A

Project Report on

GAS LEAKAGE DETECTOR

Submitted in partial fulfillment of the requirement
for the award of the diploma in
ELECTRICAL ENGG.
By
Mohd Irfan
Nirmala
Adarsh Gupta
Sateesh Yadav
Akhil Raghvanshi

Under the supervision of

Mr. A.P. Narayan ( Lecturer )

Department of Electrical Engineering

GOVT. POLYTECHNIC GONDA, U.P.
 GOVT. POLYTECHNIC GONDA
BTEUP
Department of Electrical Engineering

CERTIFICATE
It is certified that Mohd Irfan, Nirmala, Adarsh Gupta, Sateesh Yadav,
Akhil Raghuvanshi have worked under my supervision and guidance for the

project entitled on “Gas Leakage Detector “ for the requirements and

award of the Diploma with specialization in “ Electrical Engineering “ from the
Board of Technical Education Lucknow during academic year 2019 - 20. The
project embodies result of original work, and studies are carried out by the
students themselves and the contents of the project do not form the basis for
the award of any other courses to the candidate or to anybody else from this
or any other institution.

Mr. A.P. Narayan

( Guide )
 ACKNOWLEDGEMENT

I wish to express my profound gratitude and indebtedness to Lect. A.P.

Narayan and Lect. Shashank Srivastava Department of Electrical
Engineering G.P. Gonda.

Introducing the present topic and for their inspiring guidance,

constructive criticism and valuable suggestion throughout the project

work.

Last but not least, my sincere thanks to all our friends who have patiently

extended all sorts of help for accomplishing this undertaking.

Student Name
Mohd Irfan
Nirmala
Adarsh Gupta
Sateesh Yadav
Akhil Raghuvanshi

Dept. of Electrical Engineering

Govt. Polytechnic Gonda
 TABLE OF CONTENTS
GAS LEAKAGE DETECTION
ABSTRACT

1. INTRODUCTION ……………………………….. 03-07

2. FIELD OF APPLICATION OF GAS DETECTION 08-14

3. LEAKAGE DETECTION ………….................... 15-20

4. PRPOPSED SYSTEM …………………………… 21-25

5. KEY COMPONENTS ……………………… 26-37

6. ADVANTAGE & DISADVANTAGES ………… 38

7. CONCLUSION & RESULTS …………… 39-40

REFERENCES
 ABSTRACT

A Gas Leakage Letector is a device that detects the presence

of gases in an area, often as part of a safety system. This type of
equipment is used to detect a gas leak or other emissions and can
interface with a control system so a process can be automatically shut
down. A gas detector can sound an alarm to operators in the area
where the leak is occurring, giving them the opportunity to leave. This
type of device is important because there are many gases that can be
harmful to organic life, such as humans or animals.

Gas detectors can be used to

detect combustible, flammable and toxic gases, and oxygen depletion.
This type of device is used widely in industry and can be found in
locations, such as on oil rigs, to monitor manufacture processes and
emerging technologies such as photovoltaic. They may be used
in firefighting.

Gas leak detection is the process of identifying potentially

hazardous gas leaks by sensors. These sensors usually employ an
audible alarm to alert people when a dangerous gas has been detected.
Exposure to toxic gases can also occur in operations such as painting,
fumigation, fuel filling, construction, excavation of contaminated
soils, landfill operations, entering confined spaces, etc. Common
sensors include combustible gas sensors, photoionization
detectors, infrared point sensors, ultrasonic sensors, electrochemical
gas sensors, and semiconductor sensors. More recently, infrared
imaging sensors have come into use. All of these sensors are used for
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a wide range of applications and can be found in industrial plants,
refineries, pharmaceutical manufacturing, fumigation facilities, paper
pulp mills, aircraft and shipbuilding facilities, hazmat operations,
waste-water treatment facilities, vehicles, indoor air quality testing
and homes

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Chapter 1: INTRODUCTION

1.1 OUTLINE OF THE PROJECT

“Gas leak Detection& monitoring system using arduino” is a project

based on a wireless communication to enhance man and machine safety in a
petrochemical industry. In today’s world petrochemical industry although being
the largest process control industry it is also highly prone to major fire and gas
disasters. A petrochemical industry has excessively high amount of crude oil
stored within a confined area. Therefore presence of any external source which
can cause heat or fire would lead to a major disaster. Even the gas that are
present in petroleum refineries are hazardous.

The Bhopal gas tragedy, which claimed lives of nearly 3,787 people is
one of the major accidents due to gas leakage. And another instance, the
Vishakhapatnam, HPCL refinery tragedy claimed lives of 30 people. Though a
gas and fire detection system was present which is connected to the sensors
using large number of wires that run from the control room to various plant
areas, during the fire the wire itself got damaged, so the information did not
reach the control room.

So in order to avoid any hazard due fire and gas leakage in a

petrochemical industry we have designed an integrated system which will
monitor timely gas leakage in any area around the plant using Arduino which is
a wireless communication device. We have also proposed a new system which
monitors human density within the plant area. Therefore Integrated plant safety
monitor system based on arduino can realize workers attendance registration,
Real-time precise positioning, Dynamic gas concentration monitoring, Real-
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time data transmission & Danger alarm. This project is focused on
implementing the newly designed integrated system in CPCL, Manali, Chennai.

Pipeline systems deteriorate progressively over time. Corrosion

accelerates progressively and long term deterioration increases the probability
of failure (fatigue cracking). Limiting regular inspecting activities to the "scrap"
part of the pipelines only, results ultimately into a pipeline system with
questionable integrity. The confidence level in integrity will drop below
acceptance levels. Inspection of presently uninspected sections of the pipeline
system becomes a must. This project provides information on the "Gas leak
detection".

Pipelines are proven to be the safest way to transport and distribute

Gases and Liquids. Regular inspection is required to maintain that reputation.
The larger part of the pipelines system is accessible by In-Line Inspection Tools
but this access is limited to the section in between the launching and receiving
traps only. Unfortunately, corrosion does not have this limitation. The industry
looks for means of inspecting these in-accessible pressure holding piping
systems, preferably, without interrupting the operations. It is a fact that
sufficiently reliable and accurate inspection results can only be obtained by
direct pipe wall contact/access. If that is not feasible from the outside, we have
to go inside. Since modifying pipeline systems for In-Line Inspection is mainly
not practical,

A gas leak refers to a leak of natural gas or other gaseous product

from a pipeline or other containment into any area where the gas should not be
present. Because a small leak may gradually build up an explosive concentration
of gas, leaks are very dangerous.In addition to causing fire and explosion
hazards, leaks can kill vegetation, including large trees, and may release
powerful greenhouse gases to the atmosphere.Robotics is one of the fastest
growing engineering fields of today. Robots are designed to remove the human
factor from labor intensive or dangerous work and also to act in inaccessible

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environment. The use of robots is more common today than ever before and it is
no longer exclusively used by the heavy production industries. The inspection of
pipes may be relevant for improving security and efficiency in industrial plants.
These specific operations as inspection, maintenance, cleaning etc. are
expensive, thus the application of the robots appears to be one of the most
attractive solutions. Pipelines which are tools for transporting oils, gases and
other fluids such as chemicals, have been employed as major utilities in a
number of countries for long time. Recently, many troubles occur in pipelines,
and most of them are caused by aging, corrosion, cracks, and mechanical
damages from the third parties. So, continuous activities for inspection,
maintenance and repair are strongly demanded.

1.2 LITERATURE REVIEW:

G.A.Arun Kumar, K.Rajasekhar, B.V.V.Satyanarayana,

K.Suryanarayana

Murthy, 2012, “Implementation of Real time Detection of Gas

leakage in Industries using ARM7 &ZigBee”,September, pp 1-4.

In this Paper hardware for gas leakage detection and accurate location
identification system for the production safety in any risky Industries is
proposed. The detection and location are implemented based on Wireless Sensor
Networks (WSN). However, formerly the system was developed using Virtual
Instrumentation. Based on ZIGBEE and ARM7, the system is easy to be
deployed and overcomes the shortcomings on current systems. Using number of
nodes at different places of risky areas, this system can detect the leakage of gas
and immediately sends the details of that location to the observer. It is used to

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improve the rescue quality and shorten the time for rescue. Therefore it can
compensate for the weaknesses of existing systems.

Anusha, Dr. Shaik Meeravali, 2012 “Detection Of Gas Leak And Its
Location Using Wireless Sensors”, November, pp 1-8

The aim is to develop a gas leak detection and location system for the
production safety in Petrochemical Industry. The system is based on
Wireless Sensor Networks (WSN); it can collect the data of monitoring sites
wirelessly and sent to the computer to update values in the location software.
Consequently, it can give a real-time detective of the potential risk area,
collect the data of a leak accident and locate the leakage point. However the
former systems can not react in time, even cannot obtain data from an
accident and locate accurately. The paper has three parts, first, gives the
overall system design, and then provides the approaches on both hardware
and software to achieve it.

1.3 PROBLEM DEFINITION:

Increase in the complexity of process industry leads to increase in the

number of instruments to detect fire and leak. This increases the number of
cables that run from industrial sensors to the control station which leads to
messy wiring. This also increases the size of the duct. Troubleshooting the
reduced insulation or any wire open is difficult because it is a messy wiring
and identifying the individual ca very difficult along the duct. This also
increases the project cost in terms of cable cost.

The fire and gas system is generally required to be independent of the control
system. This is consistent with the fire and gas system normally having a higher
integrity requirement than the control system. Some fire and gas systems have

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been integrated with emergency shut-down systems. This remains a contentious
point.

As already mentioned, no single company can supply all the ‘best in show’
products for all the items described in this paper. There are therefore normally
interfaces between different suppliers. Minimizing interfaces, document sets and
inspections can be achieved by procuring all products from one source at the
cost of reducing choice of initiating devices and possibly increasing the initial
purchase cost.

4-20mA interfaced devices are common, enabling standard or modified

process control interfaces to be used. Field interfaces for smoke detectors, heat
detectors and manual call-points are generally two wires with modifying
components in the control system or marshalling cabinets to allow a 4-20mA
interface to be used. Any failure in the loop causes the system to fail. Presently,
the location of the personals working in the site is uncertain. In case of a
dangerous event, the Control station officers have to personally check the
positions of the workers in the particular sites. This calls for more effort and
time.

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Chapter 2: FIELD OF APPLICATIONS OF GAS DETECION

2.1 Nuclear power plants:-

Nuclear power plants must place safety concerns on the highest level
of priority before other interests such as their business interests. Regular
inspections of pipe systems need to be carried out and robots from INSPECTOR
SYSTEMS are widely used.

2.2 Conventional power plants:-

By taking advantage of the NDT inspection methods that our robots

offer, defects and faults can be avoided increasing the 'up and running' operational
time of all kinds of pipe systems. Worldwide, many power plants already use our
robots to do just this.

2.3 Refineries:-

The mineral oil industry can benefit from improved supply,

transportation, processing and distribution of mineral oil as well as improved
environmental protection. Our robots are helping to do just this.

2.3 Chemical and petrochemical plant:-

It is of course vital to continually reduce the risks brought about by the

manufacture, transport and storage of chemicals. This means that the possible
dangers need to be examined and the necessary testing and inspections carried out
in order to avoid or at least lessen and contain them. The use of our robots has
become obligatory in many well known companies.

2.4 Offshore:-

The technical demands of offshore rigs as well as safety and

environmental requirements are very high and strongly controlled. This means that

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there is an enormous amount of required Non Destructive Testing inspections. Our
robots are used worldwide in offshore applications.

2.5 Long distance city heating pipelines:-

Leakages in long distance heat conduits, caused through external

corrosion, cause energy and water losses resulting in damage to, among others,
subterranean constructions. Minimizing energy loss during the transport of heat
from source to end user is one of the most important requirements in order to
exclude danger to people and the environment. Our robots help in this important
duty.

2.6 Food and drinks industries:-

The hygiene standard in the food and drinks industries is very high.
The condition of the individual pipe networks is therefore decidedly important.
Inspection robots from INSPECTOR SYSTEMS help to maintain and ensure this
high level of hygiene.

2.7 Communal waste water pipe systems:-

Subterranean sewer systems have been responsible for the collection

and transport of waste water since planning and construction began in 1842. With
the Republic of Germany most of these sewage systems are owned by the cities and
community districts. Regular inspection of the roughly 445 km of public sewage
systems is therefore a complex and cost intensive process.

2.8 Gas pipelines:-

Within Germany the total length of the natural gas pipeline network is something
like 335 km. At the moment it is run by 18 national companies and around 730
local ones. Robots from INSPECTOR SYSTEMS are deployed for inspection and
maintenance these flexible robots are well suited for carrying out inspections on
pipe systems, especially those that have a lot of bends, vertical sections and pipe
branches.These robots are mainly used in the nuclear power industry, refineries,
chemical plants, petrochemical plants, the offshore industry, gas pipelines, the

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beverage industry and all types of pipe lines up to 500m long. Three drive elements
provide a speed of up to 200 m/h in both horizontal and vertical directions and bend
allow for effortless taking.

EXISTING SYSTEM

2.1 DEFINITION

The existing system only detects the fire and gas leakage in certain important
areas only. In existing system, the fire and gas leaks are measured and the
communication is through wires to the control station. In case of faults like
discontinuity in cables, damage to cable due to environmental conditions may lead
to loosing of vital information related to plant safety.

Increase in the complexity of process industry leads to increase in the

number of instruments to detect fire and leak. This increases the number of cables
that run from industrial sensors to the control station which leads to messy wiring.
This also increases the size of the duct. Troubleshooting the reduced insulation or
any wire open is difficult because it is a messy wiring and identifying the
individual cable is very difficult along the duct. This also increases the project cost
in terms of cable cost.

2.2 FIELD VISIT

An F&G safety system continuously monitors for abnormal situations such

as a fire, or combustible or toxic gas release within the plant; and provides early
warning and mitigation actions to prevent escalation of the incident and protect the
process or environment. By implementing an integrated fire and gas strategy based
on the latest automation technology, plants can meet their plant safety and critical
infrastructure protection requirements while ensuring operational and business
readiness at project start-up. Throughout the process industries, plant operators are

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faced with risks. For example, a chemical facility normally has potential hazards
ranging from raw material and intermediate toxicity and reactivity, to energy
release from chemical reactions, high temperatures, high pressures, etc.

According to international standards, safety implementation is organized

under a series of protection layers, which include, at the base levels, plant design,
process control systems, work procedures, alarm systems and mechanical
protection systems. The safety shutdown system is a prevention safety layer, which
takes automatic and independent action to prevent a hazardous incident from
occurring, and to protect personnel and plant equipment against potentially serious
harm. Conversely, the fire and gas system is a mitigation safety layer tasked with
taking action to reduce the consequences of a hazardous event after it has occurred.
The F&G system is used for automating emergency actions with a high-integrity
safety and control solution to mitigate further escalation. It is also important for
recovering from abnormal situations quickly to resume full production.

An industrial safety system is a countermeasure crucial in any hazardous

plants such as oil and gas plants and nuclear plants. They are used to protect
human, plant, and environment in case the process goes beyond the control
margins. As the name suggests, these systems are not intended for controlling the
process itself but rather protection. Process control is performed by means of
process control systems (PCS) and is interlocked by the safety systems so that
immediate actions are taken should the process control systems fail.

2.3 ICSS

Process control and safety systems are usually merged under one system,
called Integrated Control and Safety System (ICSS). Industrial safety systems

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typically use dedicated systems that are SIL 2 certified at minimum; whereas
control systems can start with SIL 1. SIL applies to both hardware and software
requirements such as cards, processors redundancy and voting functions. Fire and
gas detection systems are designed to mitigate unexpected events. Designers need
to know what is available in order to choose the correct systems for their plants.

The main objectives of the fire and gas system are to protect personnel,
environment, and plant (including equipment and structures). The FGS shall
achieve these objectives by:

Detecting at an early stage, the presence of flammable gas,

Detecting at an early stage, the liquid spill (LPG and LNG),

Detecting incipient fire and the presence of fire,

Providing automatic and/or facilities for manual activation of the fire

protection system as required,

Initiating environmental changes to keep liquids below their flash point.

Initiating signals, both audible and visible as required, to warn of the

detected hazards,

Initiating automatic shutdown of equipment and ventilation if 2 out of 2 or 2

out of 3 detectors are triggered, and the exhausting system.

2.4 LIMITATIONS OF EXISTING SYSTEM

The fire and gas system is generally required to be independent of the

control system. This is consistent with the fire and gas system normally having a
higher integrity requirement than the control system. Some fire and gas systems
have been integrated with emergency shut-down systems. This remains a
contentious point.

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 As already mentioned, no single company can supply all the ‘best in show’
products for all the items described in this paper. There are therefore normally
interfaces between different suppliers. Minimizing interfaces, document sets and
inspections can be achieved by procuring all products from one source at the cost
of reducing choice of initiating devices and possibly increasing the initial purchase
cost.

4-20mA interfaced devices are common, enabling standard or modified

process control interfaces to be used. Field interfaces for smoke detectors, heat
detectors and manual call-points are generally two wires with modifying
components in the control system or marshalling cabinets to allow a 4-20ma
interface to be used. Any failure in the loop causes the system to fail. Presently, the
location of the personals working in the site is uncertain. In case of a dangerous
event, the Control station officers have to personally check the positions of the
workers in the particular sites. This calls for more effort and time.

2.5 FEASIBLE SOLUTION

To overcome these difficulties we implemented a portable device. This

device can be fixed in their helmet or jacket. To measure various parameters this
device consists of sensors. They are Gas sensor, Temperature sensor, Heart beat
sensor, Pressure sensor.

These sensors in the portables device sense various parameters (gas,

temperature, pressure) continuously. And if the value exceeds the reference value,
immediately it activates the relay driver and produces an alarming sound. So it will
be useful for the person to know about hazardous situation.

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 Heart beat sensor, senses the workers heart beat continuously. If the
person loses his/her consciousness then this information is sensed by the sensor
and it will be passed to the control room.

All the communications are done by wireless zigbee protocols, so that the
informations will be transmitted without any obstructions. The main advantage of
zigbee is that it is a multimode communication, so that the data’s are transmitted
node by node

A GPS is used in our project to track the location of the person during
hazardous conditions, so that he can be rescued immediately.

Finally, all the parameters are monitored using labVIEW software. It

contains a comprehensive set of tools for acquiring, analyzing, displaying,
and storing data, as well as tools to help you troubleshoot code you write.

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Chapter 3: LEAKAGE DETECTON

3,1 Types

Gas detectors can be classified according to the operation mechanism

(semiconductors, oxidation, catalytic, photoionization, infrared, etc.). Gas detectors
come packaged into two main form factors: portable devices and fixed gas
detectors.

Portable detectors are used to monitor the atmosphere around personnel and are
either hand-held or worn on clothing or on a belt/harness. These gas detectors are
usually battery operated. They transmit warnings via audible and visible signals,
such as alarms and flashing lights, when dangerous levels of gas vapors are
detected.

Fixed type gas detectors may be used for detection of one or more gas types. Fixed
type detectors are generally mounted near the process area of a plant or control
room, or an area to be protected, such as a residential bedroom. Generally,
industrial sensors are installed on fixed type mild steel structures and a cable
connects the detectors to a SCADA system for continuous monitoring. A tripping
interlock can be activated for an emergency situation.

3.1.1 Electrochemical

Electrochemical gas detectors work by allowing gases to diffuse through a porous

membrane to an electrode where it is either chemically oxidized or reduced. The
amount of current produced is determined by how much of the gas is oxidized at
the electrode indicating the concentration of the gas. Manufactures can customize
electrochemical gas detectors by changing the porous barrier to allow for the
detection of a certain gas concentration range. Also, since the diffusion barrier is a
physical/mechanical barrier, the detector tended to be more stable and reliable over
the sensor's duration and thus required less maintenance than other early detector
technologies.

However, the sensors are subject to corrosive elements or chemical contamination

and may last only 1–2 years before a replacement is required. Electrochemical gas

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detectors are used in a wide variety of environments such as refineries, gas
turbines, chemical plants, underground gas storage facilities, and more.

3.1.2 Catalytic bead (pellistor)

Catalytic bead sensors are commonly used to measure combustible gases that
present an explosion hazard when concentrations are between the lower explosion
limit (LEL) and upper explosion limit (UEL). Active and reference beads
containing platinum wire coils are situated on opposite arms of a Wheatstone
bridge circuit and electrically heated, up to a few hundred degrees C. The active
bead contains a catalyst that allows combustible compounds to oxidize, thereby
heating the bead even further and changing its electrical resistance. The resulting
voltage difference between the active and passive beads is proportional to the
concentration of all combustible gases and vapors present. The sampled gas enters
the sensor through a sintered metal frit, which provides a barrier to prevent an
explosion when the instrument is carried into an atmosphere containing
combustible gases. Pellistors measure essentially all combustible gases, but they
are more sensitive to smaller molecules that diffuse through the sinter more
quickly. The measureable concentration ranges are typically from a few hundred
ppm to a few volume percent. Such sensors are inexpensive and robust, but require
a minimum of a few percent oxygen in the atmosphere to be tested and they can be
poisoned or inhibited by compounds such as silicones, mineral acids, chlorinated
organic compounds, and sulfur compounds.

3.1.3 Photoionization

Photoionization detectors (PIDs) use a high-photon-energy UV lamp to ionize

chemicals in the sampled gas. If the compound has an ionization energy below that
of the lamp photons, an electron will be ejected, and the resulting current is
proportional to the concentration of the compound. Common lamp photon energies
include 10.0 eV, 10.6 eV and 11.7 eV; the standard 10.6 eV lamp lasts for years,
while the 11.7 eV lamp typically last only a few months and is used only when no
other option is available. A broad range of compounds can be detected at levels
ranging from a few ppb to several thousand ppm. Detectable compound classes in
order of decreasing sensitivity include: aromatics and alkyl iodides; olefins, sulfur

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compounds, amines, ketones, ethers, alkyl bromides and silicate esters; organic
esters, alcohols, aldehydes and alkanes; H2S, NH3, PH3 and organic acids. There
is no response to standard components of air or to mineral acids. Major advantages
of PIDs are their excellent sensitivity and simplicity of use; the main limitation is
that measurements are not compound-specific. Recently PIDs with pre-filter tubes
have been introduced that enhance the specificity for such compounds as benzene
or butadiene. Fixed, hand-held and miniature clothing-clipped PIDs are widely
used for industrial hygiene, hazmat, and environmental monitoring.

3.1.4 Infrared point

Infrared (IR) point sensors use radiation passing through a known volume of gas;
energy from the sensor beam is absorbed at certain wavelengths, depending on the
properties of the specific gas. For example, carbon monoxide absorbs wavelengths
of about 4.2-4.5 µm.The energy in this wavelength is compared to a wavelength
outside of the absorption range; the difference in energy between these two
wavelengths is proportional to the concentration of gas present

This type of sensor is advantageous because it does not have to be placed into the
gas to detect it and can be used for remote sensing. Infrared point sensors can be
used to detect hydrocarbons and other infrared active gases such as water
vapor and carbon dioxide. IR sensors are commonly found in waste-water
treatment facilities, refineries, gas turbines, chemical plants, and other facilities
where flammable gases are present and the possibility of an explosion exists. The
remote sensing capability allows large volumes of space to be monitored.

Engine emissions are another area where IR sensors are being researched. The
sensor would detect high levels of carbon monoxide or other abnormal gases in
vehicle exhaust and even be integrated with vehicle electronic systems to notify
drivers.

3.1.5 Infrared imaging

Infrared image sensors include active and passive systems. For active sensing, IR
imaging sensors typically scan a laser across the field of view of a scene and look
for backscattered light at the absorption line wavelength of a specific target gas.

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Passive IR imaging sensors measure spectral changes at each pixel in an image and
look for specific spectral signatures that indicate the presence of target gases The
types of compounds that can be imaged are the same as those that can be detected
with infrared point detectors, but the images may be helpful in identifying the
source of a gas.

3.1.6 Semiconductor

Semiconductor sensors detect gases by a chemical reaction that takes place when
the gas comes in direct contact with the sensor. Tin dioxide is the most common
material used in semiconductor sensors, and the electrical resistance in the sensor is
decreased when it comes in contact with the monitored gas. The resistance of the
tin dioxide is typically around 50 kΩ in air but can drop to around 3.5 kΩ in the
presence of 1% methane.This change in resistance is used to calculate the gas
concentration. Semiconductor sensors are commonly used to detect hydrogen,
oxygen, alcohol vapor, and harmful gases such as carbon monoxide. One of the
most common uses for semiconductor sensors is in carbon monoxide sensors. They
are also used in breathalyzers.Because the sensor must come in contact with the gas
to detect it, semiconductor sensors work over a smaller distance than infrared point
or ultrasonic detectors.

3.1.7 Ultrasonic

Ultrasonic gas leak detectors are not gas detectors per se. They detect the acoustic
emission created when a pressured gas expands in a low pressure area through a
small orifice (the leak). They use acoustic sensors to detect changes in the
background noise of its environment. Since most high-pressure gas leaks generate
sound in the ultrasonic range of 25 kHz to 10 MHz, the sensors are able to easily
distinguish these frequencies from background acoustic noise which occurs in the
audible range of 20 Hz to 20 kHz The ultrasonic gas leak detector then produces an
alarm when there is an ultrasonic deviation from the normal condition of
background noise. Ultrasonic gas leak detectors cannot measure gas concentration,
but the device is able to determine the leak rate of an escaping gas because the
ultrasonic sound level depends on the gas pressure and size of the leak.

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Ultrasonic gas detectors are mainly used for remote sensing in outdoor
environments where weather conditions can easily dissipate escaping gas before
allowing it to reach leak detectors that require contact with the gas to detect it and
sound an alarm. These detectors are commonly found on offshore and onshore
oil/gas platforms, gas compressor and metering stations, gas turbine power plants,
and other facilities that house a lot of outdoor pipeline.

3.1.8 Holographic

Holographic gas sensors use light reflection to detect changes in a polymer film
matrix containing a hologram. Since holograms reflect light at certain wavelengths,
a change in their composition can generate a colorful reflection indicating the
presence of a gas molecule However, holographic sensors require illumination
sources such as white light or lasers, and an observer or CCD detector.

3.2 Hydrocarbons and VOCs

Detection of hydrocarbons can be based on the mixing properties of gaseous

hydrocarbons – or other volatile organic compounds (VOCs) – and the sensing
material incorporated in the sensor. The selectivity and sensitivity depends on the
molecular structure of the VOC and the concentration; however, it is difficult to
design a selective sensor for a single VOC. Many VOC sensors detect using a fuel-
cell method.

VOCs in the environment or certain atmospheres can be detected based on different

principles and interactions between the organic compounds and the sensor
components. There are electronic devices that can detect ppm concentrations
despite not being particularly selective. Others can predict with reasonable
accuracy the molecular structure of the volatile organic compounds in the
environment or enclosed atmospheres and could be used as accurate monitors of
the chemical fingerprint and further as health monitoring devices.

Solid-phase microextraction (SPME) techniques are used to collect VOCs at low

concentrations for analysis.

Direct injection mass spectrometry techniques are frequently utilized for the rapid
detection and accurate quantification of VOCs. PTR-MS is among the methods that

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have been used most extensively for the on-line analysis of biogenic and
antropogenic VOCs. Recent PTR-MS instruments based on time-of-flight mass
spectrometry have been reported to reach detection limits of 20 pptv after 100 ms
and 750 ppqv after 1 min measurement (signal integration) time. The mass
resolution of these devices is between 7000 and 10,500 m/∆m, thus it is possible to
separate most common isobaric VOCs and quantify them independently.

3.3 Considerations for detection of hydrocarbon gases/risk control

• Methane is lighter than air (possibility of accumulation under roofs)

• Ethane is slightly heavier than air (possibility of pooling at ground levels/pits)
• Propane is heavier than air (possibility of pooling at ground levels/pits)
• Butane is heavier than air (possibility of pooling at ground levels/pits)

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 CHAPTER 4 PROPOSED SYSTEM

Grove - Gas Sensor(MQ2)

The Grove - Gas Sensor(MQ2) module is useful for gas leakage detection (home
and industry). It is suitable for detecting H2, LPG, CH4, CO, Alcohol, Smoke or
Propane. Due to its high sensitivity and fast response time, measurement can be
taken as soon as possible. The sensitivity of the sensor can be adjusted by
potentiometer.

Features

• Wide detecting scope

• Stable and long lifetime

• Fast response and High sensitivity

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We have used a LPG gas sensor module to detect LPG Gas. When LPG gas
leakage occurs, it gives a HIGH pulse on its DO pin and arduino continuously
reads its DO pin. When Arduino gets a HIGH pulse from LPG Gas module it
shows “LPG Gas Leakage Alert” message on 16x2 LCD and activates buzzer
which beeps again and again until the gas detector module doesn't sense the gas
in environment. When LPG gas detector module gives LOW pulse to arduino,
then LCD shows “No LPG Gas Leakage” message.

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Components Used

1. Arduino UNO R3
2. LPG Gas sensor Module
3. Buzzer
4. BC 547 Transistor
5. 16x2 LCD
6. 1K resistor
7. Bread board
8. 9 volt battery
9. Connecting wires

LPG Gas Sensor Module

This module contains a MQ3 sensor which actually detects LPG gas, a
comparator (LM393) for comparing MQ3 output voltage with reference voltage.
It gives a HIGH output when LPG gas is sensed. A potentiometer is also used
for controlling sensitivity of gas sensing. This module is very easy to interface
with microcontrollers and arduino and easily available in market by name “LPG
Gas Sensor Module”. We can also build it by using LM358 or LM393 and MQ3.

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 Circuit Diagram and Description

As shown in the schematic diagram above, it contains Arduino board, LPG GAS Sensor
Module, buzzer and 16x2 LCD module. Arduino controls the whole process of this system like
reading LPG Gas sensor module output, sending message to LCD and activating buzzer. We
can set sensitivity of this sensor module by inbuilt potentiometer placed on it.

LPG gas sensor module's DO pin is directly connected to pin 18 (A4) of Arduino
Arduino and Vcc and
GND are connected to Vcc and GND of arduino. LPG gas sensor module consist a MQ3
sensor which detects LPG gas.. This MQ3 sensor has a heater inside which needs some heater
supply to heat up and it may takes up to 15 minute to get ready for detecting LPG gas. And a
comparator circuit is used for converting Analog output of MQ3 in digital. A 16x2 LCD is
connected with arduino in 4-bit
bit mode. Control pin RS, RW and En are directly connected to
arduino pin 2, GND and 3. And data pin D0-D7
D0 D7 are connected to 4, 5, 6, 7 of arduino. A
buzzer is connected with arduino pin number 13 through a NPN BC547 transistor having a 1 k
resistor at its base.

Program Description

In programming we have used digital read function to read output of LPG gas sensor module
and then performed operation according to input.

For testing this project we have used a cigarette lighter which contains LPG gas.

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Code:

#include <LiquidCrystal.h>
LiquidCrystal lcd(3, 2, 4, 5, 6, 7);
#define lpg_sensor 18
#define buzzer 13
void setup()
{
pinMode(lpg_sensor, INPUT);
pinMode(buzzer, OUTPUT);
lcd.begin(16, 2);
lcd.print("LPG Gas Detector");
lcd.setCursor(0,1);
lcd.print("Circuit Digest");
delay(2000);
}
void loop()
{
if(digitalRead(lpg_sensor))
{
digitalWrite(buzzer, HIGH);
lcd.clear();
lcd.print("LPG Gas Leakage");
lcd.setCursor(0, 1);
lcd.print(" Alert ");
delay(400);
digitalWrite(buzzer, LOW);
delay(500);
}

else
{
digitalWrite(buzzer, LOW);
lcd.clear();
lcd.print(" No LPG Gas ");
lcd.setCursor(0,1);
lcd.print(" Leakage ");
delay(1000);
}
}

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Chapter 5 - KEY COMPONENTS

RESISTOR

1. Introduction:

There is always some resistance in every circuit.

• A circuit is always made up of some wire, so there will be some resistance
there.
• Even the battery has parts that offer resistance to the flow ofelectrons.
• The only circuits that come near to zero resistance aresuperconductors.
• This resistance that is from the parts of the circuit itself (especiallythe
battery) is called internal resistance.
• This internal resistance is usually drawn into a circuitdiagram (schematic)
as shown in Figure 1.
• Notice the squiggly line just before the positive terminal ofthe battery?
That’s to show the internal resistance
of the circuit.
• That symbol, drawn any other place
in the circuit, represents an actual
resistor placed in the circuit.

2. actual Resistors:

The Example 1: What is the resistance of this resistor?

Notice that the colors on this resistor are (in order) Red, Green, Orange, and
Silver.
1. The first line is the first digit → Red = 2
2. The second line is the second digit → Green = 5
3. The third line is the multiplier → Orange = 103

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 4. The last line (if any) is the tolerance → Silver = } 10%
So the final answer would be 25 x 103Ω ± 10%
Yes, I know it's not proper scientific notation this way. You can also write it

as 25000 Ω (notice there are three zeros), or even 2.5 x 102Ω.

3. Variable Resistors

Adjustable resistors
A resistor may have one or more fixed tapping points so that the resistance
can be changed by moving the connecting wires to different terminals. Some
wire wound power resistors have a tapping point that can slide along the
resistance element, allowing a larger or smaller part of the resistance to be
used.
Where continuous adjustment of the resistance value during operation of
equipment is required, the sliding resistance tap can be connected to a knob
accessible to an operator. Such a device is called a rheostat and has two
terminals.
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 Potentiometers

A common element in electronic devices is a three-terminal resistor with a

continuously adjustable tapping point controlled by rotation of a shaft or
knob. These variable resistors are known as potentiometers when all three
terminals are present, since they act as a continuously adjustable voltage
divider. A common example is a volume control for a radio receiver.

4. Methods of Making Resistors:

There are two main methods that are used to make resistors.The most
common is to just have a bunch of wire wound up inside that little cylinder.
Known as wire-wound resistors, they depend on the fact that a certain length
of a certain piece of wire will have a certain resistance. These resistors tend
to be very reliable (with low tolerances), but cost more because of the price
of metals used in them and the machinery needed to carefully cut and wind
the wire.The other type of resistor is made of a piece of CarbonKnown as a
composition resistor, they depend on the size of the piece of carbon, and the
fact that carbon is a
metalloid (has some
metal-like properties)
that does conduct
electricity.Because
they are made from
cheapCarbon, composition resistors can cost much less than similar wire-
wound resistors. The drawback is that the carbon can be cracked while
making them, or become cracked in use. They have higher tolerances
because of the uncertainty in cutting the carbon.
In some cases it is necessary to have a circuit with resistors that you can
adjust.These resistors are known as potentiometers or variable
resistors.Often they are just a modified version of a wire-wound resistor,
although newer versions use advanced electronics instead.You’ve used one if
you’ve ever used a dimmer switch for lights in a room, or played with an

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 electric race car set.Most variable resistors are designed so that by turning a
dial or sliding a switch, you change the amount of conducting material the
current has to go through.The more conducting material the current has to go
through, the higher the resistance… less material and the resistance is less.
TRANSISTOR

5. introduction:

A Bipolar Junction Transistor (BJT) has three

terminals connected to three doped
semiconductor regions. In an NPN transistor, a
thin and lightly doped P-type material is
sandwiched between two thicker N-type
materials; while in a PNP transistor, a thin and
lightly doped N-type material is sandwiched
between two thicker P-type materials. In the
following we will only consider NPN BJTs. In
many schematics of transistor circuits (especially when there exist a large
number of transistors in the circuit), the circle in the symbol of a transistor is
omitted.

All previously considered components (resistor, capacitor, inductor, and

diode) have two terminals (leads) and can therefore be characterized by the
single relationship between the current going through and the voltage across
the two leads. Differently, a transistor is a three-terminal component, which
could be considered as a two-port
network with an input-port and an
output-port, each formed by two of the
three terminals, and characterized by
the relationships of both input and
output currents and voltages.

Depending on which of the three

29 | P a g e
 terminals is used as common terminal, there can be three possible
configurations for the two-port network formed by a transistor: common
emitter (CE), common base (CB), and common collector (CC). Here we only
consider CE and CB, as CC is not widely used.

6. Physical structure

Both electrons and holes participate in the conduction process for bipolar
devices.

BJT consists of two PNP junctions constructed in a special way and

connected in series, back to back.

The transistor is a three-terminal device with emitter, base and collector

terminals.

From the physical structure, BJTs can be divided into two groups: NPN and
PNP transistors.

7. BJT operAtion modes

The BJT operation mode depends on the

voltages at EBJ and BCJ

The I-V characteristics are strongly nonlinear

Simplified models and classifications are

needed to speed up the hand-calculation
analysis

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Bipolar transistors have five distinct regions
regions of operation, defined by BJT
junction biases.

The modes of operation can be described in terms of the applied voltages

(this description applies to NPN transistors; polarities are reversed for PNP
transistors):

Forward-active: base higher than emitter,

emitter, collector higher than base (in this
mode the collector current is proportional to base current by ).

Saturation: base higher than emitter,

emitter, but collector is not higher than base.

Cut-Off: base lower than emitter, but collector is higher than base. It means
the transistor is not letting conventional current to go through collector to
emitter.

Reverse-active: base lower than emitter, collector

collector lower than base: reverse
conventional current goes through transistor.

In terms of junction biasing: ('reverse biased base–collector

base collector junction' means
Vbc < 0 for NPN, opposite for PNP)

Forward-active
active (or simply, active): The base–emitter
emitter junction is forward
forw
biased and the base
base–collector
junction is reverse biased. Most
bipolar transistors are designed to
afford the greatest common-emitter
common
current gain, βF,
F, in forward-active
forward
mode. If this is the case, the collector–emitter
collector emitter current is approximately
proportional
onal to the base current, but many times larger, for small base
current variations.

Reverse-active
active (or inverse-active
inverse or inverted): By reversing the biasing
conditions of the forward-active
forward active region, a bipolar transistor goes into
reverse-active
active mode. In this
this mode, the emitter and collector regions switch
roles. Because most BJTs are designed to maximize current gain in forward-
forward

31 | P a g e
 active mode, the βF in inverted mode is several (2–3 for the ordinary
germanium transistor) times smaller. This transistor mode is seldom used,
usually being considered only for failsafe conditions and some types of
bipolar logic. The reverse bias breakdown voltage to the base may be an
order of magnitude lower in this region.

Saturation: With both junctions forward-biased, a BJT is in saturation mode

and facilitates high current conduction from the emitter to the collector (or
the other direction in the case of NPN, with negatively charged carriers
flowing from emitter to collector). This mode corresponds to a logical "on",
or a closed switch.

Cutoff: In cutoff, biasing conditions opposite of saturation (both junctions

reverse biased) are present. There is very little current, which corresponds to
a logical "off", or an open switch.

Avalanche breakdown region

Although these regions are well defined for sufficiently large applied
voltage, they overlap somewhat for small (less than a few hundred milli-
volts) biases. For example, in the typical grounded-emitter configuration of
an NPN BJT used as a pull-down switch in digital logic, the "off" state never
involves a reverse-biased junction because the base voltage never goes
below ground; nevertheless the forward bias is close enough to zero that
essentially no current flows, so this end of the forward active region can be
regarded as the cutoff region.

LED

8. Introduction:

A light-emitting diode (LED) is a semiconductor

light source. LEDs are used as indicator lamps in
many devices and are increasingly used for other
lighting. Appearing as practical electronic
components early LEDs emitted low-intensity red

32 | P a g e
light, but modern versions are available across the visible, ultraviolet, and
infrared wavelengths, with very high brightness.

When a light-emitting
emitting diode is forward-biased
forward
(switched on), electrons are able to recombine with
electron holes within the device,
d releasing energy in
the form of photons. This effect is called
electroluminescence and the color of the light (corresponding to the energy
of the photon) is determined by the energy gap of the semiconductor. A LED
is often small in area (less than 1 mm2), and integrated optical components
may be used to shape its radiation pattern. LEDs present many advantages
over incandescent light sources including lower energy consumption, longer
lifetime, improved physical robustness, smaller size, and faster switching.
sw
LEDs powerful enough for room lighting are relatively expensive and
require more precise current and heat management than compact fluorescent
lamp sources of comparable output.

Light-emitting
emitting diodes are used in applications as diverse
as aviation lighting,, automotive lighting, advertising,
general lighting, and traffic signals.
signals LEDs have allowed
new text, video displays, and sensors to be developed, while their high
switching rates are also useful in advanced communications technology.
Infrared LEDs
Ds are also used in the remote control units of many commercial
products including televisions, DVD players and other domestic appliances.

TYPE Passive opto-electronic

electronic device

Working principle Electroluminescence

33 | P a g e
9. FEATURES AND BENEFIT:

Efficiency: LEDs emit more light per watt than incandescent light
bulbs. The efficiency of LED lighting fixtures is not affected by shape
and size, unlike fluorescent light bulbs or tubes.

Color: LEDs can emit light of an intended color without using any
color filters as traditional lighting methods need. This is more efficient
and can lower initial costs.

Size: LEDs can be very small (smaller than 2 mm2) and are easily
attached to printed circuit boards.

On/Off time: LEDs light up very quickly. A typical red indicator LED
will achieve full brightness in under a microsecond. LEDs used in
communications devices can have even faster response times.

Cycling: LEDs are ideal for uses subject to frequent on-off cycling,
unlike fluorescent lamps that fail faster when cycled often, or HID
lamps that requires a long time before restarting.

Dimming: LEDs can very easily be dimmed either by pulse-width

modulation or lowering the forward current.

Cool light: In contrast to most light sources, LEDs radiate very little
heat in the form of IR that can cause damage to sensitive objects or
fabrics. Wasted energy is dispersed as heat through the base of the
LED.

Slow failure: LEDs mostly fail by dimming over time, rather than the
abrupt failure of incandescent bulbs.

Lifetime: LEDs can have a relatively long useful life. One report
estimates 35,000 to 50,000 hours of useful life, though time to
complete failure may be longer. Fluorescent tubes typically are rated
at about 10,000 to 15,000 hours, depending partly on the conditions of
use, and incandescent light bulbs at 1,000 to 2,000 hours. Several

34 | P a g e
 DOE demonstrations have shown that reduced maintenance costs from
this extended lifetime, rather than energy savings, is the primary factor
in determining the payback period for an LED product.

Shock resistance: LEDs, being solid-state components, are difficult to

damage with external shock, unlike fluorescent and incandescent
bulbs, which are fragile.

Focus: The solid package of the LED can be designed to focus its
light. Incandescent and fluorescent sources often require an external
reflector to collect light and direct it in a usable manner. For larger
LED packages total internal reflection (TIR) lenses are often used to
the same effect. However, when large quantities of light is needed
many light sources are usually deployed, which are difficult to focus
or collimate towards the same target.

10.APPLICATIONS:

In general, all the LED products can be divided into two major
parts, the public lighting and indoor lighting. LED uses fall into
four major categories:

Visual signals where light goes more or less directly

from the source to the human eye, to convey a message
or meaning.
Illumination where light is reflected from objects to give
visual response of these objects.
Measuring and interacting with processes involving no
human vision.
Narrow band light sensors where LEDs operate in a reverse-bias mode
and respond to incident light, instead of emitting light

35 | P a g e
 11.LED specifications:

The terminal identification of the LED can be done by the

three methods:

1. Check the biasing through multi-meter. In forward

bias the Led will glow that is positive connected to
the positive

BUZZER

12. introduction:
A buzzer or beeper is an audio signaling device, which may
be mechanical, electromechanical, or piezoelectric. Typical
uses of buzzers and beepers include alarm devices, timers and
confirmation of user input such as a mouse click or keystroke.
Mechanical

A joy buzzer is an example of a purely mechanical buzzer.

36 | P a g e
 Electro-mechanical

Early devices were based on an electromechanical

system identical to an electric bell without the metal
gong. Similarly, a relay may be connected to interrupt
its own actuating current, causing the contacts to buzz.
Often these units were anchored to a wall or ceiling to
use it as a sounding board. The word "buzzer" comes
from the rasping noise that electromechanical buzzers made.

Piezoelectric

A piezoelectric element may be driven by an oscillating

electronic circuit or other audio signal source, driven with a
piezoelectric audio amplifier. Sounds commonly used to
indicate that a button has been pressed are a click, a ring or a
beep.

13.BUZZER interfacing:

If the proper potential is provided across the buzzer it generates the sound
else not. It is of two pin configuration that is anode (+) and cathode (-). For
interfacing to any device like controller etc. we directly connect the cathode
to the GND and anode to the device like controller .Now when signal on
anode goes high buzzer activates else does-not. Vice-versa is also true.

37 | P a g e
Chapter 6

Advantages of Gas Detection

6.1 Advantages

• The pipe inspection robot inspects situation inside the pipe which will be
recorded and displayed on the monitor screen, it also facilitates working
personnel for effective observation, detection, quick analysis and diagnosis.
• Save comprehensive investment, improve work efficiency, more accurate
detection.
• Reduce the frequency of entering into the testing environment.
• Operating cost related to other method is low.
• Cost of manufacturing of this robot is relatively low.

6.2 Limitation of pipe inspection robot

• Pipe inspection robots have such limitations as their ability to turn in a T-

shaped pipe or move in a plug valve.
• Another drawback of earlier robots is that the friction between the pipe and
the cables for communication and power supply makes it difficult to move a
long distance. A fiber optic communication system can reduce the friction.
• This robot does not work in water.
• This robot works only in empty pipe.

38 | P a g e
 CHAPTER 7

CONCLUSION & RESULT

7.1 SUMMARY

“Gas leak Deection” is a project based on to enhance man and machine safety in a
petrochemical industry. As petroleum industries are the largest process control
industry it is also highly prone to major fire and gas disasters. A petrochemical
industry has excessively high amount of crude oil stored within a confined area.
Therefore presence of any external source which can cause heat or fire would lead
to a major disaster. Even the gas that are present in petroleum refineries are
hazardous. And another instance, the Vishakhapatnam, HPCL refinery tragedy
claimed lives of 30 people. Though a gas and fire detection system was present
which is connected to the sensors using large number of wires that run from the
control room to various plant areas. But during the fire the wire itself got damaged,
so the information did not reach the control room. Therefore our system is
developed with the aim of overcoming the restrictions and disadvantages of the
existing system. The system we have designed is an integrated system which will
monitor timely gas leakage in any area around the plant using Arduino which is a
wireless communication device. We have also proposed a new system which
monitors human density within the plant area. Therefore Integrated plant safety
monitor system based on Arduino can realize workers attendance registration,
Real-time precise positioning, Dynamic gas concentration monitoring, Real-time
data transmission & Danger alarm. This project is focused on implementing the
newly designed integrated system in CPCL, Manali.

39 | P a g e
7.2 CONCLUSION

“gas monitoring system using Arduino” is developed to enhance man and machine
safety in a petroleum refinery. The main objective of the project was early
detection of gas leakage around the plant area. With the detection of a gas leak the
sensor present in the plant area as well as with the plant area workers alerts the
control room personnel. Therefore with this system even the human density in the
plant area was determined. We have also analyzed various wireless technologies
and various hardware and software approaches that can be implemented. After
implementing this system in CPCL, Manali it was found out to be more efficient
than the previously existing system. And with the introduction of Arduino the
whole project cost was also reduced and human safety level was also increased.

7.3 FUTURE SCOPE

In addition to the developed system, the system can be enhanced by adding a

control element which controls the gas leakage if it exceeds the specified upper
explosive level for the various gases in the plant area. This can be achieved by any
gas leakage indication in any part of the plant alerts the control room and then the
control valve is shut off. Therefore preventing any hazard arising due to gas
leakage.

40 | P a g e
 REFRENCES:

Books

• Theory of Machine -Prof. R. S. Khurmi & Prof. J. K. Gupta.

• Automation production systems, and Computer-Integrated Manufacturing -
Prof. M. P. Groover

Links:

• http://www.ulcrobotics.com/products
• http://www.piacr.tk/Introduction to Pipe Inspection and Cleaning Robot
• http://www.sciencedirect.com/science/article/pii/S0094114X06002254

• Jeffrey Wong,Haruo Noma,Kiyoshi Kogure, Ebrahim A.

Soujeri,Harikrishnan A. I, Rahim Rajan,Sumi M, “Design of a zigbee-based
RFID network for industry applications”, proceedings of the 2nd
international conference on Security of information and networks, 2009, pp.
111-116.

• Fabio Graziosi, Fortunato Santucci,Marco Di Renzo, Stefano Tennina,

“Locating zigbee nodes using the tis cc2431 location engine: a testbed
latform and new solutions for positioning estimation of wsns in dynamic
indoor environments”

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