INDUSTRIAL TRAINING REPORT Oil and Natural Gas corporation of India, ONGC

Dehradun

Remote controlled fan regulator

Submitted in partial fulfillment of the Requirements for the award of

Degree of Bachelor of Technology in Electronics and Telecommunication

College of Engineering, Roorkee

Submitted By

Name: Nishant NiralaUniversity Roll No:120060102072

ET-K-T1

SUBMITTED TO:

Mrs. Nidhi AggarwalDepartment of Electronics and telecommunication

COLLEGE OF ENGINEERING, ROORKEE

Contents:

1) Acknowledgement and Certificate2) About this institute3) Role of IT Division4) Abstract5) List of components used6) What is Arduino?7) Why Arduino?8) Arduino Uno R39) Arduino Uno R3 pin descriptions10) About ATMega328puA) Pin DiagramB) Pin descriptions9)About IR sensor and remote10) Circuit diagram of project11) How it works?12) Programming13) Other applications with same approach

ACKNOWLEDGEMENT

I WOULD LIKE TO GIVE MY HEARTIEST GRATITUDE TOWARDS ONGC FOR ALLOWING ME FOR SUMMER TRAINING FOR THE SUMMER 2015.

I WOULD LIKE TO EXTEND A DEEP SENSE OF GRATITUDE TO SHRI. PRIYANKAR NAINWAL, DGM E&T FOR PROVIDING NECESSARY FACILITY AND INFRASTRUCTURE FOR MY SUMMER TRAINING PROJECT.

I ALSO LIKE TO THANK SHRI. MANJEET SINGH, DEPUTY S.E. E&T, MY GUIDE AND IN CHARGE, FOR HIS ENCOURAGEMENT AND GUIDANCE WITHOUT WHICH MY TRAINING WOULD NOT HAVE BEEN COMPLETED IN THE FIRST PLACE.

I WOULD ALSO LIKE TO THANK ALL THE STAFF AND MY COLLEGUES WHO HAVE HELPED AND SUPPORTED ME.

-Nishant Nirala

About the organization

In August 1960, The Oil and Natural Gas Commission was formed. Raised from mere directorate status to commission, it had enhanced powers. In 1959, these powers were further enhanced by converting the commission into a statutory body by an act of Indian parliament.

OIL AND NATURAL GAS CORPORATION LIMITED (ONGC)

Incorporated on 23 June 1993 is an Indian public sector oil and gas company. It is a Fortune 500 company ranked 152 and contributes 77% of India’s crude oil production and 81% of India’s natural gas production. It is the highest profit making corporation in India. It was set up as a commission on 14th august 1956. Indian government holds nearly 74.14% equity stake in the company.

ONGC's operations include conventional exploration and production, refining and progressive development of alternate energy sources like coal-bed methane and shale gas. The company's domestic operations are structured around 11 assets (predominantly Oil and Gas producing properties), 7 basins (exploratory properties), 2 plants (at Hazira and Uran) and services (for necessary inputs and support such as drilling, geo-physical, logging and well services). ONGC supplies crude oil, natural gas, and value-added products to major Indian oil and gas refining and marketing companies. It primary products crude oil and natural gas are for Indian market. Q3 FY'15 Gross Revenue is 18,770 Crore.

In February 2014, FICCI conferred it with Best Company Promoting Sports Award.

ONGC wins the "Genentech Excellence Award" for the year 2013 in Platinum Category

ONGC was ranked 82nd among India's most trusted brands according to the Brand Trust Report 2012, a study conducted by Trust Research Advisory. In the Brand Trust Report 2013, ONGC was ranked 191st among India's most trusted

brands and subsequently, according to theBrand Trust Report 2014, ONGC was ranked 370th among India's most trusted brands

In 2011, ONGC was ranked 39th among the world's 105 largest listed companies in 'transparency in corporate reporting' by Transparency International making it the most transparent company in India.

Today, OIL AND NATURAL GAS CORPORATION LTD.(ONGC) is, the leader in exploration & production (E&P) activities in India having 72% contribution to India’s total production of crude oil and 48% of natural gas. ONGC has established more than 7 billion tons of in-place hydrocarbon reserves in the country. In fact, six out of seven producing basins in India have been discovered by ONGC. ONGC produces more than 1.27 million barrels of oil equivalent (BOE) per day. It also contributes over three million tons per annum of value-added-products including LPG, C2 - C3, NAPHTHA, MS, HSD, AVIATION FUEL, SKO ETC.

Institutes of ONGC

ONGC has institutionalized R&D centers in Oil and Gas, and related sectors and established separate institutions to undertake specific activities in key areas of exploration , Drilling, Reservoir management, production technology, Ocean engineering, safety and environment protection in the form of 9 independently managed R&D centers. Regional laboratories also support these institutes.

List of Institutes

1. GEOPIC- Geodata Processing and interpretation center, Dehradun since 1897.

2.KDIMPE- KeshaveDevMalviya Institute of Petroleum Exploration, Dehradun since 1962

3. IDT-Institute of Drilling Technology, Dehradun since 1978

4. IEOT-Institute of Engineering & Ocean Technology

5. ONGC Academy-Oil and Natural Gas Corporation since 1982 in Dehradun

6. INBIGS-Institute of Biotechnology and Geotectonic studies, Jorhat since 1989

7. IOGPT -Institute of Oil and Gas Production Technology

8. IPSHEM-Institute of Petroleum Safety, health and Environment management, Goa since 1989

9. IRS-Institute of Reservoir Studies, Ahmedabad since 1978

Role of IT Division

IT division in KDMIPE provides repair and maintain ace services to various equipment’s installed in different labs of KDIMPE through in-house expertise.

It also provides Repair and maintenance services through OEM/OES throughout sourcing.

It also caters IT services to KDIMPE users for complete IT infrastructure such as repair and maintenance of PC’s, Printer’s and LAN systems.

IT provides various communication services such as EPABX connections, audio visual services in various auditoriums of KDIMPE.

Components used

- Arduino UNO R3- Optocoupler-H11AA1- Triac-MOC3051- Bi Directional AC Solid State Switch- AC Motor- IR Receiver – TSOP1738- IR Remote

Each of the above listed components are thoroughly explained in the following pages.

What is Arduino ?

Arduino is a tool for making computers that can sense and control more of the physical world than your desktop computer. It's an open-source physical computing platform based on a simple microcontroller board, and a development environment for writing software for the board.

Arduino can be used to develop interactive objects, taking inputs from a variety of switches or sensors, and controlling a variety of lights, motors, and other physical outputs. Arduino projects can be stand-alone, or they can communicate with software running on your computer (e.g. Flash, Processing, MaxMSP.) The boards can be assembled by hand or purchased preassembled; the open-source IDE can be downloaded for free.

The Arduino programming language is an implementation of Wiring, a similar physical computing platform, which is based on the Processing multimedia programming environment.

Why Arduino ?

There are many other microcontrollers and microcontroller platforms available for physical computing. Parallax Basic Stamp, Netmedia's BX-24, Phidgets, MIT's Handyboard, and many others offer similar functionality. All of these tools take themessy details of microcontroller programming and wrap it up in an easy-to-use package. Arduino also simplifies the process of working with microcontrollers, but it offers some advantage for teachers, students, and interested amateurs over other systems:

Inexpensive - Arduino boards are relatively inexpensive compared to other microcontroller platforms. The least expensive version of the Arduino module can be assembled by hand, and even the pre-assembled Arduino modules cost less than $50

Cross-platform - The Arduino software runs on Windows, Macintosh OSX, and Linux operating systems. Most microcontroller systems are limited to Windows.

Simple, clear programming environment - The Arduino programming environment is easy-to-use for beginners, yet flexible enough for advanced users to take advantage of as well. For teachers, it's conveniently based on the Processing programming environment, so students learning to program in that environment will be familiar with the look and feel of Arduino

Open source and extensible software- The Arduino software is published as open source tools, available for extension by experienced programmers. The language can be expanded through C++ libraries, and people wanting to understand the technical details can make the leap from Arduino to the AVR C programming language on which it's based. Similarly, you can add AVR-C code directly into your Arduino programs if you want to.

Open source and extensible hardware - The Arduino is based on Atmel's ATMEGA8 and ATMEGA168 microcontrollers. The plans for the modules are published under a Creative Commons license, so experienced circuit designers can make their own version of the module, extending it and improving it. Even relatively inexperienced users can build the breadboard version of the module in order to understand how it works and save money.

Arduino UNO R3

The Arduino Uno is a microcontroller board based on the ATmega328 (datasheet). It has 14 digital input/output pins (of which 6 can be used as PWM outputs), 6 analog inputs, a 16 MHz ceramic resonator, a USB connection, a power jack, an ICSP header, and a reset button. It contains everything needed to support the microcontroller; simply connect it to a computer with a USB cable or power it with a AC-to-DC adapter or battery to get started.

The Uno differs from all preceding boards in that it does not use the FTDI USB-to-serial driver chip. Instead, it features the Atmega16U2 (Atmega8U2 up to version R2) programmed as a USB-to-serial converter.

Arduino Uno R3 Board

Revision 2 of the Uno board has a resistor pulling the 8U2 HWB line to ground, making it easier to put into DFU mode.Revision 3 of the board has the following new features:

1.0 pinout: added SDA and SCL pins that are near to the AREF pin and two other new pins placed near to the RESET pin, the IOREF that allow the shields to adapt to the voltage provided from the board. In future, shields will be compatible with both the board that uses the AVR, which operates with 5V and with the Arduino Due that operates with 3.3V. The second one is a not connected pin, that is reserved for future purposes. Stronger RESET circuit. Atmega 16U2 replace the 8U2.

"Uno" means one in Italian and is named to mark the upcoming release of Arduino 1.0.

Input and Output

Each of the 14 digital pins on the Arduino Uno can be used as an input or output, using pinMode(), digitalWrite(), and digitalRead() functions. They operate at 5 volts. Each pin can provide or receive a maximum of 40 mA and has an internal pull-up resistor (disconnected by default) of 20-50 kOhms.

In addition, some pins have specialized functions:

Serial: pins 0 (RX) and 1 (TX). Used to receive (RX) and transmit (TX) TTL serial data. These pins are connected to the corresponding pins of the ATmega8U2 USB-to-TTL Serial chip.

External Interrupts: pins 2 and 3. These pins can be configured to trigger an interrupt on a low value, a rising or falling edge, or a change in value. See the attachInterrupt() function for details.

PWM: 3, 5, 6, 9, 10, and 11. Provide 8-bit PWM output with the analogWrite() function.

SPI: 10 (SS), 11 (MOSI), 12 (MISO), 13 (SCK). These pins support SPI communication using the SPI library.

LED: 13. There is a built-in LED connected to digital pin 13. When the pin is HIGH value, the LED is on, when the pin is LOW, it’s off.

The Uno has 6 analog inputs, labeled A0 through A5, each of which provide 10 bits of resolution (i.e. 1024 different values). By default they measure from ground to 5 volts, though is it possible to change the upper end of their range using the AREF pin and the analogReference() function. Additionally, some pins have specialized functionality:

TWI: A4 or SDA pin and A5 or SCL pin. Support TWI communication using the Wire library.

There are a couple of other pins on the board:

AREF: Reference voltage for the analog inputs. Used with analogReference().

Reset: Bring this line LOW to reset the microcontroller. Typically used to add a reset button to shields which block the one on the board.

Power supply and voltage regulator

It mainly consists of a voltage regulator (here it is 7805). The voltage regulator plays an important role in a power supply unit. Output of thepower supply unit is always dc which is given to the controller.Voltage regulator is designed to automatically maintain a constant voltage level. Thus the voltage regulator regulates the voltage by 1V and constantly supplies the supply Voltage of 5V to the microcontroller at any instant of time.

Component Used-LM317, LM7805

Regulator Specification’s:

Vout range: 1.25 V – 37 V

Vin – Vout difference: 3 V – 40 V

Operation ambient temperature: 0℃ – 125℃Output IMAX: less than 1.5 A (assuming factory-suggested heat sinking) Minimum Load Current max: 10 mA

The LM317 is a linear voltage regulator used in DC to DC converter applications. The overall function of the LM317 is similar to that of the LM78xx series regulators. Whereas the 78xx series of regulators have fixed output voltages (ex. 7805 has 5V output), the LM317 can be adjusted to any voltage (within its limits).

The primary purpose of the regulator is to aid the rectifier and filter circuit in providing a constant dc voltage to the device. Power supplies without regulators have an inherent problem of changing of dc voltage values due to variations in the load or due to fluctuations in the input voltage. With regulator connected to the dc output, the voltage can be maintained with a close tolerant region of desired output.

Optocoupler – H11AA1

An Optocoupler, also known as an Opto-isolator or Photo-coupler, is an electronic component that interconnects two separate electrical circuits by means of a light sensitive optical interface.

The basic design of an Optocoupler consists of an LED that produces infra-red light and a semiconductor photo-sensitive device that is used to detect the emitted infra-red beam. Both the LED and photo-sensitive device are enclosed in a light-tight body or package with metal legs for the electrical connections as shown.

An Optocoupler or opto-isolator consists of a light emitter, the LED and a light sensitive receiver which can be a single photo-diode, photo-transistor, photo-resistor, photo-SCR, or a photo-TRIAC and the basic operation of an optocoupler is very simple to understand.

The H11AA1 is a bi-directional input optically coupledisolator consisting of two inverse parallel gallium arsenide infrared LEDs coupled to a silicon NPN phototransistor in a 6 pin DIP package. The H11AA1 has a minimum CTR of20 %, a CTR symmetry of 1:3 and is designed forapplications requiring detection or monitoring of AC signals.

Triac- MOC3051

The TRIAC is an ideal device to use for AC switching applications because it can control the current flow over both halves of an alternating cycle. A thyristor is only able to control them over one half of a cycle. During the remaining half no conduction occurs and accordingly only half the waveform can be utilized.

The fact that the TRIAC can be used to control current switching on both halves of an alternating waveform allows much better power utilization. However the TRIAC is not always as convenient for some high power applications where its switching is more difficult.TRIAC symbol

The circuit symbol recognizes the way in which the TRIAC operates. Seen from the outside it may be viewed as two back to back thyristors and this is what the circuit symbol indicates

On the TRIAC symbol there are three terminals. These are the Gate and two other terminals are often referred to as an "Anode" or "Main Terminal". As the TRIAC has two of these they are labeledAnode 1 and Anode 2 or Main Terminal, MT1 and MT2.TRIAC basics

The TRIAC is a component that is effectively based on the thyristor. It provides AC switching for electrical systems. Like the thyristor, the TRIACs are used in many electrical switching applications. They find particular use for circuits in light dimmers, etc., where they enable both halves of the AC cycle to be used. This makes them more efficient in terms of the usage of the power available.

While it is possible to use two thyristors back to back, this is not always cost effective for low cost and relatively low power applications.

It is possible to view the operation of a TRIAC in terms of two thyristors placed back to back.

Bi-directional solid state switch-Q6015LS

15 Amp and 16 Amp bi-directional solid state switch series is designed for AC switching and phase control applications such as motor speed and temperature modulation controls, lighting controls, and static switching relays. Standard type devices normally operate in Quadrants I & III triggered from AC line. Alternistor type devices only operate in quadrants I, II, & III and are used in circuits requiring high dv/dt capability.

Features & Benefits

• RoHS Compliant• Glass – passivized junctions• Voltage capability up to 1000 V• Surge capability up to 200 A• Electrically isolated“L-Package” is UL recognized for 2500Vrms• Solid-state switching eliminates arcing or contact bounce that create voltage transients• No contacts to wear out from reaction of switching events• Restricted (or limited) RFI generation, depending on activation point in sine wave• Requires only a small gate activation pulse in each half-cycle

Applications

Excellent for AC switching and phase control applications such as heating, lighting, and motor speed controls. Typical applications are AC solid-state switches, light dimmers, power tools, lawn care equipment, home/brown goods and white goods appliances. Alternistor Triacs (no snubber required) are used inapplications with extremely inductive loads requiringhighest commutation performance. Internally constructed isolated packages are offered for ease of heat sinking with highest isolation voltage.

IR Receiver- TSOP1738

The TSOP17.. – series are miniaturized receivers for infrared remote control systems. PIN diode and preamplifier are assembled on lead frame, the epoxypackage is designed as IR filter. The demodulated output signal can directly bedecoded by a microprocessor. TSOP17..is the standard IR remote control receiver series, supporting all major transmission codes.

Features

_ Photo detector and preamplifier in one package_ Internal filter for PCM frequency_ Improved shielding against electrical field disturbance_ TTL and CMOS compatibility_ Output active low_ Low power consumption_ High immunity against ambient light_ Continuous data transmission possible(1200 bit/s)_ Suitable burst length .10 cycles/burst

Circuit Diagram

Working of project

The circuit consists of an opto-isolated zero-crossing detector and a opto-isolated trigger circuit for the triac. The opto-isolators are necessary to keep the low voltage signal circuits away from the power circuits and provide an appropriate level of safety. As will all circuits involving mains voltage, make sure you know what you are doing.Theory of Operation

The zero-crossing detection circuit provides a 5v pulse every time the ac signal crosses zero volts. We detect this with the Arduino and leverage interrupts to time the trigger circuit precisely in synchronization with these zero-crossing events. The method for power control is shown in the diagram below.

Once a zero crossing is detected, the triac remains off for a controlled amount of time (t1) . The longer this time is, the less power the ac circuit receives. Once the “off-time”, t1 has elapsed, the microcontroller turns on the triac by applying a voltage to the gate (shown in red). Once turned on, the triac will remain on even after the gate voltage has been removed. It will turn off if the gate voltage is zero the next time the ac wave crosses zero. Because of this, we do not need to take care to turn the triac off when the ac signal crosses zero again. All we need to do is to ensure that the triac gets turnd off inside of the period of ½ wave (t3). The duration of the gate pulse (t2) is determined by a minimum requirement of the traic. If this pulse is too short, the traic will not fire Once the second zero crossing occurs, sice there is no voltage on the gate, the triac remains off until triggered again in the next ½ cycle. The net result here is that we “chop” parts of the wave out resulting in lower average power. This is essentially how one accomplishes “PWM” control of an AC wave.

We will be using interrupts and the arduino timer to precisely control the timing of the triac gate. To get a feel for the time intervals, we need to look at the AC signal and the Arduino clock.

The AC signal (in the US anyway) is 60 Hz. What this means is that the AC signal crosses zero, reaches peak positive voltage, crosses zero, reaches peak negative voltage and returns to zero 60 times each second. The period (length of time this takes) is 1/60 or 0.01667 seconds (16.67 milliseconds). A half cycle (the time between two zero-crossings) occurs in 8.33 milliseconds. This is t3 in the figure above.

The Arduino clock runs at 16 MHz, which is 16,000,000 cycles per second: one clock cycle takes 0.0625 microseconds. A single half cycle of the 60 Hz AC signal contains 133,333 clock cycles. This is important because we will be determining the time intervals by clock counts in the Arduino code, not by seconds.

There is quite a bit of good information on use of interrupts with the Arduino out on the web so I won’t cover that in much detail here. Basically the way an interrupt works is that when some event happens (either internal or external to the microprocessor), the microprocessor immediately stops what it is doing to “service” the interrupt. This allows the microprocessor to handle very time sensitive events such as the AC Phase control task here.

Programming

// Timing Sequence// * timer is set up but disabled// * zero crossing detected on pin 2// * timer starts counting from zero// * comparator set to "delay to on" value// * counter reaches comparator value// * comparator ISR turns on triac gate// * counter set to overflow - pulse width// * counter reaches overflow// * overflow ISR truns off triac gate// * triac stops conducting at next zero cross

// The hardware timer runs at 16MHz. Using a// divide by 256 on the counter each count is // 16 microseconds. 1/2 wave of a 60Hz AC signal// is about 520 counts (8,333 microseconds).

#include <avr/io.h>#include <avr/interrupt.h>

#define DETECT 2 //zero cross detect#define GATE 9 //triac gate#define PULSE 4 //trigger pulse width (counts)int i=483;

void setup(){

// set up pinspinMode(DETECT, INPUT); //zero cross detectdigitalWrite(DETECT, HIGH); //enable pull-up resistorpinMode(GATE, OUTPUT); //triac gate control

// set up Timer1 //(see ATMEGA 328 data sheet pg 134 for more details) OCR1A = 100; //initialize the comparator TIMSK1 = 0x03; //enable comparator A and overflow interrupts TCCR1A = 0x00; //timer control registers set for TCCR1B = 0x00; //normal operation, timer disabled

// set up zero crossing interruptattachInterrupt(0,zeroCrossingInterrupt, RISING); //IRQ0 is pin 2. Call zeroCrossingInterrupt

//on rising signal

}

//Interrupt Service Routines

voidzeroCrossingInterrupt(){ //zero cross detect TCCR1B=0x04; //start timer with divide by 256 input TCNT1 = 0; //reset timer - count from zero}

ISR(TIMER1_COMPA_vect){ //comparator matchdigitalWrite(GATE,HIGH); //set triac gate to high TCNT1 = 65536-PULSE; //trigger pulse width}

ISR(TIMER1_OVF_vect){ //timer1 overflowdigitalWrite(GATE,LOW); //turn off triac gate TCCR1B = 0x00; //disable timer stopd unintended triggers}

void loop(){ // sample code to exercise the circuit

i--;OCR1A = i; //set the compare register brightness desired.if (i<65){i=483;} delay(15);

}

General Training-

Introduction to ONGC Basic Electronics AC-DC Circuits Transformers (Power) Rectifiers Diode-Series, Types and Physical Specifications Introduction to Chips Transistors-NPN,PNP (Series) Filters-PI,L-Shaped PCB & Circuit Boards Fuses and Metal Oxide Varisters Opto-couplers ,LED & Sensors TRIACS & SCR Introduction to Relays Introduction to Communication Concepts SAP & SCADA Exploration & Production In ONGC Soldering & Desoldering Guidelines Instrumentation and Control Systems in ONGC Cloud Computing

Laboratory Visits-

1. Micro Biology LabBOD Incubators were demonstrated and the cooling and thermal processes being acted upon were explained.

2. Sedimentology LabWorked on a Scanning Electron Microscope with the capability of zooming levels up to 3 lakh times. The model Number was of JOIL.

3. Geochronology (GC) LabA Normal Ionization Mass Spectrometer was worked upon. The Machine contained a Turret Filament Tube and is used for Isotope Dating and each concentration of Isotope block is checked and analyzed. A Faraday Multiplier is also used.

4. HQ. Tel Bhavan MuseumThe IPE is rechristened KDIMPE by Indra Gandhi in 1981. Prior to that, a 5 year plan was initialized by Sir Nikolai AlkendrovichFlenn for Oil Exploration. Today it stands at a greater emphasis on Research, Development & Exploration and Production.

5. Stable Isotope LabA Ratio Mass Spectrometer for Genetic characterization of Molecular Mass was demonstrated. For liquid Analysis, A Gas Chromatograph which does the similar isotopic analysis was also explained. Importance of Air compressor and Vacuum tubes in the Circuits is also highlighted.

6. Diffraction and Microscopy LabAn X-Ray diffractometer was explained and worked upon.

7. ONGC Satellite CentreNetworking Concepts like MF TDMA, VOIP, Simplex, Duplex and casting methods were explained. Role of Geo stationery satellites (GSAT 10) were demonstrated. Resulting Conversion rate and capacity for the transmission was given.

8. Computer CentreHigh End IBM servers with OMEGA Software package were introduced and the role of Robotic Tape Library and Cluster based Data processing principles were explained.

9. Green BuildingThe ONGC Green hills here have a total built up area of 14,600 square metre and it is spread over five floors with the capacity to accommodate 620 persons. It can conserve water upto 30 per cent through use of onsite sewage plant and low flow sanitary sitting.

10. IDT

The Institute of Drilling Technology (IDT) was set up in 1978 at Dehradun. Institute of Drilling Technology (IDT) provides its techno-economic expertise & solutions to various field problems faced by various services of ONGC with the ultimate objective to promote cost effective E&P activities of the company.