Temperature Monitoring Software for Wireless System Solutions

The lack of real-time temperature monitoring software mechanisms in rotary digesters was resulting in overheads and hampering product quality. The plant was also at constant risk of accidents as there was no means for identifying temperature buildup inside the digestors. The conventional temperature monitoring software systems couldn’t be used in rotary digesters as they were wired and the digestor was in constant rotation. The need was to implement a real-time temperature monitoring software system considering all these aspects.

Our team performed an in-depth study of the field application, considered various technology solutions, and decided on a wireless temperature monitoring software system. The system was designed to be placed inside the digestor and continuously monitor the temperature. It would also integrate with the existing PLC system in place in the plant.

The development included designing and constructing hardware and firmware and integrating the client’s PLC over Modbus protocol. Zigbee connectivity was used for wireless communication. The system measured the temperature every 30 seconds and sent the data to the client’s SCADA system.

• Marked improvement in the product quality as it was easy to control temperature variation due to real-time monitoring.
• Enhanced plant operator safety, as the temperature can be controlled as required.
• The SCADA integration made it possible for the operator to monitor the critical temperature parameters from the control room itself.