IoT Monitoring for
Chemical & Petrochemical Plants
ROSSMA multi-parameter Ex sensors for pressure, temperature, gas concentration, and vibration monitoring at chemical facilities. Up to 4 channels per sensor. ATEX / TR CU 012/2011. DCS integration via Modbus RTU/TCP
Chemical Industry Challenges
Manual rounds, toxic environments, and strict safety requirements
Manual Operator Rounds
Inspectors check pipeline temperatures and valve positions 2-4 times per shift with portable instruments. Between rounds, overheating, open valves, and leaks go undetected.
Toxic & Flammable Gases
Gas leaks threaten personnel safety. Inspectors cannot be everywhere at once. Continuous automatic monitoring is essential.
Pipeline Temperature Control
Heat exchanger and steam line overheating is found only during visual inspection or spot measurement. Without 24/7 monitoring, insulation degradation and corrosion develop hidden.
Valve Position Control
Operators visually check whether valves are open or closed during rounds. Without wireless position monitoring (% open), errors cause cross-flows, product mixing, and incidents.
Expensive Cabling in Ex Zones
Ex-rated cable runs, penetrations, cabinets in classified areas. Cost: from $800 per additional monitoring point.
Siloed Control Systems
Pressure, temperature, gas, valve positions — separate systems and protocols. No unified facility view.
ROSSMA Replaces Manual Rounds
Wireless pipeline temperature and valve position sensors — instead of inspectors with portable instruments
Pipeline Temperature 24/7
1-Wire Ex and ANALOG Ex X4 installed on pipelines, heat exchangers and steam lines — replacing periodic inspector measurements. Data every 1-10 min. Instant alarm on overheating.
Valve Position Control — VPM
Dry Contact VPM monitors valve position (% open/close) 24/7 without inspectors. Instant dispatcher alert on unauthorized change. Automatic control replaces visual checks.
Ex Gas Analysis
Gas Analyzer Kit continuously detects CH₄, H₂S, CO and VOCs — replacing periodic gas analyzer checks during rounds. Data every 30-60 sec. MAC/LEL alarms.
Pump & Compressor Vibration
ANALOG Ex X4 monitors vibration and bearing temperature online — replacing walk-arounds with portable analyzers. Early wear detection 2-8 weeks before failure.
DCS Integration
Modbus Ex connects up to 64 existing RS-485 instruments wirelessly. ROSSMA.NETS sends data to DCS (Siemens, ABB, Honeywell, Yokogawa, Emerson) via Modbus TCP, OPC UA, MQTT.
ROSSMA.NETS HMI — ISA-18.2
Dispatcher sees all parameters on one screen — pipeline temperatures, valve positions, gas levels, vibration. ISA-18.2 alarms (5 levels). No more walking rounds — data arrives automatically.
Architecture: From Process Unit to Control Center
Ex sensors on process equipment — wireless — unified SCADA + DCS integration
Chemical Plant Equipment
Multi-parameter Ex sensors, gas analyzers, level and flow kits
Autonomous Measuring and Switching Device ROSSMA® IIOT-AMS ANALOG Ex X4
Autonomous Switching Device ROSSMA® IIOT-AMS 1-Wire Ex (Temperature Sensor)
Autonomous Measuring and Switching Device ROSSMA® IIOT-AMS Dry Contact VPM (Valve Position Monitor)
Autonomous Kit for Combustible Gas Concentration Monitoring (Gas Analyzer with LoRaWAN/NB-IoT)
Autonomous Wireless Pressure Transmitter ROSSMA IIOT-AMS P-METER
Autonomous Kit for Level Measurement
Autonomous Kit for Liquid Flow Monitoring
Measuring and Switching Device ROSSMA® IIOT-AMS MODBUS Ex Stand Alone
Economics: Wired SCADA vs ROSSMA IoT
Cost of adding monitoring points to an operating plant
| Parameter | Manual Rounds + Cables | ROSSMA IoT |
|---|---|---|
| Pipeline temperature | Inspector 2-4x/shift (portable) | 24/7 automatic (1-Wire Ex) |
| Valve positions | Visual inspection during rounds | 24/7 automatic (VPM, % open) |
| Gas detection | Portable analyzer during rounds | 24/7 automatic (Gas Analyzer Kit) |
| Pump vibration | Portable analyzer 1x/week | 24/7 online (ANALOG Ex X4) |
| Additional point | $800-1,500 (cables + Ex) | $150-1,000 (sensor) |
| Incident response | At next round (hours) | Instantly (seconds) |
Key Economic Advantages
Frequently Asked Questions
Which toxic gases can be monitored?
Compatible with Siemens/ABB/Honeywell DCS?
ATEX / TR CU for chemical plants?
Reactor pressure monitoring?
Compressor vibration diagnostics?
Level in aggressive media tanks?
Battery life in chemical plants?
ISA-18.2 alarm integration?
Ready for Wireless Chemical Plant Monitoring?
Get a system quote — from gas analysis to compressor vibration diagnostics