Pressmon prototype for Balongan

PressMon prototype: miniature Pressure Monitoring System

Overview

The PressMon prototype was developed as a miniature, or proof of concept, of the design for a Pressure Monitoring System for the Balongan Terminal to Plumpang Terminal pipeline. The actual system is designed to improve pipeline operating safety through continuous pressure monitoring, especially on the section that passes three booster pumps. It also provides web-based monitoring and functions that respond to abnormal conditions.

In the prototype, the field system is simplified to one DC booster pump and two pressure measurement points, PT-01 and PT-02. This setup represents the pressure change before and after the pump, data acquisition, pump control, local monitoring and remote monitoring.

Challenges

The main challenge was to turn a long-distance industrial system concept into a miniature that still shows the main working principles of the actual system.

Several functions had to be represented:

• Pressure monitoring at more than one point along the pipeline.

• Observing the pressure change caused by booster pump operation.

• Real-time data acquisition and processing.

• Local and web-based monitoring.

• Simulated pump start and stop control.

• A base for developing alarms and responses to abnormal pressure.

In the actual system, pressure transmitters are placed at strategic points to detect overpressure, low pressure, blockage or signs of leakage.

Solutions

The prototype uses an Arduino Nano to acquire data from the pressure transmitters and to control the equipment at the pump area. The Arduino receives data from PT-01 and PT-02 and controls the DC booster pump through a motor driver.

The data goes to a Raspberry Pi, which handles processing and visualisation. The Raspberry Pi runs a Python-based application and connects to a 7-inch LCD touchscreen for local monitoring. Through an access point, the data is also shown on a web dashboard built with Node-RED, so pressure and system status can be monitored over the network.

The prototype includes:

• Two pressure measurement points on the pipeline area.

• One DC booster pump that simulates a field booster pump.

• A switch and indicators for pump operating status.

• An Arduino Nano for acquisition and control.

• A Raspberry Pi for data processing.

• An LCD touchscreen for local monitoring.

• A Node-RED dashboard for web-based monitoring.

• A 12 VDC power supply for the prototype devices.

This setup is a simplified version of the actual architecture, which uses a PLC, a local HMI, pressure transmitters, network communication, and data integration to the control room. The diagram of the actual system also shows monitoring of run, stop and fault status, start-stop commands, and pressure on the three booster pumps.

Lessons learned

Building the miniature showed that the main concept of the Pressure Monitoring System can be validated at small scale before it is applied at a real facility. Two measurement points were enough to show the pressure change along the pipe and the effect of pump operation on system pressure.

Separating the roles, with the Arduino for acquisition and control and the Raspberry Pi for processing and visualisation, made the prototype easier to develop. However, this architecture is a demonstration. It does not directly represent the hardware standards, redundancy, protection or safety level required for an industrial implementation.

In an actual implementation, the alarm, interlock and Emergency Shutdown functions must use a control architecture and devices that meet operational safety requirements. The actual system is designed so that an abnormal condition can trigger corrective action, including a fast and safe pipeline shutdown.