IOCL Tank Level and Flow Meter Monitoring via LoRaWAN (VC-13260089)

Project Background

Indian Oil, a leading energy company in India, sought to modernize its ethanol flow and storage monitoring systems across its facilities. With increasing regulatory demands and the need for enhanced operational efficiency, Indian Oil required a solution that would provide real-time data, ensure accuracy, and enable remote monitoring capabilities. Our team at Uniconverge Technologies was tasked with designing and implementing a comprehensive LoRaWAN-based solution tailored to meet these needs.

Challenges Faced by Indian Oil

Accuracy in Measurement: Traditional systems for monitoring ethanol flow and tank levels were prone to inaccuracies, leading to potential losses and safety risks.
Lack of Real-Time Data: The existing monitoring systems lacked real-time data capabilities, resulting in delays in decision-making and responses to potential issues.
Integration Issues: Indian Oil's diverse range of equipment across various facilities posed a challenge in terms of integrating a unified monitoring system.
Scalability Requirements: Indian Oil needed a solution that could be easily scaled and adapted to different locations and equipment types without significant infrastructure changes.

Solution Overview

To address these challenges, Uniconverge Technologies implemented a sophisticated LoRaWAN-based monitoring system, which comprised two core components:

Flow Meter Integration Using RS485 (Modbus)

Objective:

To achieve precise calibration and monitoring of ethanol flow, ensuring that Indian Oil could measure the total ethanol value accurately and reliably.

Implementation Details:

Flow Meter Selection: High-precision flow meters compatible with RS485 (Modbus) were selected. These meters were capable of measuring the flow rate and cumulative ethanol quantity, providing essential data for operational decisions.
RS485 (Modbus) Integration: The flow meters were integrated with RS485 (Modbus) communication, enabling seamless data exchange between the flow meters and the central monitoring system. This setup ensured that the flow data was transmitted accurately and without interference.
Calibration Process: A continuous calibration mechanism was put in place, allowing the system to self-correct and maintain accuracy over time. This was particularly crucial in ensuring that the ethanol measurements met stringent regulatory standards.
Data Transmission via LoRaWAN: The flow data was transmitted over a secure LoRaWAN network to the central monitoring hub. This wireless transmission not only reduced the need for extensive cabling but also enabled real-time data availability, accessible from any location.

Tank Level Monitoring Using Radar Level Sensor with RS485 (Modbus)

Objective:

To provide real-time monitoring of ethanol tank levels, preventing overflows and optimizing storage capacity utilization.

Implementation Details:

Radar Level Sensor Deployment: Advanced radar level sensors were installed on the ethanol tanks. These sensors, known for their accuracy in detecting liquid levels, were crucial in providing reliable data in diverse environmental conditions.
RS485 (Modbus) Communication: Similar to the flow meters, the radar level sensors were integrated with RS485 (Modbus) communication, allowing for consistent data flow to the central monitoring system.
Data Processing and Monitoring: The tank level data was continuously processed, with real-time alerts set up for critical thresholds. For example, if the ethanol level approached the maximum capacity, an alert would be triggered, allowing for immediate corrective action.
LoRaWAN Data Transmission: The radar sensor data was sent over the LoRaWAN network, ensuring that Indian Oil's operational team could monitor tank levels remotely. This was particularly beneficial for sites located in remote areas where traditional monitoring methods were not feasible.

Benefits and Outcomes

Enhanced Operational Efficiency: The implementation of the LoRaWAN-based solution allowed Indian Oil to monitor ethanol flow and tank levels in real-time, leading to more informed and timely decision-making.
Improved Accuracy and Compliance: The continuous calibration and high precision of the RS485 (Modbus) integrated devices ensured that Indian Oil met regulatory requirements and maintained high levels of operational accuracy.
Reduced Safety Risks: With real-time monitoring and alerts, the risk of tank overflows and other safety hazards was significantly reduced, ensuring safer operational conditions.
Cost-Effective Scalability: The LoRaWAN network provided a scalable and cost-effective solution, allowing Indian Oil to expand the monitoring system to additional facilities without extensive infrastructure investments.

Conclusion

The successful implementation of the LoRaWAN-based flow metering and tank level monitoring solution for Indian Oil marked a significant advancement in their operational capabilities. By leveraging advanced IoT technologies and integrating them with existing infrastructure, Indian Oil was able to enhance the accuracy, reliability, and scalability of its ethanol monitoring processes. This project not only addressed the immediate challenges faced by Indian Oil but also positioned them for future growth and technological adoption.