Case Background
Petrochemical and oil & gas field industries cover the whole process including oil-gas exploration & drilling, production & gathering, refining production, storage & transportation, station operation and maintenance. Characterized by complex working conditions and harsh operating environments, the industries are faced with continuous and sudden gas safety risks, together with stringent compliance supervision and safety production management requirements. The core requirements are specified as follows:
1.1 Safety Requirements for Hazardous Gas Monitoring
The whole oil and gas production process continuously generates flammable, toxic and harmful gases, mainly including hydrocarbon combustible gases such as methane and ethane, as well as toxic gases such as hydrogen sulfide, carbon monoxide and volatile organic compounds (VOCs). Key points such as oil & gas wellheads, drilling platforms, gathering pipelines, refining reaction workshops, tank farms and sewage treatment areas are prone to seal aging, pipeline damage, valve leakage and other failures. Accumulated gas may easily trigger explosion, fire and personnel poisoning or suffocation accidents, which constitute the core safety hazards of the industry. All-weather and high-precision monitoring and early warning are urgently required.
1.2 Adaptation Requirements for Complex Working Conditions
Onshore oil and gas fields are mostly located in desert, gobi and open-air field environments, subject to sharp temperature changes, wind sand, dust and rain erosion. Offshore platforms suffer from high salt spray, high humidity and strong corrosion. Refining workshops have scenarios with high temperature, high pressure and vibration interference. Ordinary detection equipment tends to drift, malfunction or get damaged and cannot operate stably. Special detection equipment with high protection grade, anti-interference performance and corrosion resistance is needed to adapt to complex working conditions.
1.3 Compliance and Traceability Management Requirements
In accordance with national specifications such as the Regulations on the Safety Administration of Hazardous Chemicals and Design Standard for Combustible Gas and Toxic Gas Detection and Alarm in Petrochemical Industry, petrochemical and oil & gas enterprises must build a global gas monitoring and early warning system to realize real-time storage, traceability and non-tampering of monitoring data. Meanwhile, the system shall connect with enterprise safety platforms and government supervision systems to meet the requirements of data interconnection and compliance reporting between enterprises and government. Traditional manual inspection and scattered detection modes have problems such as missing data, disordered records and poor traceability, which can hardly meet supervision standards.
1.4 Intelligent Emergency Linkage Requirements
Traditional detection modes only support on-site audible and visual alarms, with drawbacks including delayed early warning, passive response and monitoring gaps in unattended areas. The industry is in urgent need of an intelligent system with automatic early warning, remote push, equipment linkage and data analysis functions, to realize early detection, early warning and early disposal of gas leakage, shorten emergency response time and avoid major safety accidents.
1.5 Full-scenario Coverage Monitoring Requirements
The oil and gas industry has diversified scenarios including permanent monitoring at fixed stations, mobile monitoring for equipment inspection and temporary monitoring for confined space operations. Fixed instruments are required for 24-hour online monitoring, together with portable detectors for point inspection, hazard investigation and emergency re-detection, forming an all-round monitoring system of "fixed + mobile" to eliminate monitoring blind spots.
Taizhi Solutions
This solution addresses the pain points across all business scenarios in petrochemical and oil & gas fields. Compliant with national industrial safety codes and standards, it builds an integrated intelligent gas monitoring system combining fixed online monitoring, portable mobile detection and IoT cloud platform. It fully meets gas safety monitoring requirements throughout oil & gas exploration, production, gathering, refining, storage and transportation, and delivers full closed-loop management including real-time gas concentration monitoring, accurate over-limit early warning, full data traceability, equipment linkage control and intelligent data analysis.
2.1 Solution Architecture
The overall system adopts a three-tier architecture with inter-layer linkage and collaborative management:
Terminal Perception Layer: Deploy explosion-proof fixed gas detectors, portable gas detectors and regional alarm controllers. Full collection of flammable and toxic gas concentrations is realized in key areas such as wellheads, tank farms, refining workshops, compressor rooms, valve groups and offshore platforms. Featuring high protection, corrosion resistance and anti-interference capability, the devices adapt to various harsh working conditions.
Data Transmission Layer: Support multiple transmission modes including 4G/5G, industrial Ethernet and wireless LoRa. On-site monitoring data, device status and alarm information are uploaded to the cloud platform in real time with stable transmission and low latency, ensuring real-time data synchronization, no data loss and traceability.
Platform Management Layer: Build an intelligent gas monitoring cloud platform integrated with real-time data display, concentration curve analysis, over-limit alarm push, equipment fault diagnosis, historical data query, automatic report generation and emergency linkage control. Multi-terminal access via PC and mobile terminals is supported to realize remote visual management.
2.2 Core Deployment Logic
Devices are deployed differentially for different operation scenarios. Fixed detectors are installed in batches at fixed high-risk areas such as oil & gas stations, refining workshops and tank farms to achieve 24/7 uninterrupted online monitoring. Portable detectors are equipped for routine inspection, high-altitude operation, confined space operation and equipment leakage investigation, for on-site personnel to carry out spot detection and re-detection. Data from all terminals are centrally connected to the platform to realize centralized management of full-domain monitoring data and unified risk control.
2.3 Core Advantages of the Solution
The solution features strong adaptability to working conditions, high monitoring accuracy, fast response, high intelligence, complete compliance and convenient maintenance. It supports linkage with on-site safety equipment such as fans, sprinklers and shut-off valves to form a safety closed loop of "monitoring - early warning - linkage - disposal", thoroughly solving the drawbacks of traditional monitoring including excessive blind zones, slow response, disordered management and lack of traceability.
Impl. Results
3.1 Full Blind-spot Elimination and Accurate Risk Prediction
Adopting the combined monitoring mode of “fixed-point permanent monitoring + full-coverage mobile inspection”, the system covers traditionally weak monitoring areas including outdoor oil and gas well sites, offshore platforms, closed workshops, underground pipe corridors and tank gaps without dead zones. Equipped with high-precision sensor chips, the devices feature fast response and low detection error, accurately capturing trace gas leakage and realizing advanced risk prediction. It effectively solves the defects of traditional manual inspection such as lagging detection, missed detection and false detection.
3.2 Multi-level Linked Early Warning and Efficient Emergency Disposal
The system supports a multi-level warning mechanism including on-site audible, visual and vibration alarms, platform pop-up reminders, and mobile SMS and APP push notifications. Once the gas concentration exceeds the threshold, an alarm will be triggered within seconds. Meanwhile, on-site exhaust fans, sprinkler systems and emergency shut-off valves are automatically linked to dilute and block leaked gas rapidly. Managers can receive real-time warning information and arrange on-site disposal quickly, greatly shortening the emergency response time and effectively preventing explosions, fires, personnel poisoning and other safety accidents.
3.3 Full Data Traceability and Standardized Compliance Management
The platform automatically records and stores all monitoring data, alarm records, inspection tracks and equipment operation and maintenance records in real time. The data is tamper-proof, long-term storable and queryable and exportable at any time, fully complying with national safety supervision standards for the petrochemical and oil & gas industry and meeting regulatory inspection requirements. The system can automatically generate daily, monthly and annual reports to replace manual ledger statistics and improve the standardization of safety management.
3.4 Stable Equipment Operation and Permanent Adaptation to Complex Working Conditions
All terminal devices have obtained explosion-proof and high-protection certification. With excellent performance of high and low temperature resistance, wind and sand resistance, salt spray resistance and electromagnetic interference resistance, the equipment can operate stably 7×24 hours under harsh conditions such as extreme outdoor weather, highly corrosive offshore environments and high-pressure vibrating workshop scenarios. Low equipment failure rate effectively reduces on-site operation and maintenance pressure.
3.5 Remote Intelligent Control and Lightweight Operation & Maintenance
On-site permanent duty is no longer required. Managers can view full-area monitoring data and equipment operating status in real time through the cloud platform. The system automatically diagnoses equipment faults and sensor drift to realize advance fault warning and precise maintenance. It reduces manual inspection frequency, greatly cuts labor and maintenance costs and improves the overall safety management efficiency of the plant.
Solution Value
4.1 Safety Value: Consolidate the Safety Production Barrier and Avoid Losses from Major Accidents
With full-coverage real-time monitoring, accurate early warning and intelligent linkage, the system eliminates major safety incidents such as flammable gas explosion, toxic gas poisoning and fire from the source. It protects the life safety of frontline workers and avoids huge economic losses caused by equipment damage, production shutdown and plant rectification triggered by safety accidents, consolidating the bottom line of enterprise safety production.
4.2 Compliance Value: Meet Regulatory Requirements and Mitigate Compliance Risks
The solution fully complies with national standards and safety supervision requirements related to gas monitoring in petrochemical and oil & gas industries. It realizes full monitoring coverage, traceable data, connectable transmission and standardized ledgers, completely solving enterprise compliance weaknesses. It helps avoid compliance risks including safety penalties, qualification restrictions and production suspension for rectification, and ensures regular compliant operation of enterprises.
4.3 Efficiency Value: Reduce Costs, Improve Efficiency and Upgrade Intelligent Management
Intelligent monitoring replaces traditional manual inspection and paper ledger statistics, greatly cutting manpower input and costs of equipment operation and maintenance and human resource management. Meanwhile, big data analysis enables precise localization of high-frequency leakage points, helping enterprises optimize equipment maintenance plans, reduce medium loss and equipment failure frequency, improve overall production and operation efficiency, and drive digital and intelligent transformation of traditional safety management in oil and gas chemical industry.
4.4 Brand Value: Build a Standardized Safety System and Enhance Enterprise Competitiveness
A standardized and intelligent gas safety monitoring system serves as a key symbol of standardized and modernized safety production for oil and gas chemical enterprises. It effectively improves enterprise safety management capability and industry reputation, supports enterprises to pass various safety assessments and project bidding evaluations, and strengthens core competitiveness.
4.5 Environmental Value: Control Gas Emissions and Practice Green Production
It can accurately monitor leakage and emission of methane, VOCs and other gases, detect and repair leakage points in a timely manner, reduce unorganized emissions of greenhouse gases and harmful waste gas, help enterprises fulfill environmental emission reduction requirements, avoid environmental penalties, and realize green and low-carbon production.
Equip. Intro
I will strictly output website-style English translation only, consistent with all previous paragraphs.
This solution’s supporting equipment is specially developed for harsh working conditions in petrochemical and oil & gas fields, featuring explosion-proof performance, high protection grade, high precision and high stability. The core devices are divided into three categories: fixed online monitoring equipment, portable detection equipment and cloud management platform. The specific parameters and functions are as follows:
5.1 Explosion-proof Fixed Gas DetectorAs the core monitoring device for fixed high-risk areas in the plant, it is applicable to wellheads, valve groups, compressor rooms, refining workshops, tank farms, offshore platforms and other scenarios. Adopting industrial high-precision sensor chips, it detects mainstream hazardous gases including methane, hydrogen sulfide, carbon monoxide and VOCs. With Ex d IIC T6 Ga explosion-proof certification and IP67 high protection grade, the equipment resists high and low temperatures, salt spray, dust and electromagnetic interference, and operates stably within extreme temperatures from -40℃ to +70℃. Supporting both analog and digital signal output, it connects directly with alarm controllers and cloud platforms. It delivers fast response, high accuracy and low zero drift for long-term uninterrupted online monitoring. Equipped with self-diagnosis function, it feeds back real-time operating status and simplifies daily maintenance.
5.2 Portable Gas DetectorDesigned for mobile inspection and on-site operation protection, the ultra-light and easy-to-operate handheld device is suitable for routine point inspection, high-altitude work, confined space operation, leakage investigation and emergency re-detection. It supports single-gas detection or 4-in-1 simultaneous detection of flammable gas, hydrogen sulfide, carbon monoxide and oxygen. Adopting intelligent sensing technology, it ensures accurate and stable measurement data. Equipped with a high-definition display screen, it shows real-time gas concentration, ambient temperature and device status, and provides 360° audible, visual and vibration triple alarms for clear warning recognition even in dark and noisy environments. The device supports data storage, export and wireless transmission to record inspection tracks and detection records. With long battery life and dustproof, waterproof and drop-resistant performance, it fully adapts to various field and workshop mobile operation scenarios.
5.3 Gas Alarm ControllerAs the core on-site regional management device, the controller centrally receives signals from multiple fixed detectors and displays real-time gas concentration data of all monitoring points. It supports local data storage, over-limit alarm, fault prompt and linkage output. It realizes partition management with independent alarm threshold settings for different working areas. Featuring power-off protection and data retention, the controller can operate independently without network coverage to ensure continuous on-site monitoring and stable local safety management.
5.4 Intelligent Gas Monitoring Cloud PlatformAs the intelligent core carrier of the overall solution, the platform supports data access of all terminal devices. It integrates real-time data monitoring, concentration curve analysis, multi-level alarm push, equipment status detection, fault early warning, historical data traceability, automatic report generation, hierarchical permission management and government-enterprise data docking. Compatible with Web and mobile APP terminals, it allows managers to view plant monitoring data and handle hidden dangers anytime and anywhere. Cloud data is permanently stored and tamper-proof, fully meeting industry compliance and traceability requirements. The platform can also be expanded to connect with enterprise ERP and safety management systems to support digital and intelligent upgrading of factory safety management.
