Corrosion Control and Downtime Mitigation in Control Rooms

Electronic Corrosion Control: Protect Electronic Devices and Circuits in Control Rooms

Control rooms play a pivotal role in the landscape of Industry 4.0. As leading industries adopt new technologies to meet the escalating demands for production, the integration of automation systems becomes imperative. To operate these automation systems, control rooms are necessary for building any infrastructure.

These sophisticated systems not only elevate the efficiency of the production process but also reduce the manpower required, concurrently reducing the overall cost of output. Nonetheless, the vulnerability of these systems to failures poses a critical challenge, often resulting in downtime, which translates to elevated maintenance costs and potential revenue loss.

Failures occur due to the presence of corrosive gases and airborne contaminants, generated either within the environment through chemical processing or in nearby areas such as sewage areas or landfill sites. When these corrosive gases infiltrate control rooms, they can corrode electronic circuits and devices. Thus electronic corrosion control in control rooms is essential.

The Most Effective Way of Electronic Corrosion Control in Control Rooms

Bry-Air Gas Phase Filtration Systems protect electronic equipment and devices from the threat of abrupt failures due to corrosive gases. It reduces downtime by removing corrosive gases through the process of adsorption and chemisorption. It is designed to maintain the ANSI/ISA-71.04-2013 standard, IEC standards and various other environmental standards followed by electronics manufacturers.

These GPF systems also neutralise odourous gases and make the environment comfortable for humans.

Bry-Air: A Step Ahead, Always

Bry-Air is the only Gas Phase Filtration Company in India having its own R&D and Testing Lab for granular media and chemical filters. Backed by world-class technology and systems, the laboratory is capable of testing the performance of impregnated/non-impregnated loose granular media and impregnated/non-impregnated air cleaning devices such as chemical filters, under one roof. The tests are conducted as per ISO/ASHRAE Standard 145.1 and BSR/ASHRAE Standard 145.2/ISO Standard 11155-2 guidelines. The core objectives of the tests are to assess the performance and efficiency of loose granular sorptive media and chemical filters in any particular application.

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Frequently Asked Questions

Why is corrosion a concern in control rooms?

Corrosive gases can enter control rooms through ventilation systems, door gaps, cable penetrations and pressurisation leaks. Over time, these contaminants can corrode sensitive electronic components and affect the reliability of control systems.

Which control room equipment is vulnerable to corrosive gases?

Critical equipment can include DCS, PLC, SCADA systems, protection relays, VFD control boards, MCCs, UPS systems, process analyzers and instrumentation electronics. Corrosion can affect contacts, circuit boards, terminals and other sensitive components.

What causes corrosion in industrial control rooms?

Corrosion can be caused by gaseous contaminants such as hydrogen sulfide (H₂S), sulfur dioxide (SO₂), chlorine (Cl₂), ammonia (NH₃), nitrogen oxides and other reactive gases. Their impact can increase in the presence of moisture and suitable environmental conditions.

How can corrosion levels in a control room be assessed?

Atmospheric corrosivity can be assessed using Corrosion Classification Coupons or monitored in real time using an Atmospheric Corrosivity Monitor (ACM). Corrosion Classification Coupons use standardized 30-day copper and silver exposure, while ACM provides continuous monitoring of atmospheric corrosivity.

What is ISA S71.04 and how does it relate to control room corrosion?

ANSI/ISA S71.04 provides a classification framework for airborne corrosivity in environments containing electronic equipment. The classification is based on corrosion rates measured using copper and silver coupons, with environments categorized from G1 (mild) to GX (severe).

How does gas-phase filtration help control corrosion in control rooms?

Gas-phase filtration removes gaseous contaminants from the air using technologies such as activated carbon, chemically impregnated carbon and specialized adsorbent media. Unlike conventional particulate filters, gas-phase filtration is designed to address gaseous contaminants that can contribute to electronic corrosion.

Can gas-phase filtration protect DCS and PLC systems from corrosion?

Gas-phase filtration can help reduce exposure of control-room electronics to corrosive gaseous contaminants by treating the air entering or circulating within the protected space. This can be relevant for equipment such as DCS, PLC, SCADA, VFDs, protection relays and other electronic systems.

How can I determine whether a control room requires corrosion protection?

A practical approach is to first assess the environmental corrosivity using corrosion coupons or an Atmospheric Corrosivity Monitor. The results can then be used to understand the corrosion environment and determine whether additional gas-phase filtration or other protective measures should be considered.

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