OG90
Course Contents
Module 1: Industrial IoT Foundations and Corrosion Management Strategy
Key Topics
- Overview of corrosion monitoring: manual inspection vs online digital sensing
- The role of industrial IoT in predictive maintenance and asset lifecycle management
- Business value tracking: reducing loss of containment, field exposure and maintenance costs
- Understanding data limits: matching real-time alerts with risk-based inspection (RBI)
- Regulatory compliance, environmental risk mitigation and corporate safety mandates
- Structuring the business case: calculating return on investment for digital monitoring
- Formulating project scopes, operational baselines and stakeholder responsibilities
Module 2: Corrosion Sensing Technologies and Field Implementation
Key Topics
- Electrical resistance (ER) and linear polarisation resistance (LPR) sensor mechanics
- Ultrasonic thickness (UT) sensors, array configurations and automated wall tracking
- Advanced techniques: electrochemical noise (EN), electrical impedance and environmental sensors
- Cathodic protection tracking and remote potential monitoring network design
- Sensor placement strategy: isolating high-risk points, velocity drops and liquid traps
- Hazardous-area parameters: intrinsic safety, ATEX, IECEx and zone classifications
- Field calibration workflows, operational verification and managing measurement uncertainty
Module 3: IoT Architecture, Connectivity and Data Acquisition
Key Topics
- System components: smart sensor nodes, field gateways, edge devices and data platforms
- Telemetry selection: evaluating LoRaWAN, cellular links, satellite and industrial wireless tools
- Power management: tracking battery life metrics, solar harvesting options and usage envelopes
- Protocol standards, time stamps, sampling frequencies and edge-level data buffering
- Edge processing workflows, event-driven detection rules and local storage parameters
- Infrastructure deployment: comparing cloud, on-premise and hybrid operational models
- Connectivity testing, network redundancy loops and diagnosing communication faults
Module 4: Analytics, Alerts and Integrity Decision Support
Key Topics
- Data cleansing processes: handling sensor noise, signal spikes and missing records
- Trend analysis methodologies: calculating metal loss rates and establishing baselines
- Data contextualisation: correlating corrosion trends directly with process parameters and fluid logs
- Dashboard layout rules: building key performance indicators and exception-based visuals
- Alarm system parameters: defining thresholds, delay timers and mitigating alarm fatigue
- Anomaly detection algorithms and predictive remaining-useful-life degradation models
- Interfacing sensor platforms with maintenance management software and RBI systems
Module 5: Cybersecurity, Deployment and Lifecycle Governance
Key Topics
- Operations technology (OT) risks: understanding the connected sensor threat landscape
- Device onboarding: managing asset inventory records, security profiles and digital identities
- Network segmentation strategies using secure conduits, industrial firewalls and DMZs
- Access control structures: role-based visibility, data encryption and firmware management
- Business continuity planning: sensor data backup routines and cyber incident response rules
- Pilot testing design, commissioning protocols and site acceptance criteria
- Establishing lifecycle performance KPIs, preventive maintenance loops and sensor replacement plans