Challenges

Gas pump stations are particularly vulnerable to temperature fluctuations, especially during colder months. The freezing of additives within pump lines not only risks operational downtime but also poses safety hazards to customers attempting to use the affected pumps. The lack of real-time temperature monitoring left this gas station operator without the necessary visibility to take proactive measures, leading to potential fuel contamination and service interruptions. Additionally, any solution implemented needed to be scalable, reliable, and capable of integrating seamlessly with existing systems.

Solutions

Our team provided a comprehensive IoT solution that included both the architecture design and  installation proposal, ensuring a robust and scalable approach to the major gas station operator's needs.

Temperature Sensing and Control:

We utilized the Milesight controller as the core device for temperature monitoring and control. This controller was equipped with an RTD (Resistance Temperature Detectors) to monitor ambient temperatures around the gas pumps. The UC300 supports both 4-20mA, 0-10V input signals, and PT100 sensors, providing flexibility in sensor selection and ensuring accurate temperature readings across a broad range.

Relay Output and Automation:

The controller’s relay outputs were configured to automatically deactivate the pumps when temperatures dropped below a critical threshold (e.g. 15°F) and reactivate them once temperatures rose above the safe level (e.g. 20°F). This automation ensured that the additives within the pumps remained fluid, preventing freezing and maintaining operational integrity.

Communication and Alerts:

To ensure real-time communication, the system leveraged the LoRaWAN communication protocol for data transmission, enabling continuous monitoring and control via the client cloud platform. Additionally, visual alert systems were installed on-site, including LED indicators and digital signage, to inform both staff and customers of pump status changes. SMS alerts were also integrated to provide timely notifications to staff, allowing for immediate response to any operational issues.

Scalability and Flexibility:

The solution was designed with scalability in mind. The system architecture allows for the addition of wireless temperature sensors and remote relay controls, making it adaptable to other operational scenarios or additional pump stations. Furthermore, the hardware was protected within an IP68-rated enclosure to withstand outdoor conditions, ensuring long-term reliability.

Results

The architecture we developed provided the gas station operator with a robust framework for managing temperature-related risks. The solution enabled real-time monitoring and automated control, reducing the likelihood of additive freezing and ensuring continuous operation during cold weather. With the ability to scale and integrate the system across multiple sites, the operator is now better equipped to maintain reliable service and customer safety in challenging conditions.

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This case study illustrates the value of a well-designed IoT architecture in addressing specific operational challenges, offering both immediate solutions and long-term benefits for businesses in critical service sectors.