Design and Development of Cloud Server Enabled Chlorine

Leakage Detection and Control System

Dr Umesha K1 Nandhiniumesh2
1
Department of Electronics and Communication Engineering,Jawaharlal College of Engineering and Technology,affilated to APJ Abul Kalam
Technological University.Mobile No:9526733335,hodeee@jawaharlalcolleges.com,
2
Deaprtment of Computer science ,California Sate University ,Dominguez Hills,Carson,USA,Mobile
+15622286914,Email:nandhiniumesh10@gmail.com.

Abstract

In the paper, the hardware and software design of the chlorine leakage inspection instrument based on the ARM-7-LPC-2148
microcontroller are introduced. The design of the constant voltage circuit, signal conditioning circuit (including filtering and
amplifying circuit), power supply circuit, display circuit, and alarm circuit, and through the Wi-Fi module and the cloud server
platform to realize data storage and remote viewing of the collected data from the chlorine concentration sensor, temperature sensor,
and humidity sensor Finally, through the host computer, LABVIEW software is used to query the historical data stored on the cloud
server. The lab view software provides real-time monitoring of the collected data from the sensor through the user interface. The
equipment can be widely used in petrochemicals, the papermaking industry, textiles, water treatment, and other occasions.
Keywords :Chlorine Sensor, Smart Monitoring, chlorine concentration, Chlorine analyzer, ARM processors, humidity,Wi-Fi Module

1. Introduction

Chlorine is a toxic gas with a pungent odor. Yellow green, is an important chemical raw material. It is widely used in
petroleum and chemical industry, pharmacy. Plastic pigment synthetic fiber industry, textile industry, papermaking
industry disinfection etc. However when chlorine gas leaks or is used improperly, it will cause serious consequences for
the employees and the social environment. According to the national standard, the maximum allowable concentration of
chlorine is lmgm3. Once the chlorine dioxide has been exceeded for a long time, it will cause poisoning. This seriously
affects the health status of the workers. Mild patients will have mucosal irritation symptoms: moderate patients will
develop bronchitis and bronchopneumonia: severe cases will have pulmonic edema, coma and systemic death and
respiratory arrest. So the effective monitoring of chlorine and timely alarm is a very important means to ensure the
safety, it can not only prevent the occurrence of accidents. Also can detect the leakage fault of equipment. Have
significance for toxic post production safety and health care.
The system uses ARM 7- 2148 LPC as the core design, including constant voltage circuit, signal conditioning circuit
(including filtering and amplifying circuit). Power supply circuit, display circuit and alarm circuit, and also needs the
GPRS module and tile cloud server platform to realize data storage and remote viewing.
STM32F1O3ZET6 is the STM32 series microcontroller enhanced high-capacity single-chip microcomputer. Using
ARM 32 bit Cortex-M3 kernel. STM32F 103 microcontroller system clock, frequency of 72MHz. The main system
consists of 4 drive units and 4 passive units. The 4 driving units including the Cortex-M3 kernel D-Code bus (data bus).
S-Code bus (rstem bus) and general DMA1 and DMA2: The 4 passive units include internal SRAM. The internal flash
memory. FSMC. AHB to APB Bridge. This system structure greatly improves the flexibility and efficiency of CPU D-
Code bus and DMA bus access to SRAM. Flash memo and peripheral devices, which is the biggest difference between
STM32 microcontroller and ordinary 16 bit microcontroller.

1.1 Process Overview

The electrolysis of brine process a sodium chloride (NaCl, salt) solution (brine) is electrolytically decomposed to
elemental chlorine and sodium hydroxide solution and elemental hydrogen co-produces caustic soda and chlorine is
typically referred to as a chlor-alkali (C/A).
a. Brine Purification
The initial stage of purification uses sodium carbonate and sodium hydroxide to precipitate calcium and
magnesium ions as calcium carbonate (CaCO3) and magnesium hydroxide (Mg(OH)2). The precipitated impurities
are removed by sedimentation in a clarifier followed by filtration using anthracite filter. The precipitation step
alone is not enough to reduce the levels of calcium and magnesium and additional softening using ion exchange
process is required. The ion exchange chelating resin treatment is designed to decrease the alkaline earth metals.
The resin is periodically regenerated with high purity hydrochloric acid and sodium hydroxide solutions
b. Chlorine Liquefaction
The Chlorine treatment process usually takes hot; wet cell gas and convert it to a cold, dry gas. Chlorine gas
leaving the electrolysers is at approximately at 80 OC. C and saturated with water vapour as shown in fig.1. It also
contains brine mist, impurities such as N2, H2, O2 and CO2. Electrolysers are operated at essentially atmospheric
pressure with only a few milli-atmospheres differential pressure between the anolyte and the catholyte.

Fig..1. Chlorine Electrolysis

1.2. Chlorine analyzer used in plant

A chlorine analyzer consists of housing, an electro chemical sensor (with embedded temperature sensor and data
memory) and microprocessor controlled electronics. The transmitter housing is made of conductive plastic which
prevents electrostatic charge and is not affected by solvents or acids and alkaline solutions.
Electrochemical sensors are compact, require very little power, exhibit excellent linearity and repeatability and
generally have a long life span, typically one to three years. Response times, denoted as T90, i.e. time to reach 90%
of the final
Response, are typically 30-60 seconds and minimum detection limits range from 0.02 to 50ppm depending upon
target gas type. Many designs incorporate a capillary diffusion barrier to limit the amount of gas contacting the
working electrode and thereby maintaining “amperometric” cell operation.

Fig.2 Chlorine Sensor

Minimum concentration of Oxygen is required for correct operation of all electrochemical cells, making them
unsuitable for certain process monitoring applications. Although the electrolyte contains a certain amount of
dissolved Oxygen, enabling short-term detection (minutes) of the target gas in an Oxygen free environment, it is
strongly advised that all calibration gas streams incorporate air as the major component or diluents. A stand-alone
sensor is not sufficient for gas detection. Sensor signals need to be electronically conditioned (some of them
temperature-compensated), locally displayed (for calibration purposes), measuring ranges to be configured – and
for all this power is necessary. It has become worldwide accepted that gas detection transmitters are operated by 24
V DC, and this voltage may vary within wide limits, e.g. between 16 and 30 volts. The transmitter’s electronics
convert the sensor signal into an output current so with clean air (zero point) at the sensor a current of 9 4 mA
flows to the control unit, while it is 20 mA at full scale deflection. If the cable between transmitter and controller is
cut, no current will flow (the current is 0 mA), and the controller will recognize this condition, activating a fault
alarm. Moreover, signals lower than 3.8 mA or higher than 20.5 mA are not interpreted as a measuring signal but
as special signals to indicate under range (negative measuring values) or over range, and also special maintenance
signals. The 4 to 20 mA-signal is a worldwide accepted industry standard which, in opposite to voltage signals,
does not depend on the cable resistance, which has low impedance (resistance) and is relatively immune to
electromagnetic interferences. Transmitters with electrochemical sensors have such a low power consumption that
they can be operated with even less than 4 mA, and can draw, depending on the gas concentration, an additional
current of 4 to 20 mA from the power supply: Only two wires are needed for power supply and measuring signal.
However, transmitters with catalytic bead sensors or infrareds sensors have higher power consumption and require
3 wires for power supply and signal. The 4 to 20 mA signal can also be used to superimpose a symmetrical
frequency modulated signal of 0.5 mA to exchange additional digital information between controller and
transmitter.

2.0. Literature Survey

A.Remote Monitoring Of The System [1], [2], [9].

[1]The development of monitoring system about the security situation in various industries like coal production,
coal mining and chemical industries. In order to solve the problem of coal mine monitoring systems and self-
management of coal enterprises, Adopted the Socket communication mechanism based on TCP protocol, design
[2] the Real-time monitoring and development of a WEB-based remote gas monitoring system.
During the design process, took into account a lot of combustible gas sensor specific problems such as their huge
power consumption, the necessity to work in explosive environment and sensor parameters degradation. To
decrease power consumption we designed specific energy efficient algorithms for measurements. The resulting
average power consumption of the node is low enough for one year autonomous lifetime.
[9] In order to realize remote monitoring and centralized management of combustible gas. A monitoring system of
high performance fuel gas based on RS485 bus communication mode was designed. The system was composed of
center controller and unit controller. The hardware design of unit controller and center controller was introduced,
and the software design scheme of the control and communication between each controller were given analyzed.

B.Optimization control [3], [4],[6].

[3] There are few challenges in the detection of gas leaks using a mobile robot such as, the search space is vast,
needed of a certain level of intelligence so that the searching process of robot become optimal, and the complexity
to deal with unstructured environments. Combination of Particle Swarm Optimization(PSO) and Fuzzy Logic
Control(FLC) can answer these challenges, PSO role as each robot can conduct cooperation in the searching
process of robots, where robots can tell the nearest other robot best position..
[4] As results of the simulation showed that PSO-FLC control can detect gas leak's source better based on the
output of velocity and turning control as well as better travel time search, compared with the control of mobile
robots without any PSO or FLC.
[6] Gas-fired has been widely applied to the residents and the life. All reasons of gas leaks cause personal injury
and property damage. And those cause huge energy waste. The current gas leaks detector in family is single alarm
function, at the same time it is not widely used. To solve these problems, paper designed a gas leaks automatic
detection and processing device by using the Fujitsu MB95204K.The device through the indoor corresponding gas
concentration measurement and the concentration of the gas software installed state threshold ways to judge
whether to make the each level operation

C. Smart Monitoring System [5], [7], [8].

[5] IoT is an expanding network of physical devices that are linked with different types of sensors and with the
help of connectivity to the internet, they are able to exchange data. Through IoT, internet has now extended its
roots to almost every possible thing present around us and is no more limited to our personal computers and mobile
phones. Safety, the elementary
[7] The traditional Gas Leakage Detector Systems though have great precision, fail to acknowledge a few factors in
the field of alerting the people about the leakage. Therefore we have used the IoT technology to make a Gas
Leakage Detector having Smart Alerting techniques involving calling, sending text message and an e-mail to the
concerned authority and an ability to predict hazardous situation so that people could be made aware in advance by
performing data analytics on sensor readings.
[8] The oil and gas industries are investing more time and more money in wireless sensor technologies to help
reducing risks to personnel and plant by using early-warning devices such as gas detectors. This can help to
provide more time to take remedial or protective action. Gas leakage is also concern with residential, commercial
premises and gas powered transportation vehicles. This paper provides a means for detecting the leakage of
harmful gases and monitoring system which is economical to manufacture and which may be readily installed in
service stations, pressure gas storage tank environments, gas yards, utility areas like kitchen, and gas powered
vehicles.
3.0 System Analysis
The hardware and software design of the chlorine leakage inspection instrument based on ARM-7 LPC 2148 is
developed. The design of the constant voltage circuit, signal conditioning circuit (including filtering and
amplifying circuit), power supply circuit, display circuit and alarm circuit and through the GPRS module and the
cloud server platform is used to realize data storage and remote monitoring the data. The host computer which has
LABVIEW software is used to analyze the historical data stored in the cloud server
3.1. Overview of Internet of Things
Cloud servers offer great benefits over the traditional options of shared or dedicated servers. In some respects cloud
servers work in the same way as physical servers but the functions they provide can be very different.
3.2 Traditional Servers Vs. Cloud Servers
3.2.1. Traditional servers
Traditionally, there are two main options for hosting; shared hosting and dedicated hosting as depicted in fig3.
a. Shared Hosting
 The cheaper option, as servers are shared between the hosting provider’s clients (e.g. one client’s website
will be hosted on the same server as those of other clients)
 Suitable for small enterprises, where the required capacity is relatively low
 Setup is inflexible and cannot cope with a large amount of traffic
2. Dedicated Hosting
 A much more advanced form of hosting, whereby clients purchase whole physical servers
 The entire server is dedicated to one client, with no one else sharing it
 In some instances, a client may utilize multiple servers which are all dedicated to their use
 Allows for full control over hosting
 Capacity needs to be predicted, with enough resource and processing power to cope with expected traffic
levels. If this is underestimated it can lead to a lack of necessary resource during busy periods, while
overestimating will mean paying for unnecessary capacity.
3.2.2 Cloud Hosting
 Clients get the best of both worlds: resource can be scaled up or scaled down accordingly, making it more
flexible and, therefore, more cost-effective
 When there is more demand placed on the servers, capacity can be automatically increased to match
demand without needing to be paid for on a permanent basis
 Cloud servers can run on a hypervisor. The role of a hypervisor is to control the capacity of operating
systems so it is allocated where needed
 There are multiple cloud servers which are available to each particular client. This allows computing
resource to be dedicated to a client if and when it is necessary – additional capacity is temporarily
accessed when required, and then removed when no longer needed
 Cloud servers offer more redundancy – if one server fails, others will take its place
Fig..3 Traditional hosting vs Cloud Hosting
4.0 Development of Wireless Chlorine Detector-proposed system

The LPC 2148 microcontrollers are based on a 16-bit/32-bit ARM7TDMI-S CPU with real-time emulation and
embedded trace support, that combine the microcontroller with embedded high-speed flash memory ranging from
32 kB to 512 kB as shown in fig4. A 128-bit wide memory interface and unique accelerator architecture enable 32-
bit code execution at the maximum clock rate. For critical code size applications, the alternative 16-bit Thumb
mode reduces code by more than 30 % with minimal performance penalty. Due to their tiny size and low power
consumption, LPC2141/42/44/46/48 are ideal for applications where miniaturization is a key requirement, such as
access control and point-of-sale. Serial communications interfaces ranging from a USB 2.0 Full-speed device,
multiple UARTs, SPI, SSP to I2C-bus and on-chip SRAM of 8 kB up to 40 kB, make these devices very well
suited for communication gateways and protocol converters, soft modems, voice recognition and low end imaging,
providing both large buffer size and high processing power. Various 32-bit timers, single or dual 10-bit ADC(s),
10-bit DAC, PWM channels and 45 fast GPIO lines with up to nine edge or level sensitive external interrupt pins
make these microcontrollers suitable for industrial control and medical systems.
ARM is a 32-bit instruction set architecture. Today many embedded applications like smart phones, set-top boxes,
digital television, digital camera use ARM processors due to their cost effectiveness and low power consumption.
ARM architecture is compatible with all four major OS i.e. Symbian OS, Palm OS, Windows and Android OS. III.
AR
 Fig.4. Hardware Block Diagram
4.1 ESP 8266 WI-FI MODULE
The ESP8266 is a low-cost Wi-Fi microchip with full TCP/IP stack and microcontroller capability produced by
Shanghai-based Chinese manufacturer, Espressif Systems.The chip first came to the attention of western makers in
August 2014 with the ESP-01 module, made by a third-party manufacturer, Ai-Thinker. This small module allows
microcontrollers to connect to a Wi-Fi network and make simple TCP/IP connections using Hayes-style commands.
However, at the time there was almost no English-language documentation on the chip and the commands it
accepted. The very low price and the fact that there were very few external components on the module which
suggested that it could eventually be very inexpensive in volume, attracted many hackers to explore the module,
chip, and the software on it, as well as to translate the Chinese documentation. The ESP8285 is an ESP8266 with 1
MB of built-in flash, allowing for single-chip devices capable of connecting to Wi-Fi. The ESP8266 Wi-Fi Module
is a self-contained SOC with integrated TCP/IP protocol stack that can give any microcontroller access to your Wi-
Fi network. The ESP8266 is capable of either hosting an application or offloading all Wi-Fi networking functions
from another application processor.
.
4.2 Temperature Sensor LM35
In general, a temperature sensor as shown in fig5.is a device which is designed specifically to measure the hotness
or coldness of an object.LM35 is a precision IC temperature sensor with its output proportional to the temperature
(in °C).With LM35,the temperature can be measured more accurately than with a thermistor. It also possess low
self-heating and does not cause more than 0.1 °C temperature rise in still air. The operating temperature range is
from -55°C to 150°C.The LM35’s low output impedance, linear output, and precise inherent calibration make
interfacing to readout or control circuitry especially easy. It has find its applications on power supplies, battery
management, appliances, etc

.
Fig..5 LM35 Temperature sensor Pinout

4.3 MQ-2 SENSOR

Lower conductivity in clean air is a feature of the MQ-2 semiconductor sensor for flammable gas-sensitive material,
which is depicted in Fig. 6. The conductivity and gas concentration of the sensor are increased when the target
flammable gas is present. The change in conductivity is converted to the output signal of gas concentration using a
straightforward electrocircuit. The MQ-2 gas sensor can detect propane and methane simultaneously because of its
high sensitivity to LPG, hydrogen, propane, and butane. The sensor has the potential to identify many flammable
gases, particularly methane. It is inexpensive and useful for a variety of purposes.
Fig.6 MQ-2 Gas Sensor

4.4 Sensitivity Adjustment

Resistance value of MQ-6 is difference to various kinds and various concentration gases. So, when using these
components, sensitivity adjustment is very necessary. we recommend that you calibrate the detector for1000ppm of
LPG concentration in air and use value of Load resistance ( RL) about 20KΩ(10KΩ to 47KΩ).When accurately
measuring, the proper alarm point for the gas detector should be determined after considering the temperature and
humidity influence.
4.5 HC-05-Bluetooth Module
HC-05 module is an easy to use Bluetooth SPP (Serial Port Protocol) module, designed for transparent wireless
serial connection setup. Serial port Bluetooth module is fully qualified Bluetooth V2.0+EDR (Enhanced Data Rate)
3Mbps Modulation with complete 2.4GHz radio transceiver and baseband. It uses CSR Bluecore 04-External single
chip Bluetooth system with CMOS technology and with AFH (Adaptive Frequency Hopping Feature). It has the
footprint as small as 12.7mmx27mm. Hope it will simplify your overall design/development cycle.
5.0 Result and Discussion
Fig. 7 shows the fabricated gas leak detection device was tested using Labview software at different pressures in
order to evaluate its proper working. Factors like voltage output, leak detection accuracy, and the time in which the
device was able to detect the leak or pressure drop and produce the alarm were also measured. From Fig. 8, it is
visible that using the LabView software, a few other devices were also connected to the system, which include a
pressure gauge, voltage and psi meter, which provide the values in digital format, an alarm that indicates that the 46
pressure drops below 1.9 psi, and a pressure graph.
Y = MX + B ------- (3)
Where Y is the pressure measured and X is the voltage output. Also, by substituting the maximum and minimum
voltage values and pressure values, we can calculate the parameters M and B, which are used in calculating the
pressure for a particular voltage.
0 = M (0.06) + B -------- (4)
7.25 = M (2.82) + B ----- (5)
Were, 0 and 7.25 are the minimum and maximum pressure values measured, and 0.06V and 2.82V are the voltage
outputs from the system. By subtracting eqs. (5) and (4), we get M = 2.62 and B = -0.1572..

Fig.7 Fabricated gas leak detection device

Fig.8 Circuit diagram of proposed system

5. Conclusion
introduced a chlorine gas leak detector system using the ARM 7-LPC 2148 controller, which stored the collected
chlorine parameters in the Thingspeak cloud server, where temperature, humidity, and chlorine concentration in
ppm can be viewed and historical data collected during different emergency situations. To monitor the collected and
stored data on the cloud server in real time, LabView software is used. The Labview software collects the data from
sensors through a wireless medium. Temperature and humidity sensors are used to measure the concentration of
chlorine in the working atmosphere with high accuracy. When the chlorine concentration crosses the predetermined
value that is above 0.5 ppm, the alarm unit starts, and the relay that controls the chlorine outlet valve is suddenly
closed. Once the chlorine concentration attains the steady state value that is below 0.5 ppm, the relay comes back to
the normal open position.
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