Low-Cost IoT-Based Sensor System A Case Study On Harsh Environmental Monitoring
Low-Cost IoT-Based Sensor System A Case Study On Harsh Environmental Monitoring
environmental monitoring.
Article:
Sunny, A.I., Zhao, A., Li, L. et al. (1 more author) (2021) Low-cost IoT-based sensor
system: A case study on harsh environmental monitoring. Sensors, 21 (1). 214. ISSN
1424-8220
https://doi.org/10.3390/s21010214
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sensors
Communication
Low-Cost IoT-Based Sensor System: A Case Study on Harsh
Environmental Monitoring
Ali Imam Sunny 1 , Aobo Zhao 1 , Li Li 1, * and Sambu Kanteh Sakiliba 2
1 Nuclear AMRC, Advanced Manufacturing Park, Brunel Way, Rotherham S60 5WG, UK;
[email protected] (A.I.S.); [email protected] (A.Z.)
2 Solartech-UK Ltd., 11 Llansannor Drive, Cardiff, Wales CF10 4BW, UK; [email protected]
* Correspondence: [email protected]
Abstract: Wireless Sensor Networks (WSNs) are promising technologies for exploiting in harsh envi-
ronments such as can be found in the nuclear industry. Nuclear storage facilities can be considered
harsh environments in that, amongst other variables, they can be dark, congested, and have high
gamma radiation levels, which preclude operator access. These conditions represent significant
challenges to sensor reliability, data acquisition and communications, power supplies, and longevity.
Installed monitoring of parameters such as temperature, pressure, radiation, humidity, and hydrogen
content within a nuclear facility may offer significant advantages over current baseline measurement
options. This paper explores Commercial Off-The-Shelf (COTS) components to comprise an installed
Internet of Things (IoT)-based multipurpose monitoring system for a specific nuclear storage situation
measuring hydrogen concentration and temperature. This work addresses two major challenges of
developing an installed remote sensing monitor for a typical nuclear storage scenario to detect both
hydrogen concentrations and temperature: (1) development of a compact, cost-effective, and robust
multisensor system from COTS components, and (2) validation of the sensor system for detecting
temperature and hydrogen gas release. The proof of concept system developed in this study not only
demonstrates the cost reduction of regular monitoring but also enables intelligent data management
through the IoT by using ThingSpeak in a harsh environment.
Citation: Sunny, A.I.; Zhao, A.; Li, L.; Keywords: low-cost sensor; energy harvesting; wireless sensor network; IoT; harsh environment;
Kanteh Sakiliba, S. Low-Cost
condition monitoring
IoT-Based Sensor System: A Case
Study on Harsh Environmental
Monitoring. Sensors 2021, 21, 214.
https://doi.org/10.3390/s21010214
1. Introduction
Received: 10 November 2020 According to the Nuclear Decommissioning Authority (NDA), on 1 April 2016 the
Accepted: 23 December 2020 total amount of radioactive waste is estimated to be 4.77 million m3 [1]. This increasing
Published: 31 December 2020 amount of waste material, which needs to be stored, treated, and disposed of in a proper
manner, presents a great number of technical and temporal challenges for the nuclear
Publisher’s Note: MDPI stays neu- industry [2]. In the decommissioning site at Cumbria, United Kingdom, the majority of
tral with regard to jurisdictional clai- the country’s nuclear wastes are currently stored on site. Depending on the type and
ms in published maps and institutio- radioactivity, varying storage strategies are applied within this site. One of the legacy
nal affiliations. storage facilities at Sellafield requires extraction of the historic Magnox Swarf, which is
followed by packaging the material for interim storage before the final processing of the
geological disposal. Over many decades of interim storage, a monitoring system needs
Copyright: © 2020 by the authors. Li-
to be implemented in order to predict the correct chemical evolution of the waste, which
censee MDPI, Basel, Switzerland.
is mainly affected by the release of hydrogen gases and heat dissipation. This requires
This article is an open access article
an assurance monitoring scheme in order to make sure that the hydrogen emissions and
distributed under the terms and con- temperature of radioactive waste are well within the accepted parameter ranges.
ditions of the Creative Commons At- The Internet of Things (IoT) is composed of numerous inter-related and interconnected
tribution (CC BY) license (https:// devices, machines, and objects sharing data over a network aimed at reaching a common
creativecommons.org/licenses/by/ goal [3]. Being an enabling technology of Industrial Revolution 4.0, the goal of the IoT is to
4.0/). allow things and objects to be connected anytime and anywhere with anyone using any
network, path, and service. Nowadays, the IoT is offering innovative solutions through
advanced sensing technologies for major industries, e.g., healthcare services, the food
supply chain, mining production, transportation and logistics, and firefighting [4]. The
nuclear industry is no exception. One of the crucial aspects of the IoT is data management.
Intelligent data management and data processing within the IoT system through the help
of advanced Artificial Intelligence (AI) techniques [5,6] will further enhance the nuclear
waste management productivity, safety and durability.
The primary parameters of interest in the condition monitoring of legacy nuclear
waste containers are temperature variation and hydrogen gas release rate. Innovative ways
to efficiently monitor these parameters from every container utilizing wireless data transfer
could provide a greater level of safety assurance over a longer period of time. Numerous
research projects have been carried out on Wireless Sensor Networks (WSNs) for varying
applications, but the main difference with respect to the gaseous sensors used in WSNs
is the power consumption. Some investigations are focusing on the implementation of a
WSN-based air monitoring system. Each reported solution varies in the type of sensors
tailored for the individual case for the purpose of optimizing power consumptions. To
the best of the authors’ knowledge, there are no existing cost-effective devices that have
been developed for the nuclear waste storage application. Different energy harvesting
techniques have also been applied to develop such systems such as shown in Wang et al. [7].
They developed a wireless sensor network system where a solar panel is mounted on the
sensor node, harvesting constant energy and providing adequate power to the sensors. A
study on low-power Surface Acoustic Wave (SAW) sensors has been carried out in order to
address the energy issues [8]. Furthermore, a reduction in power consumption has been
adopted based on the duty cycle measurements using off-the-shelf sensors [9,10]. In addi-
tion, other low-power sensor systems have shown huge potential in harsh environmental
conditions [11–15]. However, none of these sensors have taken into consideration the
extreme environmental effects when deployed in real scenarios, such as high temperatures,
release of hazardous gases, or changes in atmospheric conditions. Moreover, all of the
aforementioned systems require bulky equipment to be connected in order to extract data.
The purpose of this paper is to develop a low-cost, compact, multimodal characteri-
zation sensor system with the current state-of-the-art, Commercial Off-The-Shelf (COTS)
components. The IoT could provide an installed remote measurement system on each
legacy nuclear waste container, thus providing a real-time understanding of the condition
of the entire nuclear waste storage content deployed for in-situ or ex-situ measurements. In
the paper, we have focused on the characterization of the sensors’ behaviors and firmware
optimization. The outcome is a qualitative estimation of the gas concentration, which is
essential to discriminate the small changes that will be presented as a result of changes in
chemical reaction rates.
The paper is organized as follows: Section 2 describes the sensing principles, the
sensor selection, and the proposed integration, followed by a description of the sensor
calibration. Section 3 outlines the experimental setup. Section 4 presents the results and
discussions. Finally, in Section 5, the conclusions and the future development perspectives
are described.
The sensors used in the project are in the MQ family along with the Bosch Sensortec
BME680. To achieve the sensing and monitoring function, the system is constructed using
two solar panels for energy harvesting with a chargeable battery and a power management
circuit, a hydrogen sensor MQ-8, a multifunction environment sensor BME680, a Wi-Fi
Module ESP8266EX, and a Wemos organic light-emitting diode (OLED) display. The circuit
connectivity can be seen in Figure 2. The power lines deliver the electricity from the energy
harvesting and the power management module to the sensors and the communication
module, which is shown as blue lines in Figure 2. The environment data are collected
in two forms: analogue data and digital data. The digital data are transmitted via I2 C
buses, shown as brown lines. The Serial Clock Line (SCL) is sent by ESP8266EX as a clock
signal and the Serial Data Line (SDA) as a bidirectional data signal. The analogue data are
collected directly using the ADC (Analog to Digital) port of the microcontroller, which is
shown as pink lines. Then, the ESP8266EX module can send the data to the base station via
self-contained Wi-Fi protocol. The specifications of the components are introduced in the
following section.
with constant 5 V. The DC–DC converter that is already embedded in the ESP8266EX
Board converts the circuit voltage to 3.3 V. The power of the circuit (without the Hydrogen
sensor) is 0.1 W. Therefore, the energy for one day is about 2.4 Wh/day, assuming that
the power is on for 24 h. The MQ-8 sensor uses 0.5 W of power due to the embedded
heater; hence, the energy for one day is 12 Wh/day. In short, the total power of the circuit
including the hydrogen sensor MQ-8 is 0.6 W, and the total maximum energy consumption
is 14.4 Wh/day.
Figure 4. Example of data representation through the Application Programming Interface (API)
provided by the open application platform Thingspeak.com.
a way that it can recognize the number of gases simultaneously. The MQ family sensors
are capable of measuring the concentration and substances that co-exist in a mixture. In
the calibration process, we used a voltage sensor to adapt a voltage result of the gas
sensor [19]. The first formula is used in [20], showing it is nonlinear for the sensor with gas
concentration (1):
− β
R/R0 = 1 + k gas Cgas (1)
where R is the sensor resistance, R0 is the sensor resistance, Cgas the concentration of the
used gas, β is the law of the characteristic power of the sensor, and kgas is the gas constant.
The formula shows a power function with a negative exponent as:
According to [20], the formula for measuring the clean air resistance with a known
supply voltage VCC and a load resistance R L of 10 kΩ can be found as:
R L (VCC − Vout )
Rclean_air = (3)
Vout
where
R L = Load resistance
VCC = Sensor supply voltage
Vout = Output voltage
Therefore, the sensor resistance R0 can be determined by the ratio of clean air resistance
and air ratio as stated as below:
R
R0 = clean_air (4)
airratio
Rclean_air is the sensor reference resistance for clean air. airratio = 9.56 and represents a
constant of the MQ-8 sensor.
If ppm is the gas concentration in parts per million, then according to nonlinear
regression, the output equation of the sensor is:
n
R gas
ppm = m (5)
R0
R gas
log( ppm) = logm + nlog (6)
R0
R gas
logm+nlog( )
ppm = 10 R0
(7)
In the equations, Rgas is the sensor resistance in the presence of gas. The subscript gas
stands for certain gases where H2 is hydrogen. From the datasheet, there is no formula pro-
vided for each gas type of MQ sensor. Using the datasheet’s graphical representations [16],
we extracted the formula of gas and this is shown in Figure 5.
We used the MQ-8 sensor to extract the points on the graph (log ppm H2 = logm +
RH
nlog( R02 )) for H2. A set of points was extracted using WebPlotDigitizer to get a mathematical
model that matches the data. Figure 6a shows the sensitivity curve, which shows the VRL in
hydrogen with different concentrations and that the resistance load RL is 10 kΩ, and Figure
6b shows the long-term stability curve. The response graphs of the sensor provided by the
manufacturer are plotted under standard conditions [16]. It provides the baseline of the
characterizations for different practical applications, in this case, nuclear waste storage.
Sensors 2021, 21, 214 7 of 12
𝑜𝑔(𝑝𝑝𝑚𝐻2 ) 𝑙𝑜𝑔𝑚 +
𝑅𝐻2
𝑛𝑙𝑜𝑔( ))
𝑅0
10 kΩ, and
Figure 5. WebPlotDigitizer plotting for the MQ-8 sensor to extract the point for H2.
𝑜𝑔 𝑝𝑝𝑚 𝑙𝑜𝑔𝑚
𝑛𝑙𝑜𝑔
(a) (b)
Figure 6. Sensor characteristics: (a) the sensitivity curve; (b) the long-term stability curve [16].
shielding is required, and neither is a communication protocol with loss detection and re-
transmission. A 3D model rendering image is shown in Figure 7, which depicts the stacking
up of the legacy nuclear waste containers within the storage facilities. The containers have
four filters on the lid to vent hydrogen gas to the ambient. The sensors can be fixed in the
vicinity of the filters. Therefore, to replicate the scenario in a laboratory-based experiment,
a small stainless steel cubic box was used for the validation of the multidetector sensor’s
performance within the metal’s proximity.
Figure 7. Concept design for legacy nuclear waste containers containing the four filters. The filters
are recessed and screwed into the box lid, which provides two pathways to each filter.
(a) (b)
Figure 8. Experimental validation setup: (a) scenario 1 and (b) scenario 2.
Sensors 2021, 21, 214 9 of 12
In scenario 2, a hydrogen gas bottle is used to generate a hydrogen stream in the metal
container and increase the hydrogen concentration level inside. The stream is produced
at ambient temperature and guided into the metal box. This is shown in Figure 8b. The
environmental parameters are monitored during the process for analyzing the influence of
the hydrogen concentration increase.
Figure 9 below shows the overall sensor system prototype. The total size of the
prototype is only 3 cm high, 6 cm long, and 1.5 cm wide with the PTFE casing, which has a
temperature tolerance of up to 250 ◦ C, used to protect the electrical components.
Figure 9. Compact robust multisensor system prototype in a thermally resistant PTFE case.
through the small window or via the heat interchange through the metal wall. Notably, the
error bar between different tests is also smaller than the outside results for temperature
and pressure measurement. It suggests that the inside measurement is more stable.
(a) (b)
(c) (d)
Figure 10. Scenario 1 test results for both inside and outside the stainless steel box: (a) Temperature; (b) Humidity;
(c) Pressure; and (d) Air quality index.
Figure 11. Scenario 2 test results for the detection of H2 components in comparison with the other
environmental parameters.
It is shown that the hydrogen concentration level starts to increase as the stream starts,
which shows that the hydrogen sensor is working properly. At the same time, it shows
a decrease in all other parameters. The decrease in temperature can be explained by the
temperature decrease, which happens when the pressurized gas is released from the bottle.
As there is no water content in the hydrogen stream, the humidity also decreased during
the process. The pressure seems to decrease but is actually increasing and decreasing due
to environmental influence.
Author Contributions: Conceptualization, A.I.S. and S.K.S.; Investigation, A.I.S. and A.Z.; Method-
ology, A.I.S.; Validation, S.K.S.; Visualization, A.I.S. and A.Z.; Writing—original draft, A.I.S. and
Sensors 2021, 21, 214 12 of 12
A.Z.; Writing—review and editing, A.I.S., A.Z., and L.L., Supervision, L.L. All authors have read and
agreed to the published version of the manuscript.
Funding: This research received no external funding.
Institutional Review Board Statement: Not applicable.
Informed Consent Statement: Not applicable.
Data Availability Statement: Data sharing not applicable.
Acknowledgments: The authors would like to thank the Design and Prototyping Group of AMRC
for providing CAD design support.
Conflicts of Interest: The authors declare no conflict of interest.
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