Minimizing Hazardous Leaks in Large Oil Refineries with ICP DAS USA’s ZigBee Wireless Solutions
Introduction
As Industry 4.0 and the Industrial Internet of Things (IIoT) continue to advance, improving industrial safety has become a top priority. This case study highlights how ICP DAS USA used ZigBee wireless technology to implement a reliable gas leak monitoring solution for Taiwan’s largest petroleum supplier, helping improve safety while overcoming the challenges of monitoring a large refinery site.
The customer operates three refineries with a combined processing capacity of 720,000 barrels of crude oil per day, supplying approximately 70% of Taiwan’s oil demand. This project was implemented at a refinery in Kaohsiung, Taiwan.
Challenge: Gas Monitoring Across a Large Refinery
Covering approximately 170 hectares, the refinery includes dozens of large storage tanks spread across the site. Monitoring gas concentrations at multiple locations and transmitting data back to the control center posed significant challenges due to long transmission distances, extensive wiring requirements, and high installation costs.
To address these issues, the customer selected the ICP DAS USA’s ZigBee Gas Detection Solution, which provides reliable wireless communication and flexible deployment across large industrial facilities.
Solution: Flexible ZigBee Wireless Gas Detection
The ICP DAS USA’s solution uses the ZT-2017C ZigBee Current Input Module to convert signals from gas sensors into digital data. The information is transmitted wirelessly through the ZT-2510 ZigBee Repeater, extending communication coverage across the refinery. Data is then sent to the ZT-2570 ZigBee Converter and delivered to the control center via Ethernet.
Integrated with the SCADA system, the solution enables real-time gas concentration monitoring and alarm notifications, helping operators quickly identify and respond to potential hazards.
The system architecture is shown below:
Key Features and Benefits
Enhance Oil Refinery Safety with ICP DAS USA
The ICP DAS USA’s ZigBee wireless monitoring solution provides reliable gas leak detection across large refinery sites. By combining wireless sensing, mesh networking, and SCADA integration, the solution improves safety, reduces wiring costs, and enables real-time visibility into potential hazards.
Key Features and Benefits
Enhance Oil Refinery Safety with ICP DAS USA
The ICP DAS USA’s ZigBee wireless monitoring solution provides reliable gas leak detection across large refinery sites. By combining wireless sensing, mesh networking, and SCADA integration, the solution improves safety, reduces wiring costs, and enables real-time visibility into potential hazards.
Insert system architecture 2
Integrated Environmental, Safety, and Power Monitoring Solution
ICP DAS USA provides a comprehensive environmental, safety, and power monitoring solution designed for industrial facilities. The portfolio includes smart power meters, air quality monitoring modules, liquid leak detection systems, access control solutions, edge controllers, and cloud-based management software, enabling centralized monitoring, automated alerts, and improved plant safety.
Key Solution Components
Smart Power Monitoring
The PM Series Smart Power Meters deliver accurate, real-time energy monitoring and support multiple communication protocols, helping operators track energy usage and improve operational efficiency.
Air Quality and Gas Detection
The DL-1000 Series Air Quality Data Loggers monitor critical environmental parameters, including H₂S, CO, CO₂, O₂, particulate matter, temperature, and humidity. Built-in data logging and alarm functions provide early warning when gas concentrations exceed safe limits.
In refinery applications, the DL-1000 Series continuously monitors H₂S levels and triggers alarms through edge controllers when thresholds are exceeded, helping prevent safety incidents and environmental hazards.
Liquid Leak Detection
The iSN Series Leak Detection Modules work with sensing cables to detect liquid leaks from pipes, tanks, and other equipment. Leak events are immediately reported to the control center, enabling rapid response and reducing potential damage.
Access Control Integration
The tM-PD3R3 Digital Input & Power Relay Module supports plant access control systems by communicating with card readers and controllers. Authorized access can be managed automatically, while unauthorized access attempts can generate instant alerts for security personnel.
Wireless Data Collection and Communication
The MDC-211-ZT ZigBee Modbus Data Concentrator gathers data from multiple devices and simplifies communication between Modbus RTU and Modbus TCP networks. Its ZigBee wireless capability reduces wiring requirements and enables reliable communication across large facilities.
Intelligent Edge Monitoring and Alarming
The PMC-2241M IIoT Power Meter Concentrator combines data collection, remote monitoring, logic control, and alarm management in a single platform. Built-in automation rules can trigger notifications via email, messaging applications, and other channels when abnormal conditions are detected.
To prevent data loss, the PMC-2241M stores data locally during network interruptions and automatically synchronizes it once communications are restored.
Cloud-Based Management
IoTstar, ICP DAS USA’s IIoT cloud management platform, enables remote monitoring and management of controllers, sensors, and connected devices from a web browser. Users can view real-time data, monitor multiple sites from a single dashboard, and create customized visualizations tailored to their operational needs.
Conclusion
Maintaining safety in petrochemical facilities is essential for protecting workers, surrounding communities, and the environment. Early detection of gas leaks, liquid leaks, abnormal air quality conditions, and unauthorized access can significantly reduce operational risks.
Built on decades of experience in industrial automation, ICP DAS USA delivers reliable, application-focused solutions that help organizations improve environmental monitoring, enhance plant safety, and streamline operations. As industrial monitoring requirements continue to evolve, ICP DAS USA remains committed to providing innovative technologies that support safer and more efficient facilities.
