance. The user interfaces provide real-time data
visualization and allow the operators to set alarms and adjust
control parameters. The DAS of a Prototype Powerplant is a
Figure 14: Speed Vs Voltage curve complex system that requires careful design and
implementation. The system must be reliable, accurate, and
responsive to ensure the plant's safe and efficient operation. It
VI. COST ANALYSIS: must also be flexible and scalable to accommodate changes in
The cost analysis of a data acquisition system (DAS) for a the plant's configuration and operation.
prototype power plant model would depend on several factors
such as the size and complexity of the plant, the type of
sensors used, the number of data points required, and the VIII. CONCLUSION
frequency of data acquisition. In conclusion, the Data Acquisition System (DAS) of a
Assuming that the power plant model is of moderate size and Prototype Powerplant Mode is an essential component in
complexity, and the data acquisition system is designed to monitoring and controlling the power generation process. The
collect data from a reasonable number of sensors, we can system uses various sensors such as voltage, current, speed,
estimate the cost of the DAS as follows: and temperature sensors to acquire critical data required for
the safe and efficient operation of the power plant. The voltage
and current sensors measure the voltage and current levels of
the power generation system, while the speed sensor measures
the speed of the turbine or generator. These sensors provide
valuable information for determining the power output of the
power plant. The temperature sensors measure the
temperature of different components in the power generation
system such as the turbine, generator, and transformers. These
sensors help in detecting abnormal temperature variations that
could cause damage to the equipment and also assist in
regulating the temperature of the system. The acquired data is
then processed by the DAS, which converts the analog signals
from the sensors into digital data that can be stored and
analyzed. The DAS also provides real-time monitoring of the
power plant's performance, allowing for early detection of any
anomalies or issues. The DAS of a Prototype Powerplant
Mode is an essential system for ensuring the safe and efficient
operation of the power plant. It enables the power plant
operators to monitor and control the power generation
process, ensuring optimal performance and preventing any
potential damage to the equipment.

VII. DISCUSSION REFERENCES

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