oil well monitoring and control based on wireless sensor ... · sensor (ultrasonic sensor)...

Oil Well Monitoring and Control Based on Wireless Sensor Networks using

Atmega 2560 Controller

R.Barani 1

, Mrs.V.Jeya lakshmi 2

1PG Part Time Student, ECE Department, Anna University, Chennai

2Assistant Professor, ECE Department, Kamaraj College Of Engineering and Technology,

Virudhunagar, Tamilnadu, India

[email protected],

[email protected]

Abstract

Most of the Oil Pumping Units (OPU) are

manually monitored. This existing oil-pumping

systems use a high power-consuming process, is

incapable of OPU’s structural health monitoring.

In this paper, a sensor network based intelligent

control is proposed for power economy and efficient oil well health monitoring. The condition

of the oil storage tanks can be monitored using

sensors like level sensor, temperature sensor and

gas sensor. These sensors are fixed inside the oil

storage tanks. The sensor output is given to a

microcontroller located in each oil well. Based on

the condition of the oil storage tanks, the oil

pumping motor is controlled. The monitored

information about each oil well is wirelessly

transmitted to an administrator located in a remote

location. By this method, multiple oil wells within

the transmission range of the wireless sensor

network used can be monitored and controlled.

1. Introduction

Sensor networks have drawn much attention for

their broad practical applications-investigate

specific sensors and sensor networks for air-craft

structural health and performance monitoring. A

real-time radiological area monitoring sensor

network is developed in for emergency response.

In this paper, a sensor network based intelligent

system is proposed for remote oil well health

monitoring and automatic oil-pumping control. The

motivation of developing this system is that 1) due

to the special nature of oil exploration and oil

drilling, the majority of oil pumping units are

spread over barren hills, mountains and deserts, and

2) the existing oil-pumping systems still adopt

manual control.

Existing manual control systems have three

evident drawbacks: 1) The OPU administrators

have to frequently go to the oilfield to check the

OPU status and collect its health analysis data. For

the sake of the harsh oilfield environment,

especially in the winter when it is chilly and

snowing overspreading the whole oilfield, it is

quite difficult to effectively manage and maintain

all OPU manually. 2) Power consumption for OPU

is huge during the oil-pumping process. Especially

in barren oil wells, power wastage is extremely

high because each oil-pumping is not filled under

such condition and thus oil production greatly

drops even though the OPU pumping stroke

remains high. And 3), since an administrator has to

take charge of a number of oil wells, an OPU

malfunction is difficult to locate and repair in a

reasonable time, which causes an oil production

drop.

To overcome these three disadvantages of the

existing manual control system, a sensor network

based automatic control system is proposed for

OPU management and oil well health monitoring

based on wireless sensor networks using Atmega

2560 Controller.

Monitoring multiple oil wells: The proposed

system consists of three-level sensors:

First level sensors (FLS) – designed with a

temperature sensor, a level sensor and a gas

sensor used for oil well data sensing.

Intelligent sensors (IS) –control head (Atmega

2560 Controller) performs significant

malfunction detection and indication based on the elementary processing of data, such as

short circuit and over current.

Third level sensors (TLS) -PC is used for

receiving data from the control heads

periodically and for monitoring the Oil

Pumping Unit from a remote location using

zigbee.

R Barani et al , International Journal of Computer Science & Communication Networks,Vol 3(6),341-346

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ISSN:2249-5789

Figure 1. Block diagram of monitoring and

intelligent control

Proposed Methodology:

Setup for a single oil well

Figure 2. Proposed system methodologies

2. System Descriptions

The IS consists of the following three modules:

a central processing unit (CPU) module, a sensing

module, a wireless communication module and a

user interface module.

1) Sensing Module: It consists of temperature

sensor, level sensor and gas sensor for data sensing

from an Oil Pumping Unit. The unit converts all

measurements into electrical signals and then

transports them into its corresponding control

heads.

Ultrasonic sensor

Ultrasonic Sensor is used for Oil level measurement in Oil storage tank. The sensor

is fixed at the top of the tank facing the oil

stored.

Working Voltage : 5V(DC)

Working Current : max 15 ma

Working frequency : 40HZ

Output Signal : 0-5V (Output high when

obstacle in range)

Sentry Angle : max 15 degree

Sentry Distance : 0.02m - 5m

High-accuracy : .01m

Input trigger signal : 10microseconds TTL impulse

Echo signal : output TTL PWL signal

Size : 45*20*15mm

Figure 3 Example of Ultrasonic sensors

Temperature Sensor (LM 35):

Temperature Sensor is fixed inside the oil

storage tank.

It can sense temperature from -40 to 85 degree Celsius.

Figure 4. Example of Temperature sensor

Gas sensor:

High sensitivity to LPG, isobutene, propane.

Small sensitivity to alcohol, smoke.

Fast response.

Stable and long life.

Simple drive circuit

Figure 5. Example of Gas sensor


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2) CPU Module: The CPU in our system is

ATmega2560 microcontroller. It is a standard AT

mega core CPU make suitable for industrial

control.

Figure 6. ATmega2560 Microcontroller

Microcontroller ATmega2560, Operating

Voltage 5V

Input Voltage (recommended) 7-12V, Input

Voltage (limits) 6-20V

Analog Input Pins 16

Digital I/O Pins 54 (of which 14 provide PWM

output)

DC Current per I/O Pin 40 mA

DC Current for 3.3V Pin 50 mA

Flash Memory 256 KB of which 8 KB used by

boot loader

SRAM 8 KB, EEPROM 4 KB

Clock Speed 16 MHz

3) Wireless Communication Module: ZIGBEE

module is used for wireless transmission between

third level sensor and intelligent sensor.

Figure 7. Zigbee Wireless Communication

X bee Series2.

IEEE 802.15.4 standard for wireless

communication. Its range is 100-130

meters.

Reliable and requires lower power for

operation.

It has a date rate of up to 256kbps.

Ideal wireless module for communication

between control heads and PC, Cost

effective

3. Hardware & Software Requirements:

Hardware Required

Microcontroller ATmega2560 Level

Sensor (Ultrasonic Sensor)

Temperature Sensor (LM35)

Gas Sensor

Zigbee Series 2 Module

PC

Software required

Arduino C

X-CTU

4. Results & Discussion

Microcontroller Atmega 2560 controls the oil

pumping unit based on the values read by the level,

temperature and gas sensor. Microcontroller Atmega 2560 controls the oil

pumping unit based on the values read by the level,

temperature and gas sensor.


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Figure 8. Oil well parameter output 1

The normal temperature of the oil storage tank is preset as 50°C. When the output of LM35 goes

above 50°C, the oil pumping motor should be shut

down. When the temperature lies below 50°C, the

oil pumping motor keeps running.

In figure 8, the temperature of oil well is

53.90°C. The oil level is normal, but, the

temperature is above the threshold value. So, the oil

pumping motor of oil well is shut down.

Inside the oil storage tank, the normal

concentration of combustible gas level is 300ppm.

Under normal conditions, the oil pumping motor

keeps running. When the concentration of

combustible gases like natural gas, iso-butane is

high, the gas sensor output is greater than 750ppm

and the oil pumping motor is shut down.


In figure 9, the gas sensor output is 807. Since,

the concentration of gas is above the threshold

value, the oil pump is shut down.


In Figure 10 shows the working of level sensor

of oil well. The threshold value for level sensor is preset as 5cm. When the level sensor output falls

below 5cm, it shows that the oil storage tank is

almost full and the oil pumping motor should be

shut down. In figure 10, the level sensor output is

3cm and so, the oil pump is shutdown.

Table 1. Tabulation by varying input parameters

OIL WELL SENSORS OUTPUT

S.No

Temperature

(cm)

Level

(cm)

Gas

(ppm)

Motor

Condition

1 35.28 22 262 Runing

2 24.99 23 807 Shutdown

3 35.28 36 802 Shutdown

4 54.39 37 235 Shutdown

5 66.64 37 241 Shutdown

6 34.79 5 274 Shutdown

7 32.34 4 254 Shutdown

8 35.77 15 255 Running

9 35.28 3 255 Shutdown

10 53.90 30 243 Shutdown


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This table 1 shows the oil parameters

output.These outputs are obtain from

temperatue,level and gas sensors respectively.

Hardware Design Layout:

Figure 11. Top Elevation of Hardware Design

Figure 12. Bottom Elevation of Hardware Design

Figure 13. Atmega 2560 Microcontrollers

Figure 14. Control Circuit of dc Motor

Figure 15. Zigbee series 2 Module & Transmitter

Sensors

In the proposed system, the following sensors are

used which is shown below.

Figure 16. Level Sensor HC-SR04

Figure 17. Temperature Sensor LM35


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Figure 18. Gas Sensor MQ-6

5) CONCLUSION

A sensor network based oil well remote health

monitoring and intelligent control system was

developed for Oil Pumping Unit management in

the oilfield. This system consists of level sensor,

temperature sensor and gas sensor for sensing the

condition of the oil storage tank. The control head

processes the sensor output values and controls the

oil pumping motor accordingly. The control head

transmits the condition of each oil well using a Zigbee transmitter. An administrator located in the

Zigbee receiver side can monitor the oil wells using

the X-CTU software and manual monitoring in oil

wells would be avoided. When the oil storage tank

is almost full, the oil pumping motor is shut down

and there is no wastage of power. The condition of

the oil well from a remote location is received at

the zigbee receiver end and can be displayed using

X-CTU software in the range of the wireless sensor

network. In the future, the range of the wireless

sensor network can be increased by increasing the

operating power of the network. When the range of

the wireless sensor network is increases, more

number of oil wells can be monitored from a

remote location and data transfer would occur with

minimum power requirement.

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oil well monitoring and control based on wireless sensor ... · sensor (ultrasonic sensor)...

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