ProLink System Uses LonWorks Technology to Pump Up Profits for Services Stations

The close relationship that exists between an American and his or her car has proved an intriguing topic for books, plays, movies, and numerous ad hoc conversations. Today millions of cars testify to our preferred mode of transportation, whether for work or for leisure. Petroleum, the fuel that literally drives our cars, is a treasured commodity.

Founded in 1878, Red Jacket Manufacturing Company, which merged with Hydromatic Pump Company in 1981, became Marley Pump Company.Today, Red Jacket Electronics, a division of Marley Pump, designs and develops electronic products for the retail petroleum industry.The company’s products, which monitor the underground storage tank system (including the tank, pressurized piping, and containment areas), help the petroleum industry comply with EPA leak detection requirements and manage their tank inventories. Red Jacket’s LonWorks based ProLink system provides comprehensive fuel management and compliance capabilities that save service stations a significant amount of money each year.

Real-Time, Continuous Fuel-Monitoring Capability Is Key Solution Driver

According to Kent Reid, general manager at Marley Pump, "The conventional method for measuring the volume of petroleum at retail stations was very time-consuming and inefficient. Someone at the station had to physically measure the volume by dipping a measuring tool into the tanks on a daily basis." The results, relayed to a distribution center, dispersed the requisite amount of fuel. "The measurements were often inaccurate," notes Reid. "This meant that the retail station would sometimes not receive an adequate fuel supply to service its customers." He adds that the delivery of excess fuel, on the other hand, resulted in extra carrying and inventory costs for the station.

Another problem involved the need to satisfactorily monitor the site for a potential fuel leakage. "Typically, a contractor would perform annual on-site tests for leaking tanks," says Reid. "However, this person would sometimes miss either the leaks or conditions that could lead to leakage." As a result, an affected station would have to close and would also face penalties for hazardous waste materials.

Red Jacket began searching for a solution that could accommodate the different types of retail station installations. "We needed an open, flexible architecture that could be easily tailored to meet the specific needs of individual stations," emphasizes Reid.Another design goal revolved around a compatible communications media. "We required a solution that eliminated communication issues, allowing us to concentrate on our core competencies and leak detection algorithms," explains Reid.

Red Jacket Selects Flexible Echelon Networking Platform

Echelon piqued the interest of Red Jacket early in their search. "One of our manufacturers used LonWorks technology and was very happy with the results," says Reid. "Echelon’s networks allowed us to provide a flexible design to our customers at a reasonable cost."

For example, some stations may only need to monitor their piping system.The ProLink system offers the required flexibility by providing a chassis that contains a Neuron®Chip, memory, digital display, and other network cards. These cards also incorporate a Neuron Chip, which communicates across a backplane to the chassis chip.The Echelon-based ProLink system monitors the lines for leaks and shuts down the pumps if a leak is detected.

Customers can also add other network cards that perform a specific function, such as tank gauging.

The ProLink system continuously monitors the petroleum levels of the underground storage tanks to obtain data on the level, volume, and temperature of petroleum. "As the temperature changes, petroleum products can either expand or contract," explains Reid. "This can potentially lead to tank leakage." The ProLink system also provides information on petroleum loss not caused by pumping or temperature changes. Red Jacket’s Pathway Plus‚ software program calculates and compares data from different sites to the actual fuel inventory to allow service stations to instantly spot shortages and calculate net volume loss or gain for each tank.

ProLink Substantially Reduces Risk of Leakages

The LonWorks based ProLink system significantly enhances both inventory gathering activities and the environmental security of underground petroleum storage tanks.The precise measurement capabilities of the automated system eliminate errors and help retail stations maintain a balanced petroleum inventory. "Petroleum is the lifeblood of these establishments," states Reid. "The inability to provide the required fuel to the customer would result in the shutdown of the business." A realtime, continuous monitoring capability also prevents leakages and the associated penalties imposed by the EPA. "Petroleum tank tests can now be performed with two-and-a-half hours of data collected by ProLink while the station is in full operation," comments Reid. "This eliminates 25-day test collection and site shutdowns, which result in lost revenues for the station."

For example, service stations can save up to $6,000 a year in costs associated with hiring a consultant to physically test the tanks for leakages. In addition, by eliminating shutdowns, stations avoid lost revenue from the sale of both fuel and peripheral purchases such as food, drinks, and car washes. Finally, by complying with regulations regarding hazardous waste materials, service stations can eliminate clean-up expenses that cost hundreds of thousands of dollars.

Key Benefits

• LonWorks based ProLink system credited for balancing inventory and preventing petroleum leakage
• Echelon’s open networks allow customer to provide flexible designs to meet specific needs of clients
• Service stations save up to $6,000 per year by automating petroleum leakage tests

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