Case study: Monitoring Corrosion Under Insulation in ATEX/IECEx hazardous areas

February 18, 2020

Case study: Monitoring Corrosion Under Insulation in ATEX/IECEx hazardous areas

 

CorrosionRADAR leverages wireless technology to provide long-range Corrosion Under Insulation (CUI) monitoring. When they needed a way to deploy their innovative solution safely to customers in ATEX and IECEx hazardous areas, they turned to Extronics. With our grounding in wireless expertise and long years of experience providing safe products for hazardous areas since 1992, we were able to find the best way forward.

 

Read the case study: Monitoring Corrosion Under Insulation in ATEX/IECEx hazardous areas

Extronics-Corrosion Radar Case Study

The Background

CorrosionRADAR designs and supplies the world’s longest-range Corrosion Under Insulation (CUI) monitoring technology for pipelines, refineries, and more. The patented system enables proactive automated monitoring instead of time-consuming and reactive manual inspections – reducing downtime, reducing risk, and reducing costs.

Corrosion and moisture sensors are permanently embedded adjacent to pipelines, tanks, towers or vessels, under any insulation. These sensors then provide real-time data on the asset health with regards to corrosion or moisture presence. The CorrosionRADAR system can localise any corrosion under insulation, allowing early repairs to be undertaken. This minimises corrosion damage and enables focused efficient inspection and maintenance programs. This is a vast improvement over standard Risk Based Inspection (RBI) approaches.

 

The Challenge

CorrosionRADAR’s ground-breaking solution is well-suited to use in industries such as oil & gas, chemical or petrochemical, where the impact of corrosion is high and where it is impractical and expensive to continuously monitor assets using current inspection technologies. However, their system needed to be certified for use in hazardous areas with potentially explosive atmospheres, which is required by many of their customers.

They needed a way to install their patented sensors into ATEX and IECEx hazardous areas to better serve their customers. The sensors also connect via wireless gateways to deliver information back to the control centre, so they needed a partner who understood how to maintain peak wireless performance whilst ensuring the safe operation of specialist wireless equipment in explosive atmospheres.

 

The Solution

For help making their innovative system suitable for use in hazardous areas, CorrosionRADAR turned to Extronics. With over 25 years’ experience in designing and manufacturing for explosive atmospheres, as well as particular expertise with wireless technology, Extronics could quickly determine the best way forward.

To make the entire solution simple to install, Extronics recommended using an Ex d explosion proof enclosure as the main protection concept, which we supplied with space for CorrosionRADAR’s branding and in blue, matching their company colours.

As well as selecting a suitable, compliant power supply for CorrosionRADAR’s specialist equipment, Extronics designed and fitted a coin cell protection PCB to ensure ongoing safety once installed.

CorrosionRADAR were able to take advantage of Extronics’ exclusive iSOLATE technology, with the solution incorporating iSOLATE501 RF isolators and iSOLATE-CT explosion-proof connector transits, making the RF outputs intrinsically safe and allowing the use of simple apparatus antennas for wider transmission of data.

iSOLATE501iSOLATE-CT

Extronics also added some additional features to make the solution easier to use, such as an external Ex d lamp to show visually when the unit was powered on and an external hazardous area USB port to collect sensor information and diagnostics without opening the enclosure, if a wider network is not available for any reason.

 

CorrosionRADAR now have a safe, practical way to deliver their ground-breaking technology into ATEX and IECEx areas, with multiple units already deployed in the field.