Omniflex Blog

Preventing nuclear events with remote monitoring

Posted by Darren Barratt on Wednesday, April 23. 2025

Monitoring temperature is crucial in the nuclear industry. If a reactor or fuel rod’s temperature rises to a potentially dangerous level, it runs the risk of fires and other catastrophic events. Having unexpected high temperatures can cause environmental and health risks as well as unplanned downtime, preventing essential work being conducted, therefore knowing about a potentially dangerous situation arising before it takes hold is pivotal for both safety and business. Here, Gary Bradshaw, director at Omniflex, highlights the important role remote monitoring technology plays in the nuclear sector.

A nuclear facility has several applications where temperature monitoring is important. This includes aspects that stem from the reactors and spent fuel rods, dry stores and, even, the reactor core.

It’s important that any temperature measurement is accurate as even minor inaccuracies can lead to significant risks, including overheating or mismanagement of a cooling system. Reliability is essential so no anomalies go undetected, especially when potentially hazardous equipment is involved.

The centre of spent fuel rods, for example, can be as hot as 1,000 degrees Celsius when they are removed. They are radioactive and take several years to cool. Though they typically go through a vitrification process to encapsulate them in glass after removal and then stored in concrete, spent fuel rods still need to be monitored for many years given their hazardous nature, as their temperature can still increase to dangerous levels.

This, along with the radiation exposure, highlights the harsh conditions that must be withstood by any technology when monitoring nuclear sites. Some nuclear facilities have a lifespan of over 150 years before radioactive material can be removed, so whatever may have been developed for a nuclear plant in the 1990s needs to last to the 2140s so products supplied to do the monitoring have to last for decades and not become obsolete.

The Reactors, spent fuel rods, dry stores and other facilities requiring temperature monitoring are usually monitored with thermocouple / RTD sensors wired to a remote monitoring system. This remote monitoring system accepts the signal from the temperature sensors, ensuring real time temperature measurements are accurately taken so that any out of limit alarms are immediately alerted to the operators to act before it reaches a critical stage.

This applies to any facility at a nuclear site. Remote monitoring technology can keep track of any temperature data and feed back into control rooms in real time – ensuring those facilities can stay ahead of any potentially dangerous situation.

The data can feed into alarm annunciators or SCADA PC-based monitoring software, which can flag a potentially dangerously high temperature to the control room at a nuclear facility so any potentially abnormal conditions can be acted upon. In many instances the SCADA monitoring system also provides historical logging for post event analysis and reporting.

For example, Omniflex’s Maxiflex IO system has dedicated temperature modules which have been designed specifically for accurate temperature monitoring. Each input is fully isolated and can take data from any type of thermocouple or RTD, they have inbuilt CJC (cold junction compensation) and can generate rate of rise alarm profiles as well as providing four independent trip points. Each trip point can then generate a digital output which can be displayed on an alarm annunciator, or it could be networked via ethernet, CONET, or wirelessly back to the control room to be displayed on a SCADA system. This allows all temperature data to be logged in real time and historically, providing a bigger picture of the environment which can help identify any potential underlying problems.

Omniflex’s specialist remote temperature monitoring solutions have been used for reactors, fuel rods and other facilities within the nuclear sector, and are designed for all aspects of temperature monitoring. Its Alarm Annunciator product range has been through the Nuclear SIL process – EMPHASIS – where products are subject to stringent studies and tests as they are assessed through the IEC 61508 Functional Safety Standard.

By implementing advanced remote monitoring solutions, you can ensure real-time data tracking and rapid response to critical temperature changes, safeguarding health, safety and operational efficiency.

Omniflex have been manufacturing remote monitoring and alarm annunciator systems since 1965 and all Omniflex products have a lifetime support policy which ensures it will continue to manufacture and support its products regardless of their age for as long as they are still operational and in service.

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Boosting long-distance critical signal delivery in mining

Posted by Darren Barratt on Wednesday, April 23. 2025

Ian Loudon, International Sales Manager at remote monitoring specialist Omniflex, explains how long-distance mining conveyor monitoring challenges may be combatted using bidirectional fibre-optic modules.

In mining applications globally, conveyor belts of up to 20km are used to transport ore from the excavation point to various locations, including processing and stockpiling sites. Damage to conveyors often cause cargo spillage and create major safety risks. To manage this, mining conveyors usually feature contacts that indicate problems like breakages, but these are often unreliable over the long distances involved.

In mining operations worldwide, conveyors are used to move cargo from the point of excavation to processing and storage areas. These conveyors often operate up large inclines and over long distances, meaning reliability is extremely important. Ensuring operational efficiency and minimising disruptions are vital for meeting stringent production quotas.

The conveyor belts in mining environments are constantly exposed to harsh conditions like dust, wear and tear, and are at risk of being damaged by falling rocks. Furthermore, dust and debris build-up on the belt mechanics can cause damage and potential stoppages. This makes fault detection and maintenance critical ongoing considerations for operators.

Conveyor belt safety is equally important. Belt breakages can have catastrophic consequences – causing damage to infrastructure, environmental spills and even worker injuries or fatalities.

Overcoming conveyor challenges

Telemetry systems are vital tools for ensuring the smooth and safe operation of conveyor belts. They are used to monitor belt tension, speed and alignment continuously, and can detect anomalies that are indicative of potential problems. Real-time data transmission allows for early intervention, preventing minor issues from escalating into catastrophic failures. In the unfortunate, yet common, event of a belt breakage, sensors can immediately trigger emergency shut-off mechanisms, minimising damage to assets and potential injuries to personnel.

However, maintaining reliable long-distance signal delivery in these challenging environments can be difficult for several reasons. First, signal strength can be extremely hampered in any underground operations, as dense rock formations interfere with radio wave transmissions.

Next, mines generate a significant amount of electromagnetic interference (EMI), which is exacerbated in environments with a large volume of copper cabling, such as those used to power motors or pumps with drives. Furthermore, mining applications often take place in harsh environments where temperature, humidity and dust levels can place excessive strain on electronic equipment.

Finally, the distances involved are also a limiting factor for many transmission options. Copper wiring is extremely costly and, when required to run over many kilometres, the costs are often prohibitive. Furthermore, copper systems do not guarantee reliable transmission over those distances with standard communication links on copper wires like RS 485, which is generally limited to about a kilometre of reliable transmission.

Fibre-optic improvements

Omniflex’s FCX module is a bidirectional fibre-optic transceiver, meaning it combines both transmission and reception capabilities into one device. This eliminates the need for separate modules, halving the number of modules required in any given setting, and dramatically reducing costs for purchasing and installation. Costs are reduced further because fibre-optic cabling is much cheaper than copper, lowering the cost per module.

Watch FCX video here to find out more - https://youtu.be/dzI6_zSQih8

Reliability is also improved significantly as fibre-optic transmission is immune to the effects of EMI and resistant to the effects of radio frequency interference (RFI). This is because fibre optics use light pulses to transmit data, and light is unaffected by electromagnetic fields, unlike copper cables that are highly susceptible to the effects of both EMI and RFI. The transceiver is compatible with either 850nm multi-mode or 1,310nm single-mode fibre-optic cabling; the latter can send switch contact signals up to 20km of range, which is significantly better than copper cable systems.

Fibre-optic transmission also offers safety benefits for mine applications. For example, unlike copper cables, fibre-optic cables do not generate sparks, and so are not potential ignition sources in mine operations that include potentially flammable or explosive environments.

Omniflex’s FCX bidirectional fibre optic module is certified for use in SIL-2 applications. The module’s output contact is designed with dual-signal detector relays in a 1oo2 configuration, with fault indication meaning system designers can trust that the risk associated with transmitting remote emergency stop or interlock switch contact signals over long distances can be limited to appropriate levels using the module.

To find out more about the FCX module’s remote safety applications in the mining industry, visit Omniflex’s website: https://www.omniflex.com/dsview.php?hid=C2477A-2.

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How CP system design can support ESG commitments

Posted by Darren Barratt on Wednesday, April 23. 2025

Major infrastructure like wharves, bridges, pipelines and tanks are under constant threat of corrosion, which, should it take hold, will render them unsafe. Traditionally, phase control cathodic protection (CP) systems were used to safeguard infrastructure, but these come with numerous challenges such as the expense of copper cabling and the associated power loss. These become bigger problems for asset owners who must now contend with environmental, social and governance (ESG) reporting. Here David Celine, managing director of cathodic protection(link is external) specialist Omniflex, explains how CP system design can support ESG commitments, while simultaneously lowering costs and improving maintenance capabilities.

At the heart of any impressed current CP (ICCP) system is a transformer rectifier unit (T/R), which supplies the necessary electrical current for ongoing protection. There are two main types of T/R that can be used to supply current for an ICCP system: phase control and switch-mode. While both technologies are hugely important to the global CP market, it is not always clear which is best to use for a specific project.

In phase control CP systems, AC power is passed through a large AC transformer and then rectified to produce a controlled DC output to the anodes. In switch-mode systems, AC power is first rectified to high voltage DC power and then much smaller high frequency transformers and rectifiers are used to create controlled DC outputs. This technique allows smaller and more efficient outputs to be created that can be more easily controlled.

Phase control systems have been the traditional go-to for CP consultants globally. However, as ESG commitments become increasingly important for asset owners, switch-mode systems are an increasingly attractive alternative, especially on concrete structures, where a larger number of small zones need to be protected.

CP system design supporting ESG

For asset owners and infrastructure managers, ESG is becoming increasingly crucial for driving sustainable and responsible operations while enhancing long-term value.

Strong ESG practices help mitigate environmental risks, such as corrosion and climate change impacts, ensure worker safety and promote transparent, data-driven decision making. Furthermore, ESG initiatives align operations with global sustainability goals, reinforcing a commitment to preserving resources and fostering resilience in critical infrastructure. Reduction of CO2 emissions and, therefore, increasing electrical power usage efficiency, is a major factor when reporting ESG and this is an area where switch-mode CP systems excel compared with their phase control counterparts.

A phase control system running at 100 per cent capacity is, at best 80 to 85 per cent efficient. However, because of oversizing, systems never run at anything close to 100 per cent capacity. In real-world applications, phase control systems operate at a peak of 60 per cent efficiency. Furthermore, as phase control systems rely on a single large T/R to distribute current across a whole structure, they require extensive copper cabling for use. This is both extremely expensive and causes power loss. It is not uncommon for a phase control system to lose around half its voltage in the cabling, which can further reduce the efficiency down to 30 per cent.

In contrast to this, switch-mode CP systems consistently operate at 90 per cent efficiency, even when running at 50 per cent capacity, meaning overall power consumption is dramatically reduced compared with phase control systems.

Small, compact switch-mode T/Rs also make the technology ideal for use in distributed CP systems on large structures, where locating T/Rs closer to the anodes provides significant savings in installation costs, due to reduced cabling, and lower energy costs due to reduced volt drops in the cabling. Because switch-mode systems can use smaller T/Rs that are closer to each individual anode, the copper losses are largely eliminated. As a result, over 80 per cent of the power reaches the anodes in switch-mode systems.

When it comes to system installation, the distributed nature of switch-mode systems means that costs are greatly reduced compared with phase control systems. Also, CO2 emissions are massively reduced when using switch-mode systems and, in many cases, can be less than half of the emissions generated when installing a phase control system.

Supporting ESG with remote monitoring

Large CP systems typically feature many anodes that must be monitored and controlled and switch-mode technology allows each to be managed individually. For example, a typical concrete wharf structure could have hundreds of anodes along its length and each needs individually monitoring and adjustment over time. Relying on conventional manual system inspections and adjustment is a very costly and risk prone effort, because of the length of time required for completion, often in dangerous locations, such as under a wharf in a boat, and the expense involved in paying an qualified technician to carry out this work.

This is where a switch-mode CP system in combination with remote monitoring becomes a must. Deploying this technology for use in combination with switch-mode CP systems delivers three key advantages for port asset managers that, conveniently, align with improving ESG practices.

But remote monitoring is not only the domain of new installations. It is possible now to also retrofit legacy cathodic protection systems with remote monitoring and control.

This provides asset owners with access to real-time data on an ongoing basis including total power consumption, anode current outputs, reference electrode test data and anode health condition. By having ongoing access to this live data, engineers can quickly identify abnormalities and address any problems before they escalate, ensuring ongoing asset protection.

Next, they will incur lower maintenance costs on an ongoing basis as the need for site visits and physical inspections is drastically cut. For example, a typical CP installation with no remote monitoring will be inspected twice a year, and significant on-site time consumed taking readings, whereas the same CP system monitored remotely need only be visually inspected once a year, with far less time on site taking readings, reducing operational costs.

Finally, remote monitoring improves ongoing personnel safety. CP protected infrastructure is often located in hazardous and difficult-to-access environments and remote monitoring lessens the need for technicians to physically visit these sites, improving overall safety. By reducing on-site inspections, the risk of accidents and injuries is significantly reduced.

Omniflex’s CP systems and remote monitoring options allow asset owners and site managers to monitor ongoing system status and collect real time data, facilitating data-driven decision making across the board. They have also been designed to allow CP consultants to conduct all the required specialist cathodic protection testing remotely, and to set output currents remotely, without the need for site visits or manual inspections, cutting costs and improving asset protection.

In an increasingly ESG-conscious world, adopting a CP system design that lowers costs, power consumption and CO2 emissions while providing more data for owners and managers and improving worker safety is a no-brainer.

To find out more, visit www.omniflex.com.

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