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ECWAY TECHNOLOGIES 
IEEE PROJECTS & SOFTWARE DEVELOPMENTS 
OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE 
BANGALORE / HYDRABAD 
CELL: 9894917187 | 875487 1111/2222/3333 | 8754872111 / 3111 / 4111 / 5111 / 6111 
Visit: www.ecwayprojects.com Mail to: ecwaytechnologies@gmail.com 
PETROCHEMICAL LEVEL INDICATOR AND CONTROLLER WITH 
TEMPERATURE MONITORING FOR SPINNING / COTTON PROCESS 
INDUSTRIES 
ABSTRACT 
In spinning mills Petrochemical based cleaning solutions are used for cleaning of raw 
cotton. This petrochemical liquid is pumped from tank to the process container by using 
an AC motor. The process container is the capacity of 2000 liters. The motor takes more 
than one hour to fill the process container. An operator has to pay attention to the 
container to switch off the motor to avoid overflow of petrochemical. During the process 
390C temperature has to be maintained. 
If a system is developed for automation of pump for filling the container, no operator is 
required for supervising the system. Automatic water level controllers are already 
available in the market. But these controllers are not suitable for this application, as the 
electrodes are having direct contact with the content. As it is petrochemical based liquid, 
direct contact with electrodes is not acceptable. 
We implemented a unique system for this application by using magnetic sensors. The 
sensors are fixed at specified locations on the container. A floating magnet floats on the 
liquid and triggers the magnetic sensors one-by-one based on the liquid level. 
Microcontroller monitors the liquid level and the level displayed on LCD. If the 
maximum level is reached, the microcontroller switches off the motor. If the liquid 
reaches the lower level, the controller drives the driver circuit and switches on the motor. 
A thermistor is used as temperature sensor. The microcontroller compares the temperature 
with a ref constant and if the temperature increases beyond 390C, the controller drives the 
siren circuit to alert the operator.
This project is specially designed for spinning / cotton process Industries. Direct contact 
of level probes with the content / liquid is completely avoided in this project. Magnetic 
sensors / Reed switches are used as level sensors. Thermistor is used as temperature 
sensor. The level of the content and its temperature is monitored by the microcontroller 
and displayed on LCD. 
Relay driver circuit can be activated by sensing “Level Full” and “Low Level” indicators 
and operates the motor automatically. Siren driver circuit would be activated by 
thermistor sensor. As magnetic sensors / reed switches are used, the problem of 
oxidization of level probes is completely eliminated. This is an advanced, trouble-free, 
and fit and forgets system for industrial applications. 
This project uses regulated 5V, 500mA power supply. 7805 three terminal voltage 
regulator is used for voltage regulation. Bridge type full wave rectifier is used to rectify 
the ac out put of secondary of 230/12V step down transformer. 
BLOCK DIAGRAM
Petrochemical level indicator and controller with temperature monitoring for spinning or cotton process industries

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Petrochemical level indicator and controller with temperature monitoring for spinning or cotton process industries

  • 1. ECWAY TECHNOLOGIES IEEE PROJECTS & SOFTWARE DEVELOPMENTS OUR OFFICES @ CHENNAI / TRICHY / KARUR / ERODE / MADURAI / SALEM / COIMBATORE BANGALORE / HYDRABAD CELL: 9894917187 | 875487 1111/2222/3333 | 8754872111 / 3111 / 4111 / 5111 / 6111 Visit: www.ecwayprojects.com Mail to: ecwaytechnologies@gmail.com PETROCHEMICAL LEVEL INDICATOR AND CONTROLLER WITH TEMPERATURE MONITORING FOR SPINNING / COTTON PROCESS INDUSTRIES ABSTRACT In spinning mills Petrochemical based cleaning solutions are used for cleaning of raw cotton. This petrochemical liquid is pumped from tank to the process container by using an AC motor. The process container is the capacity of 2000 liters. The motor takes more than one hour to fill the process container. An operator has to pay attention to the container to switch off the motor to avoid overflow of petrochemical. During the process 390C temperature has to be maintained. If a system is developed for automation of pump for filling the container, no operator is required for supervising the system. Automatic water level controllers are already available in the market. But these controllers are not suitable for this application, as the electrodes are having direct contact with the content. As it is petrochemical based liquid, direct contact with electrodes is not acceptable. We implemented a unique system for this application by using magnetic sensors. The sensors are fixed at specified locations on the container. A floating magnet floats on the liquid and triggers the magnetic sensors one-by-one based on the liquid level. Microcontroller monitors the liquid level and the level displayed on LCD. If the maximum level is reached, the microcontroller switches off the motor. If the liquid reaches the lower level, the controller drives the driver circuit and switches on the motor. A thermistor is used as temperature sensor. The microcontroller compares the temperature with a ref constant and if the temperature increases beyond 390C, the controller drives the siren circuit to alert the operator.
  • 2. This project is specially designed for spinning / cotton process Industries. Direct contact of level probes with the content / liquid is completely avoided in this project. Magnetic sensors / Reed switches are used as level sensors. Thermistor is used as temperature sensor. The level of the content and its temperature is monitored by the microcontroller and displayed on LCD. Relay driver circuit can be activated by sensing “Level Full” and “Low Level” indicators and operates the motor automatically. Siren driver circuit would be activated by thermistor sensor. As magnetic sensors / reed switches are used, the problem of oxidization of level probes is completely eliminated. This is an advanced, trouble-free, and fit and forgets system for industrial applications. This project uses regulated 5V, 500mA power supply. 7805 three terminal voltage regulator is used for voltage regulation. Bridge type full wave rectifier is used to rectify the ac out put of secondary of 230/12V step down transformer. BLOCK DIAGRAM