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Design and development of microcontroller-based temperature

monitoring and control system for power plant generators
To cite this article: Sukumar Ponnusamy et al 2021 IOP Conf. Ser.: Mater. Sci. Eng. 1055 012158

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IVC RAISE 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1055 (2021) 012158 doi:10.1088/1757-899X/1055/1/012158

Design and development of microcontroller-based

temperature monitoring and control system for power plant
generators

Sukumar Ponnusamy1*, Ravi Samikannu2, B A Tlhabologo3, W Ullah4 and

Srinivasan Murugesan5
1
Department of Electronics and Communication Engineering, Nandha Engineering
College, Erode, India.
2,3
Department of Electrical, Computer and Telecommunications Engineering,
Botswana International University of Science and Technology, Palapye, Botswana
4
School of Electrical and Information Engineering, University of the Witwatersrand,
South Africa.
5
Department of Electrical and Electronics Engineering, Kongu Engineering College,
Erode, India.

*Email:[email protected]

Abstract. The protection of turbine generator systems is an important factor that must be
considered in power plant for efficient production of electricity. This project deals with
temperature level monitoring of the power generator and it will be compared with the
predetermined standard value through an LM35 sensor. Once it exceeds the predetermined
value then the cooling fan will automatically turn on which will be useful to prevent the
generator from internal winding thermal failure. The protection system consists of 16x2 LCD
display, LM35 temperature sensor, a coolant fan and a microcontroller [ATMEGA328P]. The
internal winding temperature of generator is increased as the turbine is rotated at its axis which
may lead to major damages in the axial position and shafts of the power generator. To
overcome this, an LM35 sensor is connected and linked with the microcontroller which
monitors the temperature and once it exceeds the standard temperature the coolant fan
automatically is turned on by the microcontroller and the heat of the steam will be countered by
the cooling air produced by the coolant fan. The fan runs continuously until the temperature is
sensed to have dropped below the standard temperature. At the same instances, the LCD
display outputs readable current temperature parameters for the operator. The protection of
power generator system is a vital component in power plant for efficient production of
electricity.

Keywords: Power generator, Temperature monitoring, Microcontroller, Sensor.

1. Introduction
Nowadays electrical energy plays vital role in many different industries like textile, chemical, steel,
mining, petroleum, manufacturing industries. The protection of power generator systems is an
important factor that must be considered in power plant for efficient production of electricity. The
Mettur Thermal Power Station consists of four units with a generation of 840MW. Each generator has

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IVC RAISE 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1055 (2021) 012158 doi:10.1088/1757-899X/1055/1/012158

a capacity of 210MW, 15.75kV, 3 phase output. The main aim is to improve cooling system of the
generators used in thermal power plants which in turn results in improving the efficiency of the
generator. When the efficiency is increased people will be benefitted due to increase in power
production and the protection of generators improved. The winding temperature of the coil increases
due the continuous generation of the power from the generator. Non conductivity water is used to
reduce the generator winding temperature. This water system is known as Stator Water System (SWS).
The SWS includes measurements of winding temperature that is conducted to cooling water and the
current through the coil since temperature directly proportional to current. The existing system makes
use of individual hard wires with relay logic, electrical contacts and individual monitoring system
process complicates the present system.
In this paper, the intent is to design and develop a temperature monitoring and control system using
microcontroller and Arduino pack. This is such that the controller will switch the cooling fan either
‘on’ when temperature exceeds the threshold value or ‘off’ when the temperature is lower than the
threshold. This is to keep the temperature of the generator shaft and rotor low and avoid overheating.
Furthermore, the system gives a user interface through an LCD display where the plant operator can
visualize the temperature and status of the coolant fan.

2. Literature Review
Support Vector Machines (SVMs) were mainly used to represent binary classification[1]. In several
proposed method, the construction of multiclass classifier is made up of the combination of various
binary classifiers. The performance can be compared with three methods based on binary
classification: “one-against-all”, “one-against-one” and DAG SVM. In this experiment “one-against-
one” and DAG are more appropriate when compared to other methods. In larger problems, support
vectors are enough for considering all data at once. New Results on Error Correcting Output Codes
(ECOC) of Kernel Machine has interpreted the multiclass classification problem by using margin-
based binary classifier in the structure of error correcting output codes[2]. This context addresses the
decoding and model selection which are the two most important open problems. In this paper, new
decoding function combines the margin over the class conditional probabilities. In model selection,
tuning of hyper parameter can be performed by bounding the Leave One Out (LOO) occurred in the
ECOCs kernel machines.
Integration of Low-cost consumer electronics for In-situ condition monitoring of wind turbine
blades has interpreted the wind turbine blades as resistant to fatigue and robust to loading but it not too
heavy [3].The most important materials used in the construction are glass, reinforced plastic, wood
and steel. Hence it is difficult to predict the lifespan of the turbine blades, so it is monitored
continuously. The Condition Monitoring (CM)system of turbine blades is not extensively used. In this
paper, the changes occurred in the dynamic properties of the turbine blades are detected by the in-situ
vibration of CM system. Wireless Sensor Networks (WSN) in Smart Grid holds the advantages when
compared to the traditional communication in current electric power system [4]. Presently, WSN
enhances the generation, delivery and utilization of the current electric power system for the future
generation electric power system. This is to say smart grid. This paper describes WSN applications
along with the opportunities, challenges and future work in the application of smart grid. By using
field test on compliant with IEEE 802.15.4 WSN, noise in background, characteristics of channel and
2.4-GHz frequency band attenuation can be measured. Transformer Fault Diagnosis Using Self-
Powered RFID Sensor and Deep Learning Approach has interpreted that the fault diagnosis is
performed based on deep learning and Radio Frequency Identification Sensor (RFID) whereas in
transformers[5],the RFID sensor tag functions (signal collection, data storage and wireless
transmission) act as a power source for electromagnetic field. In deep learning technique, Stacked De
noising Auto encoder (SDA) is essential for learning strong features in the measured signals. The
power supply can produce DC voltage of 2.5V and for efficient power buck-boost converter
topologies are used for both increasing and decreasing the voltage to regulate it[6].

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IVC RAISE 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1055 (2021) 012158 doi:10.1088/1757-899X/1055/1/012158

Shichen Zou et al., has interpreted the substantial increase in cyberattacks by the usage of vast
internet connections. Abnormal behaviour detection system plays a vital role in computer network
security[7][8][9]. Moreover, the rapid increase in the intrusions diversity, the existing method of
intrusion system uses machine learning approach(learning of classifier based on handcrafted feature
vector) is used to detect high false alarm rate in these attacks. The abnormal behaviour occurred in the
large-scale traffic data network uses the combination of both deep feature extraction and ensembled
multilayer SVMs in a distributed network. Literature survey supports available guide to a specific
topic. Fuzzy logic control is also one of the methods that have proved to be efficient in temperature
response control when compared to PI control in simulation for a plastic extrusion plant[8]. To further
reduce the signal distortion in monitoring and control, intelligent controllers such as microcontrollers
can be implemented[9]. The literature review for the stator water cooling system of power generators
gives an overview for the topic and provide a solid background for the paper. It helps to define the
problem on cooling system for power generator in stator winding and used to solve the previous
problem on the cooling system by introducing new technology. The problem occurs in the operation
of the cooling system of power generators by implementing LM35 sensor. Recently the technology
has been developing in the area of operation and maintenance of power generator with good potential
for further developments.

3. Methodology
In proposed work, using Arduino, the step response is given to the solenoid value which can circulate
and control the temperature by automating the coolant fan to turn on so that the stator can maintain the
winding temperature at constant level. The stator cooling water plants disperses and supervises the
cooling water (neutral water contains very less oxygen content and electrical conductivity). The
proposed work methodology is achieved by interfacing various components being temperature sensor,
coolant fan and LCD display to the Arduino board. Figure1 shows the block diagram of the proposed
system. The power generation of LMW turbine generator is normally high. Due to continuous
generation of the power from generator, the winding temperature of the generator coil will be
increased. As a result, the coolant fan must be used to reduce the generator winding temperature. The
winding temperature of the generator is reduced by using the coolant fan if it exceeds the
predetermined temperature.

Figure.1Block diagram of proposed system

3.1 Arduino
Arduino is an openly accessible paradigm consisting of both hardware and software. The Arduino
Software works based on AVR RISC architecture commonly applied for Arduino boards[10]. It gives

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IVC RAISE 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1055 (2021) 012158 doi:10.1088/1757-899X/1055/1/012158

a platform for the microcontroller (ATMEGA328P) to be loaded and reprogrammed according to user
composed code in an intrinsic environment for a rapid microcontroller base project development [11].
In this case, the use is to receive analogue input from LM35 and give digital output to motor driver
and LCD display. Arduino UNO board synchronize the temperature of the power generator winding as
an input to the Arduino. The input is measured by using the temperature sensors in the analogue form
and this gets converted into digital form using Analogue to Digital Convertor (ADC) which is inbuilt
in the microcontroller. The predetermined value of the temperature is programmed into the Arduino.
The actual input that is the temperature is compared with the predetermined value which is
programmed in Arduino. If there any variations occurring in the compared value, then it sends the
signal to the driver circuit to automate the coolant fan to control the temperature of the generator.

3.2 Temperature sensor

An authentic IC temperature sensor (LM35) whose analogue output corresponds to temperature (in
°C) with a linear scale factor[12] of 10mV is used for temperature monitoring. The sensor is such that
it does not need external recalibration. Its circuitry is sealed hence it does not undergo oxidation and
self-heating. By using LM35 sensor, the temperature can be evaluated precisely than that of a
thermistor. Temperature sensor is used to figure out the heat evolved in winding of the generator in
analogue pattern and the data is delivered to the Arduino in digital pattern through an input pin of the
chip configured with ADC.

3.3 Coolant fan

The coolant fan is fixed to the Arduino which is connected to the LM35 sensor. Once the temperature
of the winding generator exceeds the predetermined value, the coolant fan will be automatically turned
on and the temperature will be compensated by the cooling air produced by the coolant fan and it will
help to maintain the temperature of the generator.

3.4 Liquid Crystal Display (LCD)

LCD screen is a digital display component that can be interfaced with Arduino. An in-built Liquid
Crystal library in Arduino gives control over LCD such that itcan be interface with the coded program
for display purposes. A 16x2 LCD module has capability to be configured to either 4-bit modeor 8-bit
mode. In the project it is configured such that only the 4 input pins to the modules will be used, that is
4-bit mode. The model is chosen because it uses less connections and can be used more effectively
compared to 7-segments displays. All these operations are monitored in LCD display which is
interfaced with Arduino. It displays the predetermined value of the temperature. In abnormal
condition, the variations in the temperature will also be displayed in the LCD display. According to
the variations the coolant system is activated, and the status of the coolant system is also displayed.

3.5 Motor driver

A conventional Motor driver (L293D) which is bidirectional can provide current up to 600mA given a
voltage range of 4.5V to 36V. It admits DC motor to drive in either direction. L293D16-pin IC is
designed with capability to drive and regulate a set of two DC motors together in either direction as it
chores on the H-bridge circuit approach[13][14].Since a single L293D chip consists of two H-Bridge
circuits inner to the IC, it can drive two dc motors individually[15]. However, each bridge pair ought
to be enabled through the enable pin which keeps it active. H-bridge circuit allows voltage to flow in
either of the two directions. The change in direction of the motor is either clockwise or anticlockwise
and it is with respect to voltage direction change. H-bridge IC is therefore hypothetical for driving a
DC motor. Because of its size and bidirectional drive properties, it is notably used in robotic
application and servo motor drives to control the DC motors.

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IVC RAISE 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1055 (2021) 012158 doi:10.1088/1757-899X/1055/1/012158

4. Result and Discussion

Arduino’s microcontroller is loaded with a coded one by Arduino IDE software. The codetakes charge
of the whole system operation, being, to monitor, control and regulate all parameters. Furthermore, the
microcontroller is separately provided with a set standard temperature value. The 50Hz, 230Vacinput
is supplied to a step-down transformer and rectified 5Vdc supply is fed to the Arduino through
rectifiers and capacitor filters. This is to power up the Arduino pack, LCD, motor and enables the
motor driver chip. A parameter from model stator winding is provided as a stimulus to the sensor.
Temperature sensed from LM35 is given to the Arduino as analogue input. During simulation in
proteus, when there is any variation in the actual value and the standard value then it sends the signal
to the driver circuit, either to start cooling or to stop the cooling fan. When temperature exceeds the set
threshold value (290C), Arduino chip gives input pin of the H-bridge a digital signal to drive the
motor, hence the coolant fan runs accordingly at 1500rpm to reduce the temperature to normal
standard temperature. All these operations are also monitored inLCD display which is interfaced with
Arduino in 4-bit mode through data pinsDB4, DB5, DB6 and DB7.Simulation diagram of the
proposed system is shown in Figure2. Figure3 shows the coolant fan at off condition and Figure4
shows the coolant fan at on condition where the temperature is above the cut in point.

Figure 2. Simulation diagram of the proposed system

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IVC RAISE 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1055 (2021) 012158 doi:10.1088/1757-899X/1055/1/012158

Figure 3. Coolant Fan at Off Condition

Figure 4. Coolant Fan at On Condition

As visualised in Figure4, when pin 2 is logic HIGH at 5V, the LCD screen goes on. The display
contrast is controlled by a 10K potentiometer connecter to pin 3 (VEE). Varying the potentiometer
controls the current to the background lighting diodes of the screen. Pin 4 is always logic HIGH
provided by Arduino output pin 12. This function selects DATA register. When logic LOW, it will go
to the COMMAND register. The DATA register allows display of interpreted data through data pins.
Furthermore, pin 5 is in logic LOW (connected to ground) to keep the LCD in WRITE mode. Pin 6 of
the LCD display is the ENABLE pin, which keeps the module enabled to receive and display. It is at
logic HIGH when the system is running. This state is maintained by digital output pin 12 of the
microcontroller.
Temperature is measured and monitored continuously using the LCD display as shown in Figure5.
When the temperature of the winding is less than or equal to 29°C then the system is in
normalcondition. In Figure6, the temperature is 29°C which is in normal condition. Throughout the
normal temperature, the state of the coolant fan is in OFF condition as shown in Figure6.

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IVC RAISE 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1055 (2021) 012158 doi:10.1088/1757-899X/1055/1/012158

Figure 5. Temperature at normal condition

Figure 6. Condition of temperature and state of coolant fan

At abnormal condition, the winding temperature increases above 29°C and the value ofabnormal
temperature will be visualised in LCD display as shown in Figure7 together with the state of the
coolant fan. At abnormally high condition the temperature is high, and the value is displayed in the
LCD display as shown in Figure8through the data pins. At the same time, Arduino operates the driver
circuit through digital output pin 7 of microcontroller chip being logic HIGH hence input 1pin 6 of the
motor driver is also logic HIGH and the coolant fan gets activated and runsaccordingly until the
temperature returns to normal. The photograph of the proposed project hardware module is also shown
in Figure8.Furthermore, LCD display is used to demonstrate the current (based on calculation ratios in
the code) and temperature of the winding.

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IVC RAISE 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1055 (2021) 012158 doi:10.1088/1757-899X/1055/1/012158

Figure 7. Temperature at abnormal condition

Figure 8. State of Temperature and coolant fan

5. Conclusion
The stator cooling system will increase the efficiency of power generator by reducing the heat
developed in the winding of the power generator by using cooling air from the coolant fan. This is
achieved by automating the coolant system to turn on when the temperature is higher than normal
value. The control is done by a coded microcontroller. In this system the stator winding temperature of
power generator was fully monitored in the LCD display. Flow of cooling air into the stator will lead
to effective control and maintenance of the temperature in the stator winding with more sensitivity

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IVC RAISE 2020 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 1055 (2021) 012158 doi:10.1088/1757-899X/1055/1/012158

which prevent overheating in windings in case of any sudden increase in the load of the power
generator. When this project is executed, it makes it easier and user friendly to control and monitor
temperature of the power generator. The outcome of the project will have more sensitivity and
accuracy. The project can be developed further by incorporating measurement, monitoring and control
of additional parameters such as stator water flow, stator water conductivity, stator core temperature
and implement sealed oil cooling system for both stator and rotor protection from high temperature.

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