Pressure Monitoring and Predictive Maintenance

Predictive Maintenance in The Oil and Gas Industry

Absolute Gauge Pressure


The global energy landscape revolves significantly around the oil and gas industry. This sector, responsible for fueling the world’s power needs, is intertwined with a multitude of operations that span exploration, extraction, refining, distribution, and sale of petroleum and natural gas products. In addition, this sector also provides the raw materials for most plastics and as we know they are perhaps the most used material on our planet, daily.

As a pivotal economic catalyst across nations, the industry constantly grapples with multifaceted operational challenges and safety concerns. Among these, managing pressure stands as a critical task that directly impacts the efficiency, safety, and profitability of operations.

Pressure, as a parameter in the oil and gas industry, is more than just a number. It is a driving force that controls the movement and behavior of fluids throughout the value chain. From the oil wells during drilling to the pipelines carrying the refined products, maintaining optimal pressure conditions is fundamental for ensuring smooth, efficient, and safe operations. 

Monitoring pressure, therefore, is an indispensable practice in this sector. It involves the careful tracking and control of pressure within various processes and equipment. This vital data can provide valuable insights into operational efficiency and maintenance scheduling. As we tread deeper into the era of Industry 4.0, characterized by the integration of advanced digital technologies and automation, the approach to pressure monitoring has undergone substantial transformation. The emergence of smart sensors, Internet of Things (IoT) technologies, Machine Learning (ML), and data analytics has revolutionized pressure monitoring, making it more accurate, real-time, and insightful.

Predictive maintenance emerges in this context as a powerful tool that can harness the potential of pressure monitoring to the fullest. Leveraging advanced analytics and ML, predictive maintenance enables the forecasting of potential equipment failures before they occur. When integrated with pressure monitoring, it can not only predict possible malfunctions but also identify sub-optimal pressure conditions that may hamper operational efficiency or safety. This proactive approach to maintenance significantly reduces unplanned downtime, enhances productivity, lowers maintenance costs, and ensures regulatory compliance.

Pressure Monitoring and Predictive Maintenance Enhancing performance in the Oil and Gas Industry

The Role of Pressure Monitoring in Oil and Gas Operations

Pressure monitoring holds a paramount position in the oil and gas industry. Across the entire supply chain, from the extraction of raw materials to refining and transportation, maintaining and monitoring optimal pressure levels is crucial for operational efficiency, equipment integrity, and safety.

  1. Importance of Pressure in Drilling Operations
    Drilling operations in the industry heavily depend on maintaining the right pressure balance. During drilling, the pressure of drilling mud needs to be precisely controlled to prevent blowouts from sudden pressure changes within the wellbore. Conversely, too much pressure in the drill pipe can lead to fractures in the formation, causing potential damage to the well and the environment. Here, precise pressure sensors play a vital role in providing real-time data to help operators keep these risks at bay.
  2. Role of Pressure in Extraction and Production
    In the extraction and production phase, pressure monitoring is essential to maximize yield and control flow rates. Monitoring the pressure of reservoirs helps optimize extraction rates and extends the life of the wells. Maintaining pressure balance in production lines prevents pipe rupture and leakage, ensuring safety and preventing costly production shutdowns.
  3. Impact on Transportation and Storage of Oil and Gas

    The significance of pressure monitoring continues in the transportation and storage phase of oil and gas. Pipelines transporting these fuels operate under high pressures, requiring constant monitoring to prevent failures and ruptures. Similarly, storage facilities, such as gas tanks, need continuous pressure monitoring to prevent overpressure conditions that could lead to catastrophic failures.

    Wireless sensors are especially suite for this type of application as they can be attached to tanks and/or pipelines that can extent for long distances, where mains power might not be available. They are also suitable for hard to reach locations and since NCD Industrial Wireless Pressure Sensors have battery life of up to 10 years they will not require monitoring or replacement.

    Absolute Gauge Pressure - Product Image

  4. Introducing Predictive Maintenance in Pressure Monitoring

    Incorporating predictive maintenance into pressure monitoring systems at each of these stages can significantly enhance the safety and efficiency of operations. Predictive maintenance algorithms, coupled with advanced pressure sensors, can identify patterns and trends that signal potential equipment failures or unsafe conditions.

    In order for the system to work efficiently the two components need to work well both on their own, but more importantly in conjunction. The sensors have to take accurate measurements over a wide enough range (psi and °C/ °F in this particular case) with good accuracy in order to obtain valid and more importantly detailed enough data. The aforementioned NCD sensor has the following parameters (we consider these values to represent what a high-quality industrial grade sensor would have):

    • Operating Range 0 to 10,000psi, -40°C to +85°C (-40°F to 185°F)
    • Industry Standard 1/4-inch NPT Male Connector
    • Accuracy ±0.5%FS (pressure) ±1.5 (Temperature)
    • Sampling Frequency 1.5ms
    • Long Term Stability: ±0.3%FS/year

    Furthermore, the sensor has to easily integrate with the backend where the actual database is and where the ML algorithm is running in order to perform the predictive maintenance analysis. Thus, the data should be delivered reliably, it should be secured and it should be parsed in such a way that it can easily be retried and formatted. 

    For the aforementioned reasons NCD sensors utilize DigiMesh®, a protocol that is AES encrypted (secure), it is long range (up to 2miles) and reliable (mesh networking is easy to extent and also self-regenerating in case of a node failing). Additionally, the sensors in this line of devices are designed to be flexible when it comes to platform integration. One only needs to connect them to a Gateway or Modem configure Node-RED to extract and manipulate the measurement data in the desired way and it can be forwarded to the platform of your choice. Popular options are AWS IoT Core, Azure IoT Hub, Losant or simply utilize MQTT (which is the standard for IoT messaging) to send it to an end-point where your MQTT Broker will pick it up.

    By leveraging ML and data analytics, predictive maintenance takes pressure monitoring to the next level. It allows operators to move from a reactive approach to a proactive one, reducing equipment downtime, enhancing safety, and optimizing operational efficiency.

Introducing predictive maintenance in pressure monitoring

The Consequences of Inadequate Pressure Monitoring

The consequences of inadequate or ineffective pressure monitoring in the oil and gas industry are potentially severe. Incorrect pressure readings can lead to equipment malfunction, costly operational downtime, environmental disasters, and, in the worst case, human casualties.

  1. Risks Associated with Overpressure or Underpressure

    The consequences of inadequate or ineffective pressure monitoring in the oil and gas industry are potentially severe. For instance, a sudden surge in pressure could cause a pipeline to rupture, leading to a massive oil spill. This can result in significant environmental damage, regulatory penalties, costly clean-up operations, and a tarnished reputation for the responsible company. Similarly, low pressure in a gas storage tank might suggest a leak, which could lead to potential fire hazards, asset damage, or even explosions.

    Unlike other industries where some measure of failure (sub-optimal operation of equipment) can be tolerated, oil and gas applications need to adhere to very strict standards. Issues need to be addressed on time, thus it has been the norm (before predictive maintenance) to perform very costly regular inspections. This is inefficient from time and monetary perspective, yet the alternative is even more severe. Thus, the optimization predictive maintenance brings at no additional risk cost has an impact on the oil and gas industry that is much grater than the one where less demanding applications are concerned (temp and humidity in an office for example are less likely to reach critical levels without notice).

  2. Preventing Accidents Resulting from Improper Pressure Management

    Mitigating operational risks is crucial, and this is where predictive maintenance, powered by advanced pressure monitoring systems, comes into play. Predictive maintenance systems utilize the constant feed of data from pressure sensors and other related data points, which are then processed using sophisticated ML algorithms. This analysis helps identify patterns or anomalies that signal potential problems before they occur. It is not just a system that reacts to data input, it is a method that can predict (based on previous, long-term measurements) when a potential failure would happen, before the measured values even reach critical levels.

    For instance, a predictive maintenance system might recognize that a slight, consistent drop in pressure in a pipeline over time is indicative of a small leak that will worsen if left unchecked. This early detection allows for planned maintenance that can fix the problem at an early stage, before it causes significant damage or requires a full shutdown for repair.

  3. How Predictive Maintenance can help Mitigate These Risks

    Furthermore, the benefits of predictive maintenance go beyond direct operational enhancements. Companies adopting these systems demonstrate their commitment to safety, sustainability, and innovation, factors that are increasingly important to stakeholders, regulatory bodies, and the public.

    A predictive maintenance system is no a temporary, short-term solution to fixing issues in a factory or a rig, where a particular problem was creating trouble. It is an incredibly long-term investment, that has proportionately incredibly large benefits. It is a new way of approaching how to optimize the functionality of any industrial level application where long term stability is a must and efficient operation is more important than cutting short term costs.

    How predictive maintenance can help mitigate these risks

Summary and Conclusions

The oil and gas industry has witnessed substantial growth and transformation in terms of technology. There have been significant advances that have changed the way how not only the equipment operates, but also how it is maintained and serviced. This in turn has had significant impact on how companies function, are managed, and how decisions are made both in the field and in the office.

 how companies function, are managed, and how decisions are made both in the field and in the office

  1. Evolution of Pressure Sensors in The Industry

    Pressure sensors have been an integral part of the oil and gas industry for many decades. The industry has seen an evolution from simple, mechanical sensors to electronic pressure sensors, and now to smart, connected sensors. These modern sensors are not only more accurate and reliable but also capable of continuous monitoring, contributing significantly to safety and efficiency in operations, as real time data can facilitate better decision making.

    As we have seen with our example NCD Industrial Wireless Absolute & Gauge Pressure Sensor, it is now the norm for high quality sensors, to be wireless, secure, long lasting (build and battery power). In addition, proprietary technologies are less constraining and it is the measure of a good sensor if it can integrate with a wide-range of 3rd party platforms.


  2. Role of AI and ML in Predictive Maintenance and Pressure Management
    Artificial Intelligence (AI) and Machine Learning (ML) have found a place in predictive maintenance strategies, including pressure management. These technologies, through their ability to learn from historical and real-time data, can make accurate predictions about potential faults or failures. This ability to foresee issues allows for timely intervention, minimizing the chance of unplanned downtime and critical failure. This results in enormous cost saving, mainly due to optimizing working schedules and saving on component replacement (it is way cheaper to replace a worn out part than the entire system when it has critically failed).


  3. Benefits of Integrating Predictive Maintenance with Pressure Monitoring

    When predictive maintenance is integrated with pressure monitoring, the benefits are exponential. This integration allows for more efficient operations, as any deviations in pressure can be quickly identified and corrected before causing major issues. Moreover, this proactive approach extends the lifespan of equipment, reduces maintenance costs, and increases operational safety. Additionally, it can also lead to better resource management and energy savings, enhancing the industry’s sustainability efforts.

As we forge ahead into a future marked by digital transformation, the combination of advanced pressure monitoring with predictive maintenance technologies will play a crucial role. The oil and gas industry stands to gain significantly from these advancements, ensuring optimized operations, minimized environmental impact, and heightened safety standards.