Is there a more efficient way to manage industrial monitoring than the traditional tug-of-war between scheduled inspections and reactive fixes when issues arise? Let us find out!
In process industries, where every minute counts, finding the right monitoring approach stands as the cornerstone to keep operations running smoothly. Whether it is tracking fugitive emissions or safeguarding assets against corrosion, monitoring is crucial.
Traditional monitoring methods are mostly manual and have been widely employed in industrial settings, but they have significant drawbacks. These methods are often based on two factors – sticking to a strict monitoring schedule or performing reactive maintenance after significant damage has already occurred.
Recent years have witnessed a significant shift toward proactive monitoring through an event-based approach, steadily gaining momentum. This shift emphasizes moving from 'monitoring everything' to 'monitoring what matters.' This blog delves into why choosing an event-based approach over a time or schedule-based approach can be a game-changer for plant operators for emission reduction and avoiding unexpected catastrophic events due to corrosion.
The Conventional Approach: Manual, Time-Based Monitoring
Consider a situation in which you have opted for manual home security checks, where personnel patrol your property at specific intervals, such as once or a few times a day. How confident would you feel in terms of your security? In the context of emissions and corrosion monitoring, the time-based approach relies on manual methods for collecting data at fixed intervals, regardless of whether any significant event or anomaly has occurred. While this approach was effective for a while, it presents various limitations, such as:
1. Delayed Detection and Response
Sudden spikes in emissions or certain corrosion incidents may go unnoticed between monitoring intervals. With manual monitoring, you would only identify these issues during the next scheduled check, potentially weeks or months later. This delayed response can lead to environmental violations, equipment damage, safety concerns, and increased maintenance costs.
2. Human Error
Collecting data under rigid schedules and fixed intervals can create time pressure for personnel, potentially leading to human errors. Operators may inadvertently skip steps, fail to give thorough attention to the equipment being monitored, omit measurements, or make mistakes during data recording. These errors have the potential to result in inaccurate readings and overlooking critical events.
3. Limited Coverage
Conventional monitoring techniques are constrained by human capacity. Operators cannot be everywhere at once, and they cannot monitor continuously. This creates vulnerabilities in inspections, which can pose risks when dealing with emissions and corrosion.
4. Safety Risks
Manual monitoring poses risks for operators, often requiring them to enter hazardous environments for data collection or equipment inspection. This exposure puts them at risk of encountering toxic emissions, high temperatures, and various safety hazards.
5. Manual Labor Variance
Another downside of time-based, manual monitoring is the inconsistency in manual labor variance arising due to limited access to expertise, inconsistent work processes, and employee attrition. All these factors hamper the timely identification and resolution of issues.
Also Read: Why Now Is the Time for Industrial Operators to Embrace Digital Solutions in Leak Detection
The New Paradigm: Continuous Event-Based Monitoring
Imagine having peace of mind knowing that your home is protected by a robust security system with strategically placed sensors at entry points, windows, and other key areas that continuously oversee your home's security. The moment these sensors detect an intruder, they swiftly trigger an alarm. To ensure the safety and security of your home and loved ones, it is critical to have a reliable security system that can continuously monitor and alert you of any abnormal events.
As we transition from the comfort of our homes to the complex world of process industries, understanding the unique challenges in this field becomes paramount. Greenhouse gases (GHGs) and volatile organic compounds (VOCs) emissions may have an environmental impact, could result in potential non-compliance with stringent regulations, and may impact safety measures.
Meanwhile, corrosion, besides its environmental implications, presents a substantial threat to both equipment and personnel. Its capacity to damage equipment, raise safety concerns, and incur high maintenance costs can lead to operational downtime and reduced productivity.
The implementation of efficient monitoring systems becomes vital to swiftly detect emissions and corrosion, preventing damage, mitigating safety hazards, and ensuring environmental compliance.
The Significance of Event-Based Monitoring in Industrial Operations:
1. Timely Detection & Alerts
Event-based monitoring ensures that any abnormal event is detected as it occurs. This immediate response enables timely interventions to mitigate emissions anomalies and corrosion incidents, preventing costly downtime, environmental penalties, and equipment damage.
2. Accurate Insights
Event-based monitoring leverages sensor technology and automated systems to provide precise, dependable insights. This eliminates the risks of human error and missed critical events and allows operators to focus on potential concerns. With enhanced insights, operators can make informed decisions that improve operational outcomes.
3. Expansive Reach
Automated and continuous monitoring are highly effective at simultaneously monitoring multiple points, providing comprehensive coverage that significantly reduces the risk of missing critical events. This encompasses scenarios like emissions surpassing regulatory thresholds or corrosion emerging in various locations. Through swift anomaly detection and proactive measures, operators can effectively avert the escalation of potential complications.
4. Enhanced Safety and Compliance
Event-based monitoring is an effective way to ensure safety and regulatory compliance in process industries. It allows operators to monitor critical parameters remotely, eliminating the need for frequent on-site visits without sacrificing visibility into occurrences in the field.
Continuous data collection reduces the chances of oversight and facilitates immediate corrective actions when deviations from regulatory standards are identified. Moreover, it safeguards the reputation and financial stability of companies, while also providing a safer working environment for operators.
5. Efficient Resource Allocation
Event-based monitoring optimizes resource allocation by directing attention and resources where needed the most. This approach can significantly reduce monitoring costs while ensuring high-quality data insights.
In Summary
In the modern landscape of industrial operations, event-based monitoring is emerging as a superior alternative to time-based monitoring. With its capability for 24/7 continuous detection, this method empowers plant operators to take proactive measures, guaranteeing improved safety, compliance, operational efficiency, and environmental responsibility. As technology continues to advance, embracing an event-based industrial monitoring approach holds the promise of a brighter future for industrial operators.
How mPACT2WO Can Help?
mPACT2WO offers AIoT (Artificial Intelligence of Things) enabled solutions for corrosion and emissions monitoring to promote a more efficient and safe industrial future.
Contact us today to learn how our operations-centric solutions are empowering industrial operators to proactively control emissions, prevent corrosion-related disruptions, and make informed decisions based on data-driven insights.