Real Time Data Acquisition System over GPRS Link

Date: 6th August 2014

Presented by: Dr. Akhila Kumar Swar

Senior Environmental EngineerSPCB, Odisha

• Manual monitoring of stack, AAQ and effluent is time taking

• Monitoring at regular interval not feasible due to shortage of manpower in most of the SPCBs

• Analytical calculations and preparation of analysis reports is again time taking and not free from human errors.

• Uploading of these manual monitoring data in the web site of SPCBs/ CPCB takes further time and therefore no real time data is available in the web.

Background

• No real time data was available to verify the emission level in each hour as SPCB has been depending on the paper based hard copy report from plants by post.

• No facility to display the real time data to the public to understand the prevailing situation of emission at the factory site.

• However, paper based hard copy reports sometimes creates doubts in the mind of public.

Background

• No automated reporting facility for the SPCB users

• No automated communication from SPCB with plant authority to gather knowledge on the issues related to high emission.

• No SMS facility on continuous high emission to both plant and to SPCB.

• No automated system with SPCB to know about the status of installation/ operation of online monitoring systems in the industries.

Background

Background

• Therefore it was necessary to introduce a transparent system to record, interpret and communicate the online monitoring data on real time basis to avoid ambiguities.

• The GAP to link SPCB/CPCB with plant and public is the main goal of RT-DAS (Real Time Data Acquisition System)

RT-DAS Background

• CPCB advised all the SPCBs of the country during 2011 to install online stack / AAQ / Effluent monitoring system and Real Time Data Transmission to the server of SPCB and CPCB.

•

• In the first phase 25 large industries of Odisha were instructed to install the online monitoring system to measure the Stack emission, Ambient Air Quality with provision of real time data transmission to SPCB.

RT-DAS Background

• SPCB Odisha reviewed the technologies available for Real Time Data Transmission inside country and abroad then adopted the GPRS based RT-DAS during 2012.

• So far 32 industries have been connected with the RT-DAS server installed at SPCB, Odisha.

• AAQ – 44 Stations

• Stack – 74 Numbers

• Water – 2 Stations

• The detailed list of the units follows:

SL.NO Plant Name AAQ Stack Water

1 ACC Limited (Baragarh) 1 1 0

2 Bhusan Energy Limited (Dhenkanal) 1 1 0

3 Bhusan Power & Steel Limited (Rengali) 0 5 0

4 Bhusan Steel Limited (Meramundali) 1 1 0

5 Captive Power Plant, HINDALCO (Hirakud) 3 4 0

6 Captive Power Plant, NALCO (Angul) 0 1 0

7 FACOR Power Limited (Randia) 0 1 0

8 GMR Kamalanga Energy Ltd (Kamalanga) 4 2 0

9 Indian Farmers Fertilizer Coperative Ltd (Paradeep) 1 0 0

10 Indian Metal & Ferro Alloys Ltd ( 120 MW PP) (Choudwar) 0 2 0

11 Indian Metal & Ferro Alloys Ltd (Choudwar) 4 9 0

12 Jindal Stainless Ltd (Jajpur) 1 2 0

13 Jindal Steel & Power Limited (Anugul) 3 7 0

14 Jindal Steel & Power Limited (Plate Mill) (Anugul) 0 1 0

15 Jindal Steel and Power Ltd (Barbil) 1 0 0

16 JK Paper LTD (Jayakapur) 1 0 0

17 NALCO Damanjodi (Damanjodi) 2 3 0

18 Nava Bharat Ventures Ltd (Dhenkanal) 1 2 0

19 Neelachal Ispat Nigam Limited (Duburi) 1 0 0

20 NTPC Limited (TSTPS) (Deepshikha) 3 6 0

21 NTPC Limited (TTPS) (Talcher Thermal) 1 1 0

22 OCL India Ltd (Rajgangpur) 4 9 0

23 Odisha Power Generation Corporation LTD (Banaharpali) 2 1 0

24 Paradeep Phosphate LTD (Paradeep) 2 2 0

25 Rourkela Steel Plant (Rourkela) 1 0 0

26 Smelter Plant, HINDALCO (Hirakud) 1 5 2

27 Smelter Plant, NALCO (Angul) 1 3 0

28 Sterlite Energy Limited (Banjari) 0 1 0

29 Tata Sponge Iron Ltd (Joda) 3 3 0

30 Vedanta Aluminium Limited (Bhurkamunda) 0 1 0

31 Vedanta Aluminium Limited (Lanjigarh) 1 0 0

32 Visa Steel Limited (Jakhapura) 1 0 0

45 74 2

• RT-DAS (Real Time Data Acquisition System) is for capturing remote data and transmit the data to the destination server for displaying at users preferable browser without any time lag.

• The data should not be captured from the local PC or PLC to avoid any manipulation.

• The data should not be history data.

• The traffic delay should not be more than certain seconds.

Concepts of RT-DAS

Concepts of RT-DAS

This is basically a M2M technology where the data can be captured from the remote devices installed in plants and transmit over a specific medium to the destination server.

The GPRS has been chosen as the transmission medium to transfer the remote data after considering the following communication medium:

1. Public Switched Telephone Network (PSTN) i.e. land lines 2. UHF/VHF (Ultra High Frequency / Very High Frequency)3. General Packet Radio System (GPRS) 4. Satellite

AAQ LOCAL PC

Transmission of data from Online analyzers to SPCB / CPCB over internet

SPCB /CPCB SERVER

Internet

• Sending data from plant Local PC or LAN system might expose to manipulation.

• The program in local PC can be programmed to reduce the value of each parameter to suit SPCB norms.

• There might be a chance of controlling/ delaying the transmission by switching off the Local PC showing it as damaged or not working.

Data Transmission through Internet

• Data can be corrupted if the Local PC in industry has virus

• Saving data in Local PC and transmitting to SPCB does not exactly satisfy the term “REAL TIME”.

Data Transmission through Internet

• To avoid data manipulation and ensure real time data transmission, Y Cable concept has been found to be most suitable by SPCB, Odisha.

• Y Cable eliminates the chance of manipulation completely as the data can be captured prior to local PC.

• No chance of controlling the transmission by the industry as the data can be captured directly from the RS232 port / 4-20ma output of analyzer.

Why Y Cable?

• No threat of virus in case of Y cable

• As the output from analyzer can be transmitted directly to SPCB without delay, the data can be termed as “REAL TIME” data

• This is basically to capture the data that goes to the local PC or PLC without disturbing the plant’s existing system.

• Using Y Cable the analyzer’s data can be bifurcated into two steams at the same time.

Why Y Cable?

Why Y Cable?

• The first stream goes to the local PC or PLC of the industry and the second stream goes to the DTU (Data Terminal Unit which is the GPRS Device) for transmission to SPCB Server over GPRS link.

• In case of analog signal from analyzer, the Dual Channel Isolator acts as Y Cable allowing the signal to flow to the PLC and to the DTU through a converter circuit (Analog to Digital Converter).

Y CABLE AAQ LOCAL PC

DTU 247 (GPRS DEVICE )

Collecting data directly from AAQ using Y Cable

GPRS Network

RT-DAS SERVER AT SPCB

BHUBNESWAR

RS232

Y CABLE

STACK ANALYZER

PLC

DTU 247 (GPRS DEVICE )

Dual Channel Isolator acts as a Y Cable in case of analog output from Stack Analyzer

Analog to Digital

Converter

RT-DAS SERVER AT SPCB BHUBNESWAR

Dual Channel Isolator

GPRS Network

CEMS

4-20ma

GGSNSGSN

VLR

PSTN

GSM NETWORK

GPRS NETWORK

Real Time Data Transmission over GPRS LinkGSM Global system for mobile communication

GPRS General Packet Radio Service

BTS Base Transceiver Station

BSC Base Station Controller

MSC Mobile Switching Centre

HLR Home location register

VLR Visitor location register

PSTN Public Switched Telephone Network

SGSN Serving GPRS Support Node

GGSN Gateway GPRS Support Node

PCU Packet Control Unit

DTU & CONVERTER

PLC

DUAL CHANNEL ISOLATOR

CEMS

BTS BSC

HLR

MSC

IP NETWORK

PCU

IP BASED GPRS BACKBONE

PACKET DATA NETWORK IP X2.5

SPCB Users

RT-DAS Server

ROUTER ISP

PLC

STACK

B T S

RT-DAS SERVER AT SPCB BHUBANESWAR

GPRS DEVICE

Dual Channel Isolator acts as Y-Cable in

Stack

Real Time Environmental Data Transmission System

AAQ

Y-Cable

LOCAL PC

GPRS DEVICE

GPRS Network

STACK ANALYZER

DTU 247 (GPRS DEVICE )

Displaying AAQ and Stack data in LED Display Board at plants main Gate

RT-DAS SERVER AT SPCB

BHUBNESWAR

AAQ STATION

DTU 247 (GPRS DEVICE )

PC

ADAM 4017+

PLC

Dual Channel Isolator

CEMS

Y Cable

ADAM 4520

AAQ

RS232

Plants Core Switch

RS232 to RJ45 Converter

RS232 to RJ45 Converter

Digital Display Board at Factory GatePM – 75 mg/Nm3PM10- 85ug/m3SO2 – 25 UG/M3

GPRS Network

4-20ma 4-20ma

4-20ma RS485

RS232

Y CABLE

STACK ANALYZER

PLC

DTU 247 (GPRS DEVICE )

Continuous High Emission Alert & SMS Communication for transparency

Analog to Digital

Converter

RT-DAS SERVER AT SPCB BHUBNESWAR

Dual Channel Isolator

CEMS

Continuous High Emission triggers the SMS alert to plant & SPCB

GPRS Network

SMS from the plant arrived at SPCB Server about the cause of high

emission and action taken

Compatibility & Operation of RT-DAS, Odisha

• RT-DAS can be connected with online analyzers of any make to capture the data and transmit to the server over GPRS link – this took lot of time to understand and fine tune the RT-DAS.

• In Odisha RT-DAS system has been connected with various types of analyzers of different make such as Teledyne, Thermofisher, Horiba, Sick, Ecotech, Environment S.A, Forbes Marshall, Emerson, Met One etc…

• The protocol of analyzer has to be matched with the GPRS Device for communication.

Compatibility & Operation of RT-DAS, Odisha

• The measurement range of each analyzer is matched with the front end software to display the exact value that shows in analyzer.

• Therefore RT-DAS consisting of Pre-Processor and an Application server is able to receive, store and process the real time data received from various online analyzers of different industries.

• This has reduced man power, space, infrastructure requirement

• The operation maintenance of the RT-DAS can be outsourced or can be run by own IT cell of SPCB / CPCB.

Features of RT-DAS

The front end of RT-DAS is equipped with BI (Business Intelligence) functionalities for a better operation. The following features are available in RT-DAS:

1. On-line Real-Time Trend2. Dash Board

Publishing the report to all the authorized users of SPCB automatically

3. 1 Hour Average Report Publishing4. 24 Hour Average Report Publishing

Features of RT-DAS

AD-HOC Reports:

SPCB users can create the AD-HOC reports when they need it. The reports can be saved in pdf and xls files and mail to different user if required.

1. 1 Hour average report with Trend Chart2. 24 Hour average report with Trend Chart3. 8 Hour average report, Online Pagination View4. Monthly average report, Online Pagination View5. Annually average report, Online Pagination View

Features of RT-DAS

 SMSC (Short Message Service Centre)

1. Alert SMS on high value emission2. Alert SMS on error detection3. On Demand/Instant SMS4. Scheduled SMS

Data Backup in RT-DAS

RTU (Remote Terminal Unit) or Data Logger can be connected just before GPRS device for saving the analyzers data for 2 years.

Two types of data transfer can be supported by RTU1. latest data (i.e. since last retrieval) from the

logger at a scheduled time. 2. “on-demand” data requested by the data server

(i.e. the user) for a specific date and time. Online CSV backup (XLS format) and restore facility has also been provided in the RT-DAS server.

Remote Observation

1. An automated trigger generates when no data received, 4 ma-20ma settings changed, sudden drop of output value of the analyzer reflected in graph in front end.

2. Constant value over a period of time triggers the event of non operation of analyzer or manipulation.

RT-DAS for Flood forecasting in Odisha over GPRS link

• Water Resource Department of Odisha has gone ahead using GPRS based RT-DAS to measure Humidity, Wind Direction, Wind Velocity, Solar exposure, Temperature, Humidity, Rain Fall, Water Depth and Water Flow parameter values from 107 stations and transmit all those remote data to their RT-DAS server installed at Bhubaneswar for simulating the Flood Forecasting model.

• The data was captured from 7 major rivers and 4 major dams as well.

• RT-DAS is already implemented and data received by Water Resource Department at Bhubaneswar.

Configuring the analyzer remotely – under development

Data communication is on HOLD in every 24 hours SPCB Server sends command to get the configuration settings from each analyzer

Analyzer 5

Analyzer 4

Analyzer 3

Analyzer 2

Analyzer 1

Configuration settings arrived in SPCB server and data communication resumes again

GPRS Network

Suggestions

• Above all, Surveillance through a team of experts through physical surprise verification of the online analyzers and data transmission systems of the industries should be devised.

• However, this will lead to voluntary compliances over a period of time to achieve the goal.

[1]. Siba. P. Panda, Jay Rath, A. K. Swar and Ranjita Panda, Real time Ambient Air Quality and Stack Emission Data Transmission through Y Cable Mode over GPRS link, International Conference on Chemical, Bio-Chemical and Environmental Science (ICBEE’2012) December 14-15, 2013 Singapore, pp 27-30http://psrcentre.org/images/extraimages/1212561.pdf [2]. Siba P. Panda, Jay Rath, A. K. Swar, Siddhanta Das, and Ranjita Panda, "Five Y Cable and a Single GPRS Device Transmitted the Real Time Environmental Data from AAQMS," International Journal of Environmental Science and Development vol. 5, no. 4, pp. 398-403, 2014.http://www.ijesd.org/index.php?m=content&c=index&a=show&catid=52&id=831

References

Live Data

The RT-DAS can be accessed by following URL:

http://117.239.117.27/ospcbrtdas

http://113.19.81.6/ospcbrtdas

References

THIS IS NOT THE END BUT THE BEGINNING OF A NEW

ERA IN RT-DAS WORLD.

References

Thank you for your time…….