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Proc.

of the 2014 9th International Conference on System of Systems Engineering (SOSE), Adelaide, Australia - June 9-13,
2014

Reliable Monitoring of Oil and Gas Pipelines using


Wireless Sensor Network (WSN) – REMONG
Husnain Saeed, Salman Ali, Sidra Rashid, Saad Qaisar Emad Felemban
National University of Sciences & Technology (NUST) Umm Al-Qura University
Islamabad, Pakistan Makkah, Saudi Arabia
{husnain.saeed, salman.ali, sidra.rashid saad.qaisar} eafelemban@uqu.edu.sa
@seecs.edu.pk

Abstract—Development in the domain of embedded Oil and gas industry has benefited from technological
systems and communication technologies have created an advancements, ranging from tiny sensors to actuators and from
industrial need to automate tasks and to render more small scale instrumentation to full scale industrial automation.
control. Rapid advancement in data processing Quite recently, WSNs have started to play their role in different
technologies, wireless communication, evolution of Micro- sections of oil and gas related industry since it provides
Electromechanical Systems, business intelligence, process sophisticated, powerful and long lasting easy to deploy
planning and control has created a room for improvement ‘sensing’ and ‘actuation’ solution. WSN technology is mostly
in all areas of industrial practices related to oil and gas oriented around power constrained solutions since sensor nodes
processing. Reliable monitoring whilst reporting to remote are deployed with view point of long life operation and
control rooms in a timely manner for oil and gas carrying reliability. However, in harsh and tough terrains as in pipeline
pipelines creates a bigger challenge due to its lengthy span. structures, sensor nodes may suffer death under a wide range of
In this paper, we investigate and propose an oil and gas catastrophic events from earthquake to explosions and network
pipeline monitoring solution based on wireless sensor related attacks or even power depletion. Hence, a rugged
networks with reliability focus on leakage sensing and design and practicality of sensor node according to the
wireless data communication. The system is developed environment to be monitored and application at hand is a
indigenously and provides capability of reporting pipeline critical task. The power issue has been addressed to some
health related statistics stretched over large geographical extent by employing ‘harvesting energy’ techniques, yet these
areas. are still in development phase while several diverse solutions
exist for other problems.
Index Terms – Oil and Gas Leakage Detection, Pipeline,
Sensing, Reliable Monitoring, Wireless Sensor Network, Since oil and gas sector heavily relies on pipelines for
ZigBee, Monitoring Software distribution purposes and processing facilities, these need to be
monitored in real time for any leakages, damages or potential
I. INTRODUCTION hazards. Without these measures, a leakage can both be
Centralized monitoring of oil and gas installations in financially devastating and can pose even bigger environmental
general and pipelines in particular lack in the aspect of hazard. Automation of pipeline monitoring and reliable
intelligent sustainable monitoring since long. This difficulty measuring of any infrastructural faults can thus provide
not only comes from the length of the pipeline infrastructure immense benefits. Hence an open platform is readily available
but also from the tough terrain and intense environment to share with research community any experience and insight
characteristics. Though, various techniques have been in implementing test-bed and sensing devices with applications
proposed for pipeline monitoring, mostly based around in fluid, oil and gas remote monitoring. In this perspective,
wireless solutions; an integrated solution for optimized reliable possibility of employing WSN technology for reliable
sensing to secure and timely data transfer over a remote control monitoring of pipelines has been explored, developed and
room is still lacking. Wireless Sensor Network (WSN) tested after thorough research. Various aspects of sensor device
technology has gained much importance for structural health design including microcontroller, sensor resolution and layout,
monitoring applications over the years due to rapid wireless communication platform; mechanical design for the
advancements in underlying technologies like sensing node and its thermal analysis as well as application specific
capability and resolution, communication protocols, processor software platform are discussed. From thorough analysis, it is
speed, energy harvesting and embedded systems. These claimed that the monitoring solution should be self-sustainable
developments are gradually being adopted in oil and gas and fully automated for a given period of time. The presented
industry to automate processes and to empower the system method would be capable of detecting leakages on its own, and
with more control. The use of sensors and actuation methods thereby informing central control about the locality and
have also gained strategic importance due to factors like intensity of the anomaly. Further, the system is designed to
business intelligence, competitive edge, time to market, quality deploy easily and encompass self-organizing, self-healing and
and reliability standardization for industry related fluid and robust working.
commodity movement, particularly the transfer of energy
related products like oil and gas. The remainder of the paper is organized as follows: Section
II provides literature review for similar wireless sensing

978-1-4799-5227-4/$31.00 ©2014 IEEE 230


solutions. Section III discusses in detail the developed solution Similarly, structural monitoring using sensor networks for
with testing parameters, design criteria and working multiple and distributed pipeline structures has been
specifications in detail. Section IV highlights wireless generically mentioned in [10]. Automation of sensor node
communication platform. Section V discusses mechanical deployment may be required in some scenario based
housing and material selection for the sensor node and its applications to counter tough terrains. A similar application is
feasibility. Section VI discusses Application Programming mentioned in [11]. Software related middleware plays an
Interface (API) and data monitoring dash board. Finally, important role in streamlining communication for wireless
Section VII concludes the work. sensor networks. A software level detailed description is
provided for developing a middleware for sensor nodes with
abstraction of hardware details as provided in [12]. Leakage
II. EXISTING SYSTEMS AND COMPARISON detection mechanism using various algorithms including
standing wave approach and its reliability has been mentioned
WSN can provision ubiquitous deployment for in [13][14].
infrastructure monitoring and are more suitable for
inaccessible, remote and hazardous environments. WSNs are Majority of the work done in sensor node deployment for
deployed in a highly dense form comprising of node clusters to pipeline monitoring either focuses on hardware details,
group specific tasked nodes together and to mange numerous software structure, data communication or leakage detection
amounts of sensing parameters systematically. Recently, with method. None has provided details and working of a system
the advancement of hardware resources, on board processing prototype for pipeline monitoring. The proposed WSN
has also benefited, and analysis of acquired data can now be architecture includes device design, inter-node communication
undertaken at sensor nodes for requisite information in a much and networking and analysis of logged sensor data. The node
intelligent and efficient manner. Infrastructure related converts measuring metrics from the attached sensors into
monitoring including oil and gas pipeline systems require a digital information to be read and acted upon by a remote
large pool of sensor nodes for monitoring. Each node in the monitoring facility. We can classify most important hardware
WSN network can act as a router in addition to its sensing resources as processing element, sensing unit, and power
responsibilities. Intelligent duty cycling of WSN nodes when manger and transceiver device. The sensing unit is directly
deployed on strategic locations of pipeline with efficient power connected to analog to digital converter (ADC) that provides
usage can allow the network lifetime to be extended to several direct data conversion from the sensor sub-unit. Since the
years. devices may be placed over large geographical monitoring
areas, the communication and networking must handle joining
Though wireless systems are now being deployed in large and leaving of hundreds of nodes while providing scalability.
numbers, optical systems prove more resilient in some cases. In Collection of data from each of the sensors is used to make
the optical fiber based oil and gas pipeline monitoring system reasonable judgments/decisions and analyze/detect the trends
[1], pressure, temperature and multiphase flow has been and patterns. For intelligently providing flexibility and
measured in a spatially distributed manner. The system allows reliability in WSN monitoring, factors like sensor layout, data
multiplexing of data, but the cost for building and deployment transmission methods, sensor node power concerns, data
are very high. In [2], a routing protocol for linearly deployed processing, analysis and inference points, operational design
sensor networks in oil and gas pipelines is mentioned. The and framework of nodes in addition to network topology,
system is optimized for low density deployment and infrastructure and sensing related technologies have been
communication efficiency; however the sensor reading related investigated.
resolution and reliability has not been mentioned. In the III. REMONG SOLUTION
magnetic-induction based pipeline monitoring system [3],
focus is on real time leak detection in both underground and Monitoring of oil and gas pipeline is a complex task
above ground pipeline. The magnetic induction based system is requiring a solution that not only senses minute changes in the
limited by the short range wireless communication problem. In fluid transfer and pipelines orientation but also reliably reports
the work mentioned by Jawhar et al. [4], a typical system for any events to remote central stations in minimum possible
wirelessly monitoring pipeline structures is provided. The work time. The REMONG solution caters aspects from reliable
is limited to broad description of the architecture design sensing to wireless transfer of events and sensing data in a
missing out the technical design details. In the work mentioned secure fashion whilst utilizing an indigenously developed
in [5], a leakage detection system is presented that relies on highly power efficient platform. For communication, the
pattern recognition algorithms. The work describes reliability system uses ZigBee modules that can be connected to a
and costs comparison for detecting different gases, however the standard ten pin UART connector. A touchscreen color LCD
technical architecture and deployment is not mentioned. In the interface is provided for user interaction with the board
work by Pakzad et al [6], a scalable wireless sensor network software and to set tunable parameters. A precision
implementation is mentioned for monitoring general structures. accelerometer is placed on the board to allow pipeline
An open source TinyOS software and hardware components orientation monitoring. The board's power source is a
have been used to demonstrate scalability of the system. In [7], rechargeable battery. The wireless sensor board is designed in
a system is presented to counter faults in infrastructure health an energy efficient way to prolong the board's runtime by
monitoring applications using sensor nodes. Self sustainability minimizing any current leakage sources in the circuitry. The
of wireless sensor networks and energy scavenging with wireless sensor board is designed to work in industrial
minimum power utilization and saving is mentioned in temperature range (-40 to 85 °C), with the LCD operation till -
[8][9][15] with focus on transmission related energy costs. 75 degree. The wireless sensor board is designed around a

231
microcontroller, to which several ICs and interfaces are The pipeline test bed for experimental verification of the
connected through different protocols as mentioned (Fig 1 and proposed solution is depicted in Figure 2. The pipeline network
2): integrates 14.1 meters long GI pipes with an internal diameter
of 2 inches in a horizontal placement. A water tank is used as
A. Microcontroller fluid supply source. The pipeline is connected with water tank
A 32-bit microcontroller based on the high-performance and an electrical motor to provide water flow in pipeline
RISC core operating at a frequency of up to 160 MHz is used. network. There are four valves in the pipeline layout to create
The microcontroller incorporates high-speed embedded artificial leaks for experimentation. Pressure transducers are
memories and an extensive range of enhanced I/Os and used to record the flow transients in the pipeline. The pressure
peripherals. A comprehensive set of power-saving modes transducers can be mounted at any location specified on the
including the sleep and hibernate for transceiver allows the pipeline.
implementation of a low-power monitoring application.

B. Interfaced Application Specific Sensors


A digital pressure and temperature sensor is used for
measuring pressure and temperature of the pipeline fluid. The
sensor selected is specially designed for oil and gas
environment parameters. The sensor power requirements are
kept at 5 V, 25 mA (max). These sensors can communicate
using RS-485, RS-23or SPI interfaces.

C. Communication Module
A ZigBee protocol based module is used for wireless Figure 2. Pipeline test-bed for testing the monitoring solution
communication. The communication module for the and the basic REMONG board
transceiver has a standard ten pins interface and a latest
ZigBee standard compliant transceiver can provide an outdoor A practical pressure trace collected from the experimental
range of 3200 m (2 miles), indoor range of 90 m (300 ft), setup with leakage is provided in Fig 3. These samples were
transmit power of +18 dBm and receiver sensitivity of -102 collected at a different sampling frequencies ranging from 500
dBm. Hz to 900Hz. It can be seen that this signal shows amplitude
decay due to presence of leak. However it is not easy to find
D. The Display Screen leak with visual inspection when the leak size is very small and
A resistive touch-screen color TFT (Thin-Film Transistor) slow and learning algorithms are therefore developed. Series of
LCD (Liquid-Crystal Display) is provided for user interaction experiments have been performed to collect pressure transients
with the board. The LCD is 2.4" diagonal in size, has 240 x by creating different size of leaks. The different leak sizes are
320 pixels with white LED backlight and can operate in the provided by opening the valve up to 25%, 50%, 75% and
range of -75 to +70 °C. completely opening the valve.

E. Power Supply A leak detection and localization algorithm has been


A rechargeable battery is used to provide power to the designed and applied on this trace set in a distributed manner.
wireless sensor board. A 2-cell 7.4 V Lithium Polymer Battery This algorithm uses the strength of wavelets to provide signal
Pack is used with the high capacity of 13,500 mAh. analysis in both time and frequency domains. The results to
pinpoint leakages are encouraging and provide the accuracy as
high as up to 90% as illustrated in following table.
Actuation (Motor, Solenoid, Alarm) Interface (Connected to connector1)
Table 1. Leakage detection results for HAAR, SYM and
Daubechies Wavelet
Interface

Multimedia S Haar Sym D4 Result of Success Rate %


Interface (VIA / Type Wavelet Wavelet Wavelet Signal
Connector2) N (Leak (Leak (Leak Analysis Haar Sym D4
Central o sample sample sample (Approx
Monitoring number) number) number) sample)
DATA Channel Microcontroller DATA Channel
CAMERA and Control Compression 274th 293rd 280th 270th 95.5 91.5 97.3
THERMAL EYE Unit 1
PIR CAMERA De-noising 300 th
300 th
300 th
270 th
90 89.5 92
PIR SENSOR
MICROPHONE
2 Compression 653rd 650th 651st 650th 99.5 99.9 100
Interface

De-noising 638th 636th 636th 650th 98.8 99 99.1

3 Compression 550th 380th 440th 500th 87 80 88


Discrete Sensors Interface RF Transceiver (DASH7,
DATA Communication
(I2C, SPI, UART, USB, RJ45) Zigbee, GPRS) De-noising 574th 380th 450th 500th 96 80 90

A comparison has been done between different types of


wavelets to detect leakage and it is found that debauches
Figure 1. The REMONG sensor board microcontroller with wavelets provide the best accuracy among the candidate
peripherals and interfaces wavelets [17].

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channel scan prior to network operation for selection of least
interfering channel. The channel scanning may take time in
orders of 122.88ms depending upon the spectrum condition.
The RSSI with ZigBee compliant devices in indoor and
outdoor environment (over pipeline structure) was calculated
with varying distances (Table 2). Omni directional low
sensitivity antennas were used to determine the minimum
Figure 3. A practical fluid pressure trace with leakage limitations of the signal ranges.
IV. DATA COMMUNICATION AND ROUTING
Table 2: Experimental results of Distance vs. RSSI, for
The UART communication interface can be integrated with ZigBee transcievers in free space and pipeline environment
standard Zigbee or DASH7 transceivers that would transmit at Distance RSSI (dbm)
2.4GHz or 400MHz frequency range. Both protocols would (meters) Outdoor Free space) Over Pipeline
allow data rates of maximum 250kbps with intermittent or Power Power Power Power
periodic signal transmissions, long battery life and secure (+2dBm) (-8dBm) (+2dBm) (-8dBm)
communications with use of already established security 5 -53 -55 -51 -55
algorithms. With use of a 128 bit symmetric encryption keys, 10 -54 -57 -52 -56
transmission distances may range from ten to half a kilometer 15 -57 -63 -56 -60
20 -59 -65 -59 -64
depending upon line of sight and antenna specifics. The 25 -64 -73 -63 -70
networking layer allows typical star and mesh topology 30 -68 -76 -67 -72
creation. Several node device types including a Coordinator, 35 -70 -79 -69 -75
Router and End node have been tested. The protocol allows 40 -72 -82 -73 -80
40 -72 -82 -73 -80
beacon, non-beacon, and CSMA/CA channel access
mechanism. The main functions of the communication layer
The pipeline infrastructure monitoring case requires linear
include data entity creation, MAC sub-layer control and
and hierarchical infrastructure layout for WSN node
routing using AODV and its variants. The Application
deployment (Fig 4). The sensory information from across
Support Sublayer (APS) is included as the main application
several zones of the pipeline are monitored and transmitted to
component that offers control services and interfaces while
cluster heads over several hops and kilometers to be
working as a bridge between network layer and other
transmitted by long haul transmission protocol including
components. The 433MHz Dash7 transmission improves
GSM. Important parameters considered for deployment of
range further to several kilometers and provides low latency
WSN in pipeline infrastructures include coverage distance,
for connection with non-stationary nodes at a maximum data
number of hops, number of nodes, sampling and energy
rate of 200kbit/s. The use of 433MHz provides robustness for
harvesting rates.
sensor applications against penetration in concrete and water
with the ability to receive signals at a larger range.

The sensor node coordinator needs to select either a 64-bit


or a 16-bit PAN ID in addition to a channel for transmission.
The ZigBee RF transmitter and receiver are assigned a 64-bit
format unique MAC address. When a node joins the network,
a 16-bit Network Address is used that is assigned by the
Coordinator. This address allows sending packets inside the
Figure 4. Linear Infrastructure monitoring using an aggregator
network so that overhead can be reduced. An ASCII string of
cluster head for WSN
20 characters is also used as a node identifier that allows
recognizing the application level flows. Sixteen sets of
In the linear pipeline monitoring topology, gateway or end
channels are used in the 2.400-2.480GHz range with a
nodes cannot communicate with other nodes more than one or
bandwidth with center to center frequency bandwidth of
two hops away. When the node wants to establish
5MHz. Different node types used inside the network are
communication and transfer packets with each other, it will
identified by a device type identifier. The basic transmission
send out broadcasts asking for the RSSI of other nodes in its
modes of the network include Unicast, Broadcast and Cluster
vicinity, and a table will be formed with RSSI of the
transmission. The Cluster transmission is used as an
neighboring nodes (Fig 5). The depicted initialization
application binding transmission flow between the cluster and
algorithm would be followed where the routing tables would
end nodes. The maximum payload size of the packet used
be built before sensing out sensor data.
inside the sensor network is 255 bytes or less depending upon
the encryption used. The power level ranges from 0 to 2mW in
The lifetime of the system can be improved by use of energy
discrete steps.
harvesting techniques as well as allowing nodes to utilize
multiple sleep cycles over an operational duty cycle. The
Concerning data transmissions, Received Signal Strength
reliability of the system would indirectly depend upon the
Indicator (RSSI) is an important factor that determines the
packet error rates, response time, packet delivery time, and
signal strength of the last RF receive packet. The ZigBee
power saving mechanisms, channel coding schemes,
module allows measuring RSSI as a function of interference
strength from 0dB to -86db. The coordinator node performs a

233
intelligent message aggregation, and resourceful node For thermal analysis, we have used the “irradiation”
placement over the entire length of the monitored area. process applied on the aluminum enclosure using
COMSOL[16]. The experiment is based on structural
Node Initialize
Broadcast Route
Wait 5 Sec mechanics thermal stress with time mode set as time
Request
dependent. We have calculated the hottest day for “Dammam”
city of 2013 which was 11th of July. By the Saudi Arab forecast
Time result, three time zones are selected. 08am, 02am (Fig 6) and
No
Over Increase
Power
Power
Maximum?
No Reply 8pm with time lapse of 6 hrs. The temperatures of these time
zones are 30◦C, 47◦C and 27◦C. The reasons behind these time
Yes zones are the maximum flow of irradiance on a metal surface.
Sleep for 2 Minutes
Coefficient of conductivity, thermal expansion rate and four
boundary conditions namely inside temperature (20◦C), outside
Update Routing
Table
New
Reply Type
Reply
Successul
temperature (zones), heat flux and fixed constraints were used
for test simulation purpose.
Old

For calculation of radiant or heat flux in thermal analysis,


Select Higher
RSSI enabled
Initialization
Complete
Start
Communication
we have used the Stefan Boltzmann Equation of radiant heat
Node
flux. The input variables for this equation are emissivity
constant ‘ɛ’. This emissivity constant is a measure of radiation
Communication
Failure/ Major Sleep
of the surface. In case of aluminum it is 0.4. Thermal proof
Period/ Other Issue paint will reflect the maximum radiation and reduce the
Figure 5. Sensor node initialization steps emissivity up to 0.1. Other variable is Boltzmann constant Ɵ
which has a constant value of 5.67e-8 W/m2K4. ‘T’ is the
V. MATERIAL SELECTION, MECHANICAL DESIGN AND temperature inputs that are 30◦C, 47◦C and 27◦C and
THERMAL ANALYSIS corresponding radiant flux.

Alloys of metals for manufacturing of device enclosure have


been used due to features like ductility, low cost, light weight VI. REMOTE MONITORING SOFTWARE DESIGN
and strong nature. Aluminum, low copper aluminum, stainless
steel and nickel aluminum alloy with a percentage of lithium The remote monitoring software solution comprises of three
have been used, related issues like poor insulation and parts: Dashboard, GUI and Middleware (Fig 7). The dashboard
interference with radio waves have been solved with use of provides real time monitoring of oil and gas pipelines. It
Polyurethane paint and raising the base of the antenna to provides in time alarm notifications to monitoring crew. In this
10mm height. The design of the device is a rectangular boxed way, the situation can be controlled without physical inspection
shape with slight curvatures at front (Fig 6). The dimensions which saves time and resources. It is accessible from any
of the enclosure are185x85x100 mm. There is a lid on the location over IP once the aggregator node transmits data over
back side which is detachable. A rectangular box at front of GSM network. It shows sensor data of different sensing nodes
the enclosure is used for the liquid crystal display. The box deployed over the pipeline infrastructure. The software
door can be opened to access LCD. For antenna, a base of includes a Menu Bar and a Tool Bar which enables us to
10mm is made for the assurance of no interference with the perform a set of functionalities mentioned below:
radio waves. The enclosure is balanced on the gas sensor
attached/coupled directly to the pipeline from top. The sensor A. Data Acquisition
is attached to the bottom of the enclosure. Rapid prototyping Advanced Messaging Queuing Protocol (AMQP) is used for
is initially employed for design and aesthetic outlook using sending data between the field and control room or the PC.
FDM machine and subsequently casting for mass production. Different queues are allotted for sensor data and are attached to
Proper mounting kits for the electronics are attached to the an Exchange which adheres to the AMQP standards. There are
inside of the enclosure. The sensor is balanced at the center of seven queues, namely: Temperature, Pressure, Date, MAC,
mass of the whole enclosure. RSSI, Battery and Number of Hops.

B. Data Representation and Maintenance


The data received from the middleware (AMQP) is
represented graphically and in tabular format. The parameter
values from sensor nodes are stored in respective database
tables. The Temperature, Pressure, Battery Levels data can be
uploaded onto the graphs or the tables.

To find out the location of sensor nodes, maps are included


in monitoring software. It is useful to get the idea of the
location where a leak has occurred. The sensor nodes are
represented by markers on the pipeline location in the map.
Figure 6. REMONG sensor node enclosure details with
temperature test simulation

234
C. Node Positioning are displayed in a very meaningful and elaborative way for
The node position represents an estimate of the actual node further analytics and interpretations.
deployed over the pipelines using node ID. It represents
relative location of the nodes in the network corresponding to ACKNOWLEDGMENT
their nodes in organized deployment case. However, when the
sensor nodes are deployed sporadically; RSSI and MAC This work is part of the REMONG project supported by the
address can be used and displayed for each node in the National Science, Technology and Innovation Plan, Saudi
software panel. Arabia grants: NSTIP-10-ELE1238-10. We are also thankful
for the assistance provided by Mr. Kamran Afridi, Mr. Adnan
Ashraf and Mr. Tayyab Shahid from NUST Pakistan.

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