Final report sample

Design and Fabrication of a PLC based Fire Detection and Extinguisher

System with GSMBy

Zeeshan Khan(BEES/S08/0128)

Syed Farrukh Zubair(BEES/F08/0168)

Junaid Eisa(BEES/F08/0116)

Under the supervision of

Tayyab Ahmed Sheikh

2014

Faculty of Engineering Sciences and TechnologyHamdard Institute of Engineering and Technology

Hamdard University, Main Campus, Karachi, Pakistan


System with GSMBy




2014




System with GSMBy




A Project Presented to the

Faculty of Engineering Sciences and TechnologyHamdard Institute of Information Technology

In partial fulfillment of the requirementsFor the degree

Bachelors of EngineeringIn

Electronics



I

Faculty of Engineering Sciences and TechnologyHamdard Institute of Information Technology


CERTIFICATEThis project “Design and Fabrication of a PLC based Fire Detection and Extinguisher

System with GSM”presented by Zeeshan Khan, Syed Farrukh Zubair and Junaid Eisa

under the direction of their project advisor’s and approved by the project examination

committee, has been presented to and accepted by the Hamdard Institute of Information

Technology, in partial fulfillment of the requirements for the bachelor degree of

Electronics Engineering.

____________________________

Tayyab Ahmed Sheikh

(Project Supervisor)

__________________

Dr. Fahad Azim (Director, HIET)

___________________________

(Member)

____________________________

(Member)

____________________________

(Date)

II

Table of Contents

CHAPTER NO. 1: INTRODUCTION13

1.1 OVERVIEW 131.2 THE NEED FOR A FIRE DETECTION SYSTEM 131.3 FIRE TRIANGLE 141.4 TYPES OF FIRE DETECTION 14

1.4.1 ACTIVE FIRE PROTECTION 14 1.4.2 PASSIVE FIRE DETECTION 15 1.5 HOW IS SMOKE FORMED…………………………………………………………………………………………………………….16

CHAPTER NO. 2: BACKGROUND AND OBJECTIVES 17

2.1 PROJECT PHASES 172.2 FIRST PHASE 17

2.2.1 GSM 432.3 OVERVIEW TO CELL CONCEPT IN CELLULAR COMMUNICATION 18

2.4 GSM SYSTEM ARCHITECTUR................................................................................................... ….....19 2.5 GSM FREQUENCIES…………………………………………………………………………………………………………………………. 2.6 SHORT MESSAGING SERVICE……………………………………….....……………………………………………………………21

CHAPTER NO.3: HARDWARE DEVELOPMENT 22

3.1 HARDWARE DEVELOPMENT 223.2 AT89S52 MICROCONTROLLER ARCHITECTURE 233.3 SUMMARY OF 8051 MICROCONTROLLER FEATURES 233.4 GSM MODEM 253.5 ACCESSING GSM MODEM USING MICROSOFT HYPERTERMINAL 263.6 TESTING OF GSM MODEM 26

3.7 LIST OF IMPORTANT AT COMMANDS………………………………………………………………… ………..29

CHAPTER NO.4: HARDWARE DEVELOPMENT 29

4.1 SECOND PHASE 29 4.2 MECHANICAL STRUCTURE 29

4.2.1 OUTER FRAME 304.2.2 WATER TANK 30

4.3 ELECTRONIC COMPONENT 314.3.1 SMOKE DETECTOR 324.3.2 PRINCIPLE OF OPERATION 32

4.3.3 CONTACTOR 33 4.3.4 OPERATING PRINCIPLE 34 4.3.5 RELAY 34

III

4.3.6 SOLENOID VALVE 354.3.6a) TWO TYPES OF CONSTRUCTION APPLY 35

4.3.6b) TYPES OF SOLENOID VALVE.........................................................................................35

CHAPTER NO. 5: OUR SYSTEM 36

5.1 SYSTEM OVERVIEW365.2 SYSTEM SCHEMATIC…………………………………………………………………………………………………………………….37

CHAPTER NO. 6: PROGRAMMABLE LOGIC CONTROLLER 39

6.1 PROGRAMMABLE LOGIC CONTROLLER 396.2 SERIAL COMMUNICATION WITH PLC 39

6.2.1 STEPS TO CONFIGURE SERIAL COMMUNICATION WITH PLC 396.3 HMI COMMUNICATION WITH PLC 41

6.3.1 WHAT IS HMI? 416.3.2 HOW TO MAKE CONNECTIONS TO EXTERNAL DEVICES 426.3.3 COMMUNICATION USING TS 436.3.4 EXTERNAL TAGS 446.3.5 INTERNAL TAGS 43

6.3.6 TAG EDITOR 44 6.3.7 UPDATING TAG VALUES IN RUN TIME 46 6.3.8 DATA LOGGING 46

CONCLUSION 56

FUTURE ENHANCEMENT 57

IV

List of FiguresFigure 2.1 : Cellular Concept...............................................................................................11

Figure 3.0 : AT89S52..........................................................................................................23

Figure 3.1: Architecture Block Diagram of AT89s52........ .... ...........................................24

Figure 3.2 :GSM Modem.....................................................................................................25

Figure 3.3.2(a) :MS Hyperterminal’s Connection Description Dialog Box........................27

Figure 3.3.2(b) :Port Setting Box.........................................................................................29

Figure 4.1 :The main contacts of a smoke detector.............................................................33

Figure 4.2 :Contactor...........................................................................................................33

Figure 4.3 : Relay................................................................................................................34

Figure 5.1: Block Diagram..................................................................................................38

Figure 5.2: Schematic of our Project...................................................................................38

Figure 6.3.1:Screenshot of HMI incorporated in our System..............................................44

Figure 6.3.2:Screenshot from WinCC Showing the Connection to the external devices....41

V

List of Tables

Table 3.1 : GSM Frequency Bands......................................................................................18

Table 4.4: Pin Assignments for DB-9..................................................................................30

VI

List of AbbreviationsGSM Global System Mobile Communication

MSC Mobile Switching Center

SIM Subscribers Identity Module

SMS Short Messaging Service

VII

DedicationThis project is dedicated to our honorable supervisors i.e. Tayyab Ahmed Sheikh, also to

the people behind this project the most co-operative and very hardworking Engr. Abdul

Haseeb and Mr. Imran Khan whose efforts made our ideas to turn in to reality. It’s a pray

to ALLAH that give success and prosperity to all the peoples who helped us in the project.

VIII

Acknowledgement

First of all we are thankful to Almighty Allah who enabled us to conduct and implement this project. Secondly we are grateful to our parents who constantly supported us in this endeavor. We also give a big thanks to our honorable teacher, Sir Tayyab Ahmed Sheikh who gave us an opportunity to go with this project and fully cooperated with us under all circumstances. Last but not the least, we would like to extend our gratefulness to our batch mates and friends who provided moral support all the way and also assisted us in some project related issues.

IX

CHAPTER 1INTRODUCTION

1.1) OVERVIEW

The project was done to obtain a better understanding of Programmable Logic Controllers. In addition we also need to have proper knowledge of different safety procedures adopted throughout the world especially the NFPA (National Fire Protection Association) standards. The foremost purpose of this project is to implement our learning, regarding PLC and fire protection, to fabricate a prototype model of an Automated Fire detection and Extinguisher System.

1.2) THE NEED FOR A FIRE DETECTION SYSTEM

Over the years death rates by fire has increased tremendously. Fire consumes homes and commercial premises quickly, indiscriminately taking lives and ruining property. No one should have to be become a victim of fire, but the reality is that people do become victims every day.

The problem with having just detection is that although you know you have a fire (the fire alarm sounders) there is no way to safely suppress the fire yourself and that’s if you are there. The Fire service will put it out when called but the smoke damage occurring before they arrive and the water damage after can be quite significant.

Fire suppression systems are used to reduce the level of damage and down time by automatically suppressing the fire.

Smoke alarms and sprinkler systems combined can reduce fire-related deaths by 82 percent and injuries by 46 percent.

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1.3) FIRE TRIANGLE

The fire triangle or combustion triangle is a simple model for understanding the ingredients necessary for most fires.

The triangle illustrates a fire requires three elements: heat, fuel, and an oxidizing agent (usually oxygen). The fire is prevented or extinguished by removing any one of them. A fire naturally occurs when the elements are combined in the right mixture.

Without sufficient heat, a fire cannot begin, and it cannot continue. Heat can be removed by the application of a substance which reduces the amount of heat available to the fire reaction. This is often water, which requires heat for phase change from water to steam. Introducing sufficient quantities and types of powder or gas in the flame reduces the amount of heat available for the fire reaction in the same manner. Turning off the electricity in an electrical fire removes the ignition source.

Without fuel, a fire will stop. Fuel can be removed naturally, as where the fire has consumed all the burnable fuel, or manually, by mechanically or chemically removing the fuel from the fire. The fire stops because a lower concentration of fuel vapor in the flame leads to a decrease in energy release and a lower temperature. Removing the fuel thereby decreases the heat.

Without sufficient oxygen, a fire cannot begin, and it cannot continue. With a decreased oxygen concentration, the combustion process slows. In most cases, there is plenty of air left when the fire goes out so this is commonly not a major factor.

1.4) TYPES OF FIRE PROTECTION

1.4.1) Active Fire Protection

Active fire protection systems need to respond effectively and appropriately to a fire. They require activation through a combination of detectors or mechanical means and may consist of fire alarms and notification systems, sprinklers, standpipes, water supplies, and smoke detectors.

Detection systems such as alarms to enable immediate evacuation and notify fire services.

Suppression systems such as sprinklers and extinguishers reduce damage to buildings and contents.

These systems help reduce the growth of a fire, thereby increasing life safety and limiting structural damage.

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Categories of Active Fire Protection

Fire suppression:-

Fire can be controlled or extinguished, either manually (firefighting) or automatically. Manually fighting a fire includes the use of a fire extinguisher or a standpipe system. Automatic fire fighting means that it includes a fire sprinkler system, a gaseous clean agent, or a fire fighting foam system. Automatic suppression systems would usually be found in large commercial kitchens or other high-risk areas.

Sprinkler systems:-

Fire sprinkler systems are installed in all types of buildings, commercial and residential. They are usually located at a ceiling level and are connected to a reliable water source, most commonly city water. A typical sprinkler system operates when heat at the site of a fire causes a glass component in the sprinkler head to break, thereby releasing the water from the sprinkler head. Sprinkler systems help to reduce the growth of a fire, thereby increasing life safety and limiting structural damage.

Fire detection:-

The fire is detected either by locating the smoke, flame or heat, and an alarm is sounded to enable an emergency evacuation as well as to dispatch the local fire department. When a fire detection system is activated, it can be programmed to carry out other actions. These include de-energizing magnetic hold open devices on fire doors and opening servo-actuated vents in stairways.

1.4.2) Passive Fire Detection

Passive Fire Protection attempts to contain fires or slow their spread, to the standard expected by building codes. A PFP system is an integral part of the building layout and construction materials, covering these key areas:

Fire-resistance rated walls.

Firewalls not only have a rating, they are also designed to sub-divide buildings such that if collapse occurs on one side, this will not affect the other side.

Fire-resistant glass using multi-layer intumescing technology or wire mesh embedded within the glass may be used in the fabrication of fire-resistance rated windows in walls or fire doors.

Fire-resistance rated floors.

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Occupancy separations. These barriers designated as occupancy separations are intended to segregate parts of buildings.

Closures (fire dampers). Sometimes fire stops are treated in building codes identical to closures.

Grease ducts. (These refer to ducts that lead from commercial cooking equipment such as ranges, deep fryers and double-decker and conveyor-equipped pizza ovens to grease duct fans)

Spray fireproofing. This is an application of intumescing or endothermic paints, or fibrous or cemented plasters to keep substrates such as structural steel, electrical or mechanical services, valves, liquefied petroleum gas (LPG) vessels, vessel skirts, bulkheads or decks below either 140 °C for electrical items or ca. 500 °C for structural steel elements to maintain operability of the item to be protected.

Fire proof cladding. Materials for such cladding include per lite, vermiculite, calcium silicate, gypsum, in tumescent epoxy, Dura steel (cellulose-fiber reinforced concrete and punched sheet-metal bonded composite panels), and Micro Therm.

Enclosures. They are boxes or wraps made of fireproofing materials, including fire-resistive wraps and tapes to protect special valves and other items deemed to require protection against fire and heat.

1.5) HOW IS SMOKE FORMED

Smoke is a collection of airborne solid and liquid particulates and gases emitted when a material undergoes combustion, together with the quantity of air that is entrained or otherwise mixed into the mass.

Smoke formation can be best explained where wood is burning.

There are four things that you find in any piece of wood:-

Water Volatile organic compounds Carbon Ash

When you put a fresh piece of wood or paper on a fire, the smoke you see is due to the volatile hydrocarbons evaporating from the wood or paper. They start vaporizing at a temperature of about 300 degrees Fahrenheit (149 degrees Celsius). If the temperature gets high enough, these compounds burst into flame. Once they start burning, there is no smoke because the hydrocarbons are turned into carbon dioxide and water (both invisible) when they burs

13

Chapter 2FIRST PHASE

2.1) PROJECT PHASES

To achieve our aim we decided to split our project into two phases. The reason behind this is the limitation in scaling an actual place to the required size for our prototype model. Factors such as room height, detector and sprinkler size could not be scaled down and thus cannot be ignored.

2.1.1) First Phase

To design GSM module for sending sms of a Fire Detection.

2.1.2) Second Phase

Design and Fabrication of a Prototype Model for a Fire Detection and Extinguisher System.

2.2) FIRST PHASE

The first phase of project consists of designing a GSM module for Fire Detection.To achieve this, NFPA provides standards for the design to minimize the risk and effects of fire by establishing criteria for building, processing, design, service, and installation equipment. The details of GSM discuss below.

2.2. 1) GSM:

Global System for Mobile Communications (GSM) is an open, non-proprietary system that is constantly

evolving. One of its great strengths is the international roaming capability. This gives consumers

seamless, standardized, same number contractibility in more than 200 countries. GSM satellite roaming

has extended service access to areas where terrestrial coverage is not available. GSM differs from first

generation wireless systems in that it uses digital technology and time division multiple access

transmission methods. Voice is digitally encoded via a unique encoder, which emulates the

14

characteristics of human speech. This method of transmission permits a very efficient data

rate/information content ratio.

From the outset, GSM has been a system designed with stringent levels of inbuilt security. With

constantly enhanced transmission protocols and algorithms added to the flexible and future proof

platform, GSM remains the most secure public wireless standard in the world.

The GSM Association, based in Dublin, Ireland and London, UK, represents the interests of more than

690 GSM, satellite and 3GSM operators, key manufacturers and suppliers to the GSM industry as well as

regulatory and administrative bodies from more than 200 countries and regions around the world. Most of

the first third generation licensees are also members. The GSM Association is responsible for the

continued maintenance of open standards and interoperability. The global cooperation between operators

is most powerfully illuminated by the success of international roaming. One of the Association's major

priorities is the development and promotion of the GSM standard worldwide.

2.3) OVERVIEW TO CELL CONCEPT IN CELLULAR COMMUNICATIONS:

The cellular systems are made up of numerous transmitting and receiving sites, whose individual

coverage areas partially overlap. The concept of frequency reuse, same frequency is used by

several sites, allows a high traffic density in a wide area. Due to the limited transmission range of

the terminals, cellular systems are based on a large number of base stations on the infrastructure

side, scattered over the area to cover, with each covering a fairly small geographical zone called

cell. Cells are often represented by hexagons as shown.

15

Fig 2.1: Cellular Concept

2.4) GSM SYSTEM ARCHITECTURE:

16

A GSM mobile station carried by the user is denoted as Mobile Equipment (ME) each mobile station is

given a unique identity. As soon as the mobile phone is turned on, it registers with the network and is

authenticated, as such the network could always find the mobile phone. A Cell is formed by the radio area

coverage of a Base Transceiver Station (BTS). Several BTS’s together are controlled by one Base Station

Controller (BSC).

The BTS and BSC together form the Base Station Subsystem (BSS) which controls the radio link with the

mobile station. The combined traffic of the mobile stations in their respective cells is routed through a

switch, the Mobile Switching Center (MSC) which performs the switching of calls between the mobile

users, and between mobile and fixed network users.

Connections originating from or terminating in the fixed network (e.g., ISDN) are handled by a dedicated

Gateway Mobile Switching Center (GMSC). GSM networks are structured hierarchically. They consist of

at least one administrative region, which is assigned to a MSC. Each administrative region is made up of

at least one Location Area (LA). A location area consists of several cell groups. Each cell group is

assigned to a BSC. Several data bases are available for call control and network management. The Home

Location Register (HLR) possesses a database that contains all data concerning the subscription of the

mobile subscriber, i.e. their access capabilities, subscribed services, and supplementary services. It also

contains information about the Visitor Location Register (VLR) that is handling the mobile station

currently by storing information about mobile subscribers that enter its coverage area. When the mobile

changes location, the HLR is updated accordingly. When there is an incoming call for the mobile, the

HLR is interrogated about the present address of the VLR. It also provides the MSC with information

about the MSC area where the mobile is actually located to allow incoming calls to be routed immediately

to the called party.

The Authentication Center (AUC) which stores information that is necessary to protect communication

through the air interface against any intrusions. The legitimacy of the subscriber is established through

authentication and ciphering, which protects the user information against unwanted disclosure. The AUC

generates and stores security -related data such as keys used for authentication and encryption. The

Equipment Identity Register (EIR) is an option the network operator can use to enforce security. With this

feature the network can identify defective or stolen mobile that may not be used in the network since the

EIR registers equipment data rather than subscriber data.

17

2.5) GSM FREQUENCIES:

In principle the GSM system can be implemented in any frequency band. However there are

several bands where GSM terminals are, or will shortly be available. Furthermore, GSM

terminals may incorporate one or more of the GSM frequency bands listed below to facilitate

roaming on a global basis.

In the above bands, mobile stations transmit in the lower frequency sub-band and base stations

transmit in the higher frequency sub-band.

2.6) SHORT MESSAGING SERVICE (SMS):

SMS stands for short message service. It is a method of communication that sends text messages

between cell phones to cell phones. It is specified by the ETSI (standards GSM 03.401 and GSM

03.382). It may contain up to 160 characters, when each character is written according the 7-bits

GSM default alphabet Next to a message the SMS contains some meta-data, for example

Info about the senders (Service center number, sender number)

Protocol information (Protocol identifier, Data coding scheme)

Time stamp

18

The cell phone constantly sends and receives information, even in idle state. It is talking to its

cell phone tower over a pathway called a control channel. The reason for this exchange is that the

cell phone system knows which cell the phone is in, and the phone can change cells as it move

around. The control channel also provides the pathway for SMS messages. When an SMS

message is sent, it flows through the SMSC, then to the tower, and the tower sends the message

to the destination phone as a little packet of data on the control channel.

19

Chapter 3Hardware Development

3.1) HARDWARE DEVELOPMENT:

Details about the decisions and acquisition regarding the cell phone, Data cable and Microcontrollers

have already been discussed but selection of microcontroller type was another stage within our

development phase.

There are two for major classes within the microcontroller family that are available in Pakistan:

ATMEGA32 and MCS52. We chose the AT89S52 microcontroller because of the following reasons:

Availability: This class of microcontrollers has large industrial application, hence is more

widely available in the market.

Inexpensive: Due to the same reasons as cited above, this brand of microcontroller is

inexpensive.

Easy programming: it took us approximately a month to get acquainted with the

programming of this microcontroller.

This microcontroller has four ports for communication purposes, which is an ideal platform to work on

since we are working with multiple devices.

Fig. 3.0: AT89S52

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3.2) AT89S52 MICROCONTROLLER ARCHITECTURE:

Fig. 3.1: Architecture Block Diagram of AT89S52

It is important to look at the architecture of the microcontroller before applying it in our project. Above is

the Block diagram of a AT89C52 microcontroller. The key components of this microcontroller are

discussed below:

3.3) SUMMARY OF 8051 MICROCONTROLLER FEATURES:

8K bytes ROM

128 bytes RAM

Four 8 bit I/O ports

21

Three timers

Serial Interface

64K external code memory space

3.4) GSM MODEM:

A GSM modem is a wireless modem that works with a GSM wireless network. A wireless

modem behaves like a dial-up modem. The main difference between them is that a dial-up

modem sends and receives data through a fixed telephone line while a wireless modem sends and

receives data through radio waves. Like a GSM mobile phone, a GSM modem requires a SIM

card from a wireless carrier in order to operate.

Fig. 3.2: GSM Modem

Computers use AT commands to control modems. Both GSM modems and dial-up modems support a

common set of standard AT commands. In addition to the standard AT commands, GSM modems support

an extended set of AT commands. These extended AT commands are defined in the GSM standards. With

the extended AT commands, various things can be done:

Reading, writing and deleting SMS messages. Sending SMS messages.

Monitoring the signal strength.

Monitoring the charging status and charge level of the battery.

22

Reading, writing and searching phone book entries.

3.5) ACCESSING GSM MODEM USING MICROSOFT HYPERTERMINAL:

Microsoft HyperTerminal is a small program that comes with Microsoft Windows. We use it to

send AT commands to the GSM modem. It can be found at Start -> Programs -> Accessories ->

Communications -> HyperTerminal.

Before programming our SMS application, it is required to check if the GSM modem and SIM

card are working properly first. The MS HyperTerminal is a handy tool when it comes to testing

the GSM device. It is a good idea to test the GSM devices beforehand. When a problem occurs,

sometimes it is difficult to tell what causes the problem. The cause can be the program, the GSM

device or the SIM card. If GSM device and SIM card with MS HyperTerminal and they operate

properly, then it is very likely that the problem is caused by the program or other hardware.

3.6) Testing of GSM MODEM:

To use MS HyperTerminal to send AT commands to the GSM modem, the following procedure

is followed:

1. We put a valid SIM card into the GSM modem. We can obtain a SIM card by subscribing to

the GSM service of a wireless network operator.

2. Then we start up MS HyperTerminal by selecting Start -> Programs -> Accessories ->

Communications -> HyperTerminal.

1. In the Connection Description dialog box (as shown in the screenshot given below) figure

4.3.2, we enter any name and choose an icon we like for the connection. Then we click the

OK button.

23

Fig. 3.3.2(a):MS HyperTerminal's Connection Description Dialog Box

4. In the Connect To dialog box, choose the COM port that your mobile phone or GSM modem

is connecting to in the Connect using combo box. For example, choose COM1 for mobile phone

GSM modem as connecting to the COM1 port. Then click the OK button.

5. The Properties dialog box comes out. Entering the correct port settings for GSM modem. Then

click the OK button. To find the correct port settings that should be used with GSM modem, one

way is to consult the manual of GSM. To check the port settings used by the wireless modem

driver on Windows 2000 and Windows XP, follow these steps:

a. Go to Control Panel -> Phone and Modem Options -> Modems tab.

b. Select your mobile phone or GSM modem in the list box.

c. Click the Properties button.

d. The Properties dialog box appears. Click the Advanced tab and then click the Change Default

Preferences button.

e. The Change Default Preferences dialog box appears as shown in below figure 4.5.2(b). The Port speed

field on the General tab corresponds to HyperTerminal's Bits per second field. You can also find the

24

setting for flow control on the General tab. On the Advanced tab, you can find the settings for data bits,

parity and stop bits.)

Fig. 3.3.2(b): Port Setting Box

6. Type "AT" in the main window. A response "OK" should be returned from the GSM modem.

Type "AT+CPIN?" in the main window. The AT command "AT+CPIN?" is used to query

whether the GSM modem is waiting for a PIN (personal identification number, i.e. password). If

the response is "+CPIN: READY", it means the SIM card does not require a PIN and it is ready

for use .As shown in below given screen shot If the SIM card requires a PIN, if need to set the

PIN with the AT command "AT+CPIN=<PIN>".

25

If you get the responses above, your GSM modem is working properly. You can start typing your

own AT commands to control the GSM modem.

3.7) List of Important AT Commands:

After successfully testing the MODEM for its correct operational state, we need to set the

MODEM parameters like Baud rate, Echo off etc to enable easier access via a microcontroller

which we used in this project.

Following is a list of the important AT commands:

Example: Send SMS From GSM modem.

AT+CMGF=1 [Enter] +CMGF=1 -Sets modem in text mode

AT+CMGS="03009209834"[Enter] -Send SMS

26

Example: Receive SMS

A SMS will be stored in the GSM modem / module and being sent via RS232 to the peripherals.

The peripherals have to send commands to the GSM unit to receive SMS and to erase SMS from

the device in order to free memory.

AT+CMGR=X[Enter] -Read SMS on memory number X

AT+CMGD=X[Enter] -Erase SMS on memory number X

Where X is the address of memory.

27

Chapter 4SECOND PHASE

4.1) SECOND PHASE

The Second Phase of our project is “Design and Fabrication of a Prototype Model of a PLC based Fire Detection and Extinguisher System with HMI Display”

This phase is further divided into two categories:

1. Mechanical Structure

2. Electronic Circuitry

4.2) MECHANICAL STRUCTURE

4.2.1) Outer Frame

Our Prototype Model is created using Metal Frames. These Frames were connected to form a Cubical Shape with dimensions 30 x 20 x 30 inch. On the front is an acrylic sheet of thickness 6mm

4.2.2) Water Tanks

The water tank deployed in our project. Which provides water to the spray Nozzles to suppress the fire when an event is occurring?

3.2.4) Spray Nozzles

28

4.3) ELECTRONIC COMPONENTS

4.3.1) Smoke Detector

The smoke detector used in our system is a photoelectric smoke detector (T-Guard TA-2188). This detector detects smoke by a couple of infra-red diodes. The principle of detecting is that granule in the smoke can reflect infra-red light. Infrared diodes are placed in the special chamber. The chamber can shield external light, but doesn’t affect the smoke in it. When there is no smoke, the diode receives very weak infrared light. When the smoke enters the chamber, the diode receives more light and when the smoke attains a certain density, the detector can give out an alarm signal. In order to reduce interference and lower power consumption, the emitting circuit adopts the pulse signal. The detector adopts the special structure design and has the dustproof, mothproof, and anti-outside light interference features etc.

Technical Specifications:-

Operating voltage : DC 24V

Static Current : < 2mA

Current : <10mA

Detecting Area : 80 square meter (with installation height of 6m-

12m) and 60 square meter (with an installation

height of less than 6m)

Output : Relay output N.O, DC 24V 100mA

4.3.2) Principle of Operation:-

In a normal state, contacts 1 and 2 will be N.C. In the event of a fire, as the smoke reaches a certain threshold value, the contacts 1 and 2 change their state to N.O.

29

Fig 4.1:-The main contacts of a smoke detector.

4.3.3) CONTACTOR:-

A contactor is an electrically controlled switch used for switching a power circuit, similar to a relay except with higher current ratings. A contactor is controlled by a circuit which has a much lower power level than the switched circuit.

Fig 4.2: Contactor

30

24V

To PLC

http://en.wikipedia.org/wiki/Relay

4.3.4) Operating Principle:-

Unlike general-purpose relays, contactors are designed to be directly connected to high-current load devices. Relays tend to be of lower capacity and are usually designed for both normally closed and normally open applications. Devices switching more than 15 amperes or in circuits rated more than a few kilowatts are usually called contactors.

The top three contacts switch the respective phases of the incoming 3-phase AC power. The lowest contact is an “auxiliary” contact which has a current rating much lower than that of the large motor power contacts, but is actuated by the same armature as the power contacts. The auxiliary contact is often used in a relay logic circuit, or for some other part of the motor control scheme. One contactor may have several auxiliary contacts, either normally-open or normally-closed, if it is required.

4.3.5) RELAYS:-

A relay is an electrically operated switch. Many relays use an electromagnet to operate a switching mechanism mechanically, but other operating principles are also used. Relays are used where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuits), or where several circuits must be controlled by one signal.

The relays used in our project are OMRON MK2P-S-DC24.

Fig 4.3: Relay

31

http://en.wikipedia.org/wiki/Electromagnet

http://en.wikipedia.org/wiki/Switch

http://en.wikipedia.org/wiki/Electric

4.3.6) SOLENOID VALVE:-

A solenoid valve is a combination of two basic functional units – (1) a solenoid (electro-magnet) with its plunger (or core) and (2) a valve containing an orifice in which a disc or plug is positioned to stop or allow flow.

The valve is opened or closed by movement of the magnetic plunger (or core) which is drawn into the solenoid when it is energized.

4.3.6a) Two Types of Constructions Apply:-

Direct Acting:-

When the solenoid is energized, the core directly opens the orifice of a Normally Closed valve or closes the orifice in a Normally Open valve. The valve will operate at pressures from 0 psi to the maximum rated value. The force needed to open the valve is proportional to the orifice size and fluid pressure. As orifice size increases, so does the required force. To open larger orifices without increasing solenoid size, internal pilots are used.

Internally Piloted:-

These valves use line pressure to assist operation. When the coil is de-energized (in a Normally Closed valve), the pilot orifice is closed and line pressure is applied to the top of the piston or diaphragm through the bleed orifice, closing the valve. When the coil is energized the core opens the pilot orifice, relieving pressure from the diaphragm or piston. Line pressure alone opens the valve by lifting the diaphragm or piston off the main orifice.

4.3.6b) Types:-

2-Way Solenoid Valve:-

Two-way solenoid valves have one inlet and one outlet, and are used to permit and shut off fluid flow.

Normally Closed (NC):-

Fluid is shut off when the coil is de-energized and flows through the valve when the coil is energized.

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.

Normally Open (NO):-

Fluid flows through the valve when the coil is de-energized and shuts off when the coil is energized.

4.3.7) CENTRIFUGAL PUMP:-

The purpose of these centrifugal pumps is to transform the motor or engine’s energy into kinetic energy and thereafter into pressurized fluid. This is achieved through the two main components within the pump. The impeller, which is the rotating part, is responsible for converting the energy into kinetic energy. The volute, which is the stationary part, works on transforming the energy into pressure.

The way these pumps function is that after fluid enters the pump, the impeller spins the fluid outward. The fluid’s pressure increases and gets pushed out of the pump and into a pipe.

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4.3.7a) Categories of Centrifugal Pumps:-Centrifugal pumps can be categorized according to the way in which fluid flows into and out of the pumps. The manner of flow depends on the pump casing and also the impeller’s design. Based on the flow type, we can classify the pumps into 3 main categories:-

Radial Flow Centrifugal Pumps:-In radial flow pumps, fluid enters at the center of impeller and flows out at right angles to the pump shaft. Pressure is developed through centrifugal force.

Axial Flow Centrifugal Pumps:-Axial flow pumps are also known as propeller pumps because the way it functions is the same as a boat’s propeller. Here the fluid is pushed by the impeller in a direction which is parallel to the pump shaft. Pressure is developed totally through the lifting action of the impeller vanes.

Mixed Flow Centrifugal Pumps:-Mixed flow pumps contain the features of both radial flow and axial flow pumps. Here the impeller pushes the fluid away from the pump shaft at an angle of more than 90 degrees. Pressure is developed partially through a centrifugal force and partially through the lifting action of the impeller vanes.

4.3.7b)Things To Note When Operating Centrifugal Pumps:-

Before turning on the pump you will need to make sure that the pump casing is filled with fluid, otherwise the pump will not work. Another thing to take note is that the pump impeller will not be able to function if the pump casing is filled with gases.

Centrifugal pumps have the tendency to overheat if the fluid level inside gets too low, while other pumps will shut themselves down when the fluid gets too low. Pump failure will occur if the fluid inside the pump casing dries up. In addition, to prevent the fluid from overheating, the flow through the pump must be maintained and monitored.

Just like any other parts of a piece of equipment, the pump impellers are subject to wear and tear over time. In centrifugal pumps, they often wear off much faster if the pump has to deal with suspended solids. The other thing to note is the corrosion inside of the pump. Generally, the speed at which corrosion develops depends a lot on what type of fluids the pumps are handling.

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CHAPTER 5OUR SYSTEM

5.1) SYSTEM OVERVIEW:-

The figure 5.1.1 shows the block diagram of the system. The sensor being employed here is a photo-electric smoke detector for heat sensing. The entire system is divided into different locations A, B, C and D. There are four sprinklers located ateach of these four locations. The smoke detector is connected to port I124.0. As soon as the smoke is detected by the smoke detector, the logic state changes from ‘1’ to ‘0’ and an alarm, connected to port Q4.7 will sound. After the alarm is activated, the solenoid valve connected through port Q124.0 will open and the water pump connected to port Q124.4 will turn on. The water will be pumped into the sprinkler system for five seconds. This value can easily be modified in the program. As a result the sprinklers will be activated. As the water from the main tank reduces, the PLC will receive signal from the low level electrode and a change takes place in the logic level from ‘1’ to ‘0’ in the port I124.1. This causes a secondary pump connected to port Q124.5 to start which transfers water from the reserve tank to the main tank. As the water in the main tank fills up, eventually it reaches the high level electrode and the logic level changes from ‘0’ to ‘1’ in the port I124.2. This results in the secondary pump to switch off.

The entire process is displayed on a computer through the HMI.

Figure 5.1: Block Diagram

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5.2) SYSTEM SCHEMATIC:-

In the schematic, the PLC S7-300 is connected to 6 relays RL1, RL2, RL3. RL3 is used to control the solenoid valves. The solenoid Valves are operated on 220V AC. RL1 is connected to the Contactor which is controlling the main pump depicted as M1, while RL2 is being used to control a contactor, which in turn is controlling the Reserve Pump.

The output ports are sourcing +24V DC, so the relays need only to be connected to -24V DC. The input ports are sinking 24V DC so the common from smoke detector is connected to the input port I124.0. here the smoke detector is basically functioning as a relay. In normal conditions the contact is NC, providing logic 1 (+24V DC) to the PLC. When smoke is detected, the contact switches to Open, a transition from 1 to 0. The level electrodes are also connected in the same manner.

The entire PLC is operated on 24V DC. To activate the modules it is necessary to supply power to the module with 24V DC

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Smoke Detect

Water Pump

Contactor

Relay

Water Flow

GSM

Siren

Controller

Relay

Solenoid Valve

Relay

Controller(PLC)

Figure 5.2:-Schematic of our system

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CHAPTER 6PROGRAMMABLE LOGIC CONTROLLER

6.1) PROGRAMMER LOGIC CONTROLLER:-

A PLC (i.e. Programmable Logic Controller) is a device that was invented to replace the necessary sequential relay circuits for machine control. The PLC works by looking at its inputs and depending upon their state, turning on/off its outputs. The user enters a program usually via software to give the desired results.

PLCs are used in many “real world” applications. If there is an industry, chances are that they are using a PLC. If you are involved in machining, packaging, material handling, automated assembly or countless other industries, you are probably already using them. If you are not, you are wasting money and time. Almost any application that needs some type of electrical control has a need for a PLC.

The PLC used in our Project is the OMRON CQM-1H.

6.2) SERIAL COMMUNICATION WITH PLC:-

6.2.1) Steps to Configure Serial Communication with PLC:-

Create a new project by clicking the new project button on the toolbar in the upper left corner of your screen.

A new window will open showing the name of your project at the top. Right click your project and choose “Insert New Object”. Choose the device you will be programming. We will be using the SIMATIC 300 Station.

You will now see SIMATIC 300 appear in the right window of your screen. It should be highlighted blue. Double click SIMATIC 300 and it will move to the left window and “Hardware” will appear in the right window.

Double click “Hardware” and a new window will open. On the left will be the SIMATIC 300 – (the name of your project). The window on the right will be the catalog of parts.

Now from the right catalog window first select the rail on which we will be mounting our modules

Then select the power supply module and CPU module. In our case it is the CPU-312C.

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After selecting the PLC model, place your I/O modules on the rail from the catalog section.

Make sure that the model number you are selecting from the catalog must match the hardware model number.

After placing the required modules on the rail, check the I/O address each module is offering.

Now for establishing a link between the hardware and software, find the interface area and click on properties. Another window, “Properties – MPI interface CPU 313-2DP” will be open. Change the address to meet your specific criteria. The PC where S-7 Simatic is installed is always addressed as 1 and the target PLC is usually addressed as 2.

Now click MPI(1) and click OK. Click OK again to close the Properties window. Save and Compile by clicking the icon located on the left of the toolbar. Download the hardware configuration to the PLC by clicking the download icon located

on the toolbar. A window titled “Select Target Module” should open. Click OK. Another window titled “Select Node Address” will open. You should see listed your node

address for the PLC you are working with as you configured it in the previous step. If not, click view and click on whatever node address appears and click OK.

GO back to the SIMATIC managerby clicking the tab on the taskbar. Click on Options. Choose Set PG/PC Interface. Choose PC Adapter (Auto). Click Properties. A new window will open, displaying either Automatic Bus Profile

Detection or Local Connection. Click Local Connection and choose USB. Now choose Automatic Bus Profile Detection and change the address to 30. You can check your connection now by clicking Start Network Detection. If a new window opens displaying Network Type = MPI, Transmission Rate = 187.5kbps, you have established a communication link with the S7-300. Click Close. Click OK. Click OK.

It is now time to start programming. Looking at the SIMATIC Manager window, click the plus sign located beside SIMATIC 300(1), click the plus sign beside CPU 313C-2DP, click the plus sign beside S7 Program(1). Now click on Blocks and you will see system data and OB1 appear in the right window on your screen.

Double click on OB1 and a new window will open named Properties – Organization Block.

Here you can choose how you want to program, in LAD (ladder), STL (statement list), or FBD (function block diagram). Choose which you want to use and click OK.

Double click OB1 again and the LAD/STL/FBD programming window will open. You can now start programming.

OR

Create a new Project. Connect the PLC through the MPI cable to the PC.

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Click on the PLC tab. Select ‘Upload Station to PG’. Enter MPI Address as ‘2’ for the targeted PLC. MPI address ‘1’ being the user PC. This will upload all the information from the PLC to the Simatic Manager that includes

module information and program. In case if the communication port is not set, then goto>> options >> set PG/PC interface

and select PC Adapter. From there select the desired MPI port.

6.3) HMI COMMUNICATION WITH PLC:-

6.3.1) What is a Human Machine Interface?

The HMI system represents the interface between man (operator) and process (machine/plant). The PLC is the actual unit which controls the process. Hence, there is an interface between the operator and WinCC flexible (at the HMI device) and an interface between WinCC flexible and the PLC. An HMI system assumes the following tasks:-

● Process Visualization:-

The process is visualized on the HMI device. The screen on the HMI device is dynamically updated. This is based on process transitions.

● Operator Control of the Process:-

The operator can control the process by means of the GUI. For example, the operator can preset reference values for the controls or start a motor.

● Displaying Alarms:-

Critical process states automatically trigger an alarm, for example, when the set point value is exceeded.

● Archiving Process Values And Alarms:-

The HMI system can log alarms and process values. This feature allows you to log the sequence of the process and to retrieve previous production data.

● Process Values And Alarms Logging:-

The HMI system can output alarms and process value reports. This allows you to print out production data at the end of a shift, for example.

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● Process and Machine Parameter Management:-

The HMI system can store the parameters of processes and machines in recipes. For example, you can download these parameters in one pass from the HMI device to the PLC to change over the product version for production.

WinCC flexible is the HMI software for future-proof machine-oriented automation concepts with comfortable and highly efficient engineering.

Fig 6.3.1:-A screenshot of the HMI incorporated in our system.

6.3.2) How to make Connections to External Devices:-

In the “Connections” editor, you create and configure connections.

Select “Connections” from the project view, and then open the shortcut menu. Select “New connection” from this shortcut menu. The new connection will be created and will open in the work area.

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PROJECT VIEW

Tool Window

Object View

Property View

Output View

Work Area

Figure 6.3.2:-A screenshot from WinCC Flexible showing the connections to the external devices.

The communication partners are visualized schematically on the “Parameters” tab. This tab provides the “HMI device”, “Network” and “PLC” areas where you can declare the parameters of the relevant interface used.

6.3.3) Communication Using Tags:-

WinCC flexible controls communication between the HMI and the PLC by means of tags.In WinCC flexible, tags are centrally managed in the “Tag” editor. There are external and internal tags. External tags are used for communication, and represent the image of defined memory locations on the PLC. The HMI and the PLC both have read and write access to this storage location. These read and write operations may be cyclic or event-triggered. In your configuration, create tags that point to specific PLC addresses. The HMI reads the value from the defined address, and then displays it. The operator may also enter values on the HMI device which will be written to the relevant PLC address.

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6.3.4) External Tags

An external tag is the image of a defined memory location in the PLC. You have read and write access to this storage location from both the HMI device and the PLC.Since external tags are the image of a storage location in the PLC, the applicable data types depend on the PLC which is connected to the HMI device.External tags enable the communication (data exchange) between the components of an automation process, e.g. between the HMI device and the PLC.

6.3.5) Internal Tags

Internal tags are stored in the memory of the HMI device. Therefore, only this HMI device has read and write access to the internal tags. You create internal tags, for example, in order to execute local calculations. You can use all basic data types for internal tags.

6.3.6) Tags Editor

In the tag editor, you create and configure tags.To open the tag editor, create a new tag or edit a tag displayed in the Object window. As an alternative, you can open the tag editor by double-clicking on the entry "Tags" in the Project window.

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The following properties can be set for tags:

● "Name"Every tag has a name which you can choose. Note, however, that the name may only occur once within the tag folder.

● "Connection" to PLC and tag "Logging cycle"For external tags, you must specify the PLC to which the HMI device is connected since these tags represent memory locations in the PLC. The available data types for a tag and their address in the PLC memory depend on the type of PLC. Furthermore, you must specify how often the tag should be updated.

● "Data type" and "Length"The data type of a tag determines which type of values will be stored in a tag, how these are saved internally and the maximum value range that can be held by the tag. Two simple examples of data types are "Int" for saving integers or "String" for saving character strings. You can input leading zeros in values for tags of data type "Integer”. For text tags of the type "String" or "StringChar", you can also set the "Length" of the tag in bytes. For all other data types, the value of "Length" is fixed.

● "Array count"You can assemble tags from a number of the same type of array elements. Array elements are saved in consecutive memory locations. Array tags are primarily used when working with larger quantities of the same form of data, e.g. for a curve buffer or in the definition of a recipe.

● "Comment"You can enter a comment for each tag to provide for a more exact documentation of your project.

● "Limits"

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You can specify a value range with an upper and lower limit range for each tag. If the process value, which should be stored in the tag, enters one of the limit ranges, alarm messages can be sent. If the process value lies outside the value range, a function list for sending messages can be processed.

● "Start value"You can configure a start value for every tag. The tag will be set to this value at runtime start. In this manner, you can ensure that the project will begin in a defined state every time it is started.

● "Logging" and "Logging limits"To ease documentation and later evaluation, data can be stored in different logs. You can set the frequency and mode of logging. Furthermore, in WinCC flexible it is possible to limit logging to data that is within or outside specified logging limits. All properties which were configured when the tag was created can be modified with the object list later where the tag is used.Example: Create a tag and configure its limit values. Link this tag to an IO field. The limit values which were set when the tag was created can be modified with the object list later when the IO field is configured.

6.3.7) Updating Tag Values in Runtime

Tags contain data which change during runtime. Value changes are handled differently at internal and external tags.If a start value has been configured for the tag, the tag will be set to this value at runtimestart. Tag values change in runtime. In runtime, you have the following options of changing the tag value:● by executing a system function, for example, "SetValue."● by operator input, for example, at an IO box● A value assignment in a script● A value change in an external tag in the PLC

Updating the value of external tags

Method for updating the value of an external tag:● Updating after an acquisition cycleNormally, tags are updated after an acquisition cycle as long as the tag appears in a picture or is logged. The acquisition cycle determines the update cycle for tag value updates on the HMI. You can either choose a default acquisition cycle, or define a user-specific cycle.● When the setting "Cyclic continuous" is activated If this setting is activated, the tag will be updated in runtime, even if it is not found in the currently open screen. This function is set, for example, for tags which are configured to trigger a function list in the event of a change in their value. Only use the "Cyclic continuous" setting for tags that must truly be updated. Frequent read operations increase communication load.

6.3.8) Data Logging

In runtime, tag values can be stored in logs for later evaluation. For the logging of a tag, you

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must specify the log in which the values are to be stored, how often this should happen andWhether only the tag values in a specific value range are to be saved.

Several steps are involved in data logging:● Creating and configuring data logsWhen creating a data log, you must define the following:– General settings, e.g. name, size, storage location– Behavior at runtime start– Behavior when the log is full● Configuring the logging of tagsYou can specify a data log for every tag. This log records the values of the tags in runtime and other information, e.g. the time the value was logged. Furthermore, you can define when and how often the value of the tag should be logged. To perform the latter, you have the following options:– "On request":The tag values are logged by calling the "LogTag" system function.– "On change":The tag values are logged, as soon as the operator device detects a change of value in the tag.– "Cyclic continuous":The tag values are logged at regular intervals. In addition to the standard cycles available in WinCC flexible, you can add cycles of your own, which are based on the standard cycles. Furthermore, you can restrict the logging to those values that are within or outside of a tolerance band. In this manner, you can distribute tag values specifically to different logs for separate analysis later.

the tags "cyclically continued" or "if changed" are logged. If the logging upon request occurs only rarely, then the sequence log is, for example, completed with cyclically logged values and the next sequence log is set up. If there is then an access to the tag that has been logged upon request, the tag cannot be shown as in runtime the current sequence log is being accessed. As a remedy, for rarely logged tags, set up a separate tag log.● Processing logged tag values furtherThe logged process tag values can be evaluated directly in your WinCC flexible project, e.g. in a trend view, or with another application, e.g. Excel.

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Future Extensions

Our Prototype Model of Fire Detection and Extinguisher System have a wide range of Future Extensions which include:

1. Fire Detection through the Surveillance Camera/Video Camera. This would involve detecting Fire through its color through Image Processing

2. Use of Wireless Smoke and Heat Detectors. This is the most recent technology now being employed all around the world

3. Monitoring of HMI Screens from virtually anywhere whether in your Office or at Home.

4. Implementation of Robotic Sprinkler System, so that only the location with Fire will receive water.

5. Detection of different types of Fires whether its Electrical, normal, or some other type of fire

6. Differentiate between false and true Alarm

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Conclusion

The objective of this task was to develop and implement a working prototype of a fire detection and extinguishing system and test its performance under different conditions while using the available local resources. By the grace of Allah, we were successful.

The main aim of undertaking any project is to learn something new and achieve something. These achievements are not only related to technical aspects, but to behavioral and cultural aspects as well.

At this important turning point in our life, we have successfully completed our student life and will now be entering a practical world filled with endless possibilities. This life is different than what we are used to where we have to shape our knowledge and theories into practical realities.

But all this is not something entirely new to us as we have already procured a taste of what is to come. Our final year project has provided us with the opportunity to experience these events. We have all been through emotions like hopelessness, panic, patience, and joy during the undertaking of our project.

There was a time when we didn’t know where to begin, a state of total confusion but as we started moving on, we became confident in ourselves. We are sure that anything is possible in this world if only one has the determination and necessary focus. In the course of time we learned multiple approaches towards problem handling and how to solve these problems in an effective manner.

We would like to conclude our achievements and lessons as follows:-

1) There was a very good practice of completing the task within the allotted time as this prepares us for the practical life.

2) We learnt how to work as a team and how a team functions.

3) It boosted our self confidence both within ourselves and in our project mates.

4) It improved our imagination and designing abilities.

5) The project enabled us to gain technical knowledge of devices and components which were previously unknown to us.

In the end we are infinitely thankful to Almighty Allah who in His infinite wisdom and knowledge, kindness and mercy granted us the strength and dedication to complete this task.

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Bibliography

1. Association, N. F. (2007). NFPA 13 : Sprinkler System. Quincy: NFPA.

2. Association, N. F. (2007). NFPA 72 : Fire Alarm Code. Quincy: NFPA.

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