The Challenges and Capabilities of Remote Monitoring

Vast networks of buried pipelines that are vital for transporting fluids—such as oil, gas, and water—face the ongoing threat of corrosion. To ensure their safety and integrity, two approaches are used. First, a protective coating is applied before burial. However, since coatings aren’t failproof, a secondary defense called cathodic protection (CP) comes into play. This technique deals with corrosion threats in areas where the coating might have defects, safeguarding essential pipelines.

Cathodic protection is a long-established technique that dates back to 1824. Its idea depends on changing the pipeline’s electrical properties, transforming it into a large cathode (negatively charged electrode) within an electrochemical cell. By doing so, CP disrupts the natural corrosion process that would otherwise degrade the pipeline.

Manual Inspections and Their Drawbacks

Cathodic protection requires constant monitoring to ensure that it’s operating optimally. Previously, this monitoring had to be done on site, with measurements taken manually. Such visits involved sending technicians to remote CP sites so that they could conduct in-person inspections. This kind of monitoring posed safety risks and incurred expenses, along with many other disadvantages:

• Reactive, Not Proactive: Manual measurements reveal problems only after they’ve occurred (and sometimes progressed significantly). This leaves the pipeline potentially unprotected for a period, increasing the risk of corrosion damage. In particular, oil and gas companies—which are responsible for hundreds or thousands of miles of pipelines where a CP inspection is only possible annually or biannually—face this issue. Gaps in the CP performance data occur; so, if a CP system malfunctions, it won’t be detected until the next site visit. 

• High Cost: Sending personnel to take manual readings can be expensive, especially for extensive pipeline networks.

• Time-Consuming: Manual measurements can be slow, particularly for long pipelines with numerous test stations. This limits the frequency of checks and increases the window for undetected issues.

• Limited Data: On-site measurements provide only a snapshot at the time of reading. They don’t capture the continuous variations in CP levels that can be important for identifying trends and potential problems.

• Human Error: Manual data readings are susceptible to human error, which could lead to inaccurate data and missed problems.

• Safety Issues: Manual inspections put crews at risk from bad weather, travel to dangerous locations, and electrical hazards. These inspections also force skilled workers to shift their focus away from proactive pipeline maintenance and optimization tasks toward laborious and lengthy data collection activities.
  

Due to these drawbacks and regulatory requirements, it became necessary to install specific devices that could remotely and continuously send CP data to pipeline operators. 

What Are Remote Monitoring Systems?

Remote monitoring systems (RMSs) are devices that transmit CP measurements and performance data directly to dedicated teams. They eliminate the need for on-site visits and are currently being adopted by many companies due to the following advantages:

• Real-Time Insights: Remote monitoring eliminates the limitations of periodic inspections by providing continuous data on pipeline CP readings. This real-time information allows for early detection of potential problems, enabling preventive actions to be taken before incidents occur.

• Enhanced Safety and Efficiency: Continuous monitoring not only improves safety by reducing the need for crews to travel to remote locations, but also enhances operations by allowing for decisions taken to be based on real-time data of pipeline performance. This translates to reduced downtime and increased throughput, ultimately leading to cost savings.

• Regulatory Compliance: Remote monitoring systems simplify compliance with regulations set by agencies like the Pipeline and Hazardous Materials Safety Administration (PHMSA). PHMSA has mandated in its Title 49 CFR Parts 192 and 195 that pipeline operators must implement robust integrity management programs. These programs emphasize the use of advanced monitoring technology and remote monitoring.

• Remote Access and Data Accuracy: Remote monitoring allows for easy access to pipeline data, regardless of location. Automated data collection and transmission minimize the risk of human error associated with manual data collection, ensuring reliable and accurate data for informed decision-making.

The Drawbacks of Remote Monitoring Systems

Although remote monitoring systems offer significant competitive advantages compared to manual monitoring methods, there are still challenges that face RMSs.

Connectivity Concerns

Ensuring reliable cellular service in remote areas can be problematic for systems that rely on cellular networks for data transmission. Alternative solutions like satellite communication may be needed. However, a solution like that comes with the cost of increased power usage and the need for a stronger/larger power source or batteries.

Hazardous Environment Considerations

Pipelines are often situated in hazardous zones, requiring monitoring equipment to meet strict safety standards. This can increase development and deployment costs. 

Data Integration and Management

Managing the vast amount of data generated by multiple monitoring systems can be overwhelming. Robust data management strategies and infrastructure are essential. 

Cybersecurity Threats

Remote monitoring systems are susceptible to cyberattacks. Implementing strict security measures is important to protect against unauthorized access, data breaches, and system disruptions.

Corrosion Challenges

While these systems can monitor corrosion through CP measurement, pinpointing specific corrosion types can be difficult. Advanced sensors, such as electrical resistance probes, are often required.

Vendor Lock-In and Compatibility Issues

Switching remote monitoring providers can be hindered by vendor lock-in or limited compatibility between different systems. This can restrict the ability to adopt newer or better solutions.

Current Capabilities and an All-in-One Solution

Generally speaking, most remote monitoring systems on the market have the following capabilities:

• Measuring ON and Instant-Off CP Readings: The instant-off (I-Off) CP readings are taken by interrupting a transformer rectifier unit (TRU) and taking the reading, or by using a direct current (DC) coupon.

• Monitoring the Effectiveness of Critical Bonds Between Pipelines: To ensure pipeline integrity and safety of operation, current exchanged between bonds is measured and reported to ensure that bonds are effective between pipelines.

• Measuring AC and DC Density: This is used to determine if a pipeline is under the threat of alternating current (AC) corrosion. In this case, the AC density is measured and monitored over a long period of time and compared to the DC density. Combining these two types of data helps determine the effect of AC voltage imposed on the pipelines or whether the adopted AC mitigation strategy is effective or not.

Despite the capabilities listed above, most remote monitoring systems don’t provide a one-size-fits-all solution. For effective data collection, multiple hardware devices are needed to capture all the required information. 

A Next-Gen Remote Monitoring Solution

Some companies have been working on developing models that monitor various kinds of measurements. For example, GPT Industries launched its revolutionary RMS, Iso-Smart™, in early 2024. As an all-encompassing toolbox, Iso-Smart™ has several features and monitors many parameters.

1. On-Potential Readings: Unlike traditional methods that require manual surveys, Iso-Smart™ continuously monitors pipe potential, ensuring proper protection against corrosion. It sets alarms for out-of-range readings and reports them to the user, and allows for long-term data collection to identify trends and optimize CP systems.
   
   
2. Instant-Off Readings: Iso-Smart™ automates I-Off testing, eliminating human error and inconsistencies associated with manual methods. It provides precise, scheduled readings during current interruptions, offering a more reliable picture of CP effectiveness.
   
   
3. Coupon Testing: Iso-Smart™ measures both I-Off and current density of coupons, providing valuable insights into CP effectiveness. This goes beyond traditional coupon testing methods.
   
   
4. Continuous and Accurate Isolation Monitoring: Unlike manual methods, Iso-Smart™ provides constant monitoring of isolation levels, detecting potential issues and allowing for timely corrective actions.
   
   
5. Simplified Bond Monitoring: The built-in, high-precision current monitoring circuit eliminates the need for external equipment and provides accurate readings of current flow through bonds, ensuring proper functioning.
   
   
6. Advanced AC Monitoring: Iso-Smart™ can distinguish true AC from DC within a single signal, eliminating the need for configuration changes. Its in-depth analysis helps identify the exact amount of AC present and potential sources based on frequencies. It goes beyond detecting AC presence, allowing for proactive mitigation strategies. The advanced AC analysis is a breakthrough technology adopted by GPT Industries, enabling users to quickly identify the source of AC interference and eliminating guesswork.

Products like Iso-Smart™ are indicative of a new wave of RMSs that offer a complete solution for pipeline integrity management.

What the Future of Remote Monitoring Looks Like

Remote monitoring is becoming an inevitable tool to ensure pipeline integrity and safety of operation. Its future is bright, with many advancements appearing on the horizon. For example, GPT Industries is developing a unit that will work with satellite communication, enabling data transfer from any part of the world—even with no cellular coverage. 

Furthermore, advancements in artificial intelligence and machine learning will drastically improve data analysis. This will improve trend analysis, predict potential issues, and optimize maintenance strategies. It’s also expected that remote monitoring units will become smaller and more efficient, allowing for easier installation as well as integration with other monitoring systems and networks.