Minimizing Hazardous Leaks in Vast Oil Refinery with ICP DAS ZigBee Wireless Solution

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Introduction:

Within the context of Industry 4.0 and the Industrial Internet of Things (IIoT), the imperative of "Enhancing Industrial Safety through Smart Technology" is paramount. This case study by ICP DAS exemplifies the utilization of ZigBee wireless technology to implement a gas leak monitoring solution for Taiwan's largest petroleum supplier. By effectively addressing challenges posed by extensive plant layouts and mitigating potential hazards in oil refineries, this solution underscores the commitment to industrial safety.

The customer operates three oil refineries tasked with processing crude oil to produce essential raw materials for petrochemical manufacturing. Combined, these refineries boast a daily crude oil processing capacity of 720,000 barrels, contributing significantly to Taiwan's national oil supply. This case study focuses on a facility situated in Kaohsiung, Taiwan.

Challenges of Gas Leak Detection in a Vast Oil Refinery

Spanning approximately 170 hectares, the oil refinery encompasses 26 large oil storage tanks, each with a capacity of 6,000 cubic meters, alongside 8 massive tanks holding 50,000 cubic meters each. Monitoring numerous storage tanks concurrently and transmitting gas data to the control center across extensive distances present significant challenges, requiring extensive wiring efforts and incurring substantial costs. Additionally, constraints imposed by maximum wiring distances further compound the complexity of the situation.

To address these challenges, the customer opted for the ICP DAS ZigBee gas detection solution. Leveraging the unique characteristics of ZigBee wireless communication technology, this solution effectively tackles identified challenges and meets operational requirements with efficiency and reliability.

ICP DAS ZigBee Gas Detection Solution: Enhancing Flexibility and Efficiency

Within this "ICP DAS ZigBee wireless solution", the ZT-2017C ZigBee Current Input Module facilitates the conversion of current signals from sensors within oil storage tanks into readable digital values for gas concentrations. These data are then transmitted via ZigBee wireless communication to the ZT-2510 ZigBee Repeater, extending the reach of ZigBee signals to ensure stable transmission across the refinery. Subsequently, the data is relayed to the ZT-2570 ZigBee Converter and forwarded to the control center via Ethernet. The SCADA system facilitates gas concentration monitoring and alerts staff to potential hazards. The system architecture is illustrated below.

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ZigBee, based on the IEEE 802.15.4 specification, serves as an ideal wireless communication protocol for automation control and distributed control systems, characterized by simplicity, strong anti-interference capabilities, low cost, and high-security features. Supporting a large number of nodes and various network topologies, ZigBee enables message transmission via multi-hop mesh networking, ensuring uninterrupted data transmission over long distances.

The ICP DAS ZT-2017C ZigBee Current Input Module is designed specifically for analog signal conversion, featuring an 8-channel analog input module that converts current signals into readable digital values for gas concentrations. These data are then transmitted to the ZT-2510 ZigBee Repeater via ZigBee wireless communication.

The ZT-2510 ZigBee Repeater extends ZigBee signal transmission distance and range, ensuring smooth communication across the mesh network despite obstacles. Addressing challenges such as wiring difficulties and data transmission issues resulting from the refinery's vast size, the ZT-2510 facilitates signal extension from the ZT-2017C ZigBee Current Input Module.

The ZT-2570 ZigBee Converter supports both Modbus RTU and Modbus TCP protocols, receiving data via ZigBee wireless communication and transmitting it to the SCADA system in the control center via Ethernet. AVEVA Edge serves as a comprehensive platform for developing full-featured HMI and SCADA applications, equipped with essential tools such as OPC UA and OPC Classic, trends, alarms, reports, recipes, and built-in SQL database support. AVEVA Edge effectively monitors gas leak events in the oil refinery, providing integration and reporting capabilities for collecting and analyzing big data.

Enhancing Oil Refinery Safety with ICP DAS Environmental Monitoring Solution

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ICP DAS offers a holistic environmental and power monitoring solution tailored to industry-specific needs, including smart power meters for energy monitoring, air quality data logger modules for air quality measurement, liquid leakage detection modules for monitoring liquid leak events, and digital input & power relay modules for access control. This comprehensive solution facilitates environmental and safety management within the plant.

Conclusion:

Ensuring the safety of petrochemical plants is paramount for industrial, public safety, and environmental concerns. ICP DAS remains committed to developing new technologies and providing tailored solutions focusing on environmental monitoring and safety to meet the specific requirements of each application. Through continuous innovation and dedication to safety, ICP DAS strives to enhance industrial safety and mitigate potential hazards in petrochemical plants.

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