Remote Monitoring and Data Transmission Solutions for Cathodic Protection Systems

Date: 11. 07. 2025 Reading time: 4 min.

One of the primary areas of activity of PSS Corporation is developing solutions for cathodic protection systems for the oil and gas sector, particularly pipelines. Such facilities typically feature extensive length and inaccessibility, often located far from control centers, power lines, and cellular coverage areas. Challenging terrain and harsh climatic conditions complicate equipment access and operation, making timely monitoring of asset conditions crucial.

Challenges Solved with Remote Monitoring

Remote data transmission helps overcome these challenges:

Difficulty or impossibility of periodic inspection and maintenance.
Receiving notifications about equipment failures.
Receiving data about the object's condition without physical inspections.
Adjusting protection parameters remotely.
Alerts for deviations from specified norms.

Regardless of the site and location specifics, our specialists offer optimal data transmission solutions. For easy management and analysis of protected structures, several software solutions have been developed, such as the "PSS.CP-Analytics" software.

Data Transmission Methods for Remote Monitoring

Numerous methods exist for data transmission and reception. Our company has developed several solutions utilizing various channels, categorized into two types:

Wired Communication Channels:

RS-485 two-wire half-duplex interface using MODBUS RTU protocol
Analog 4-20 mA current loop
Ethernet (Modbus TCP protocol)
PLC (Power Line Communication)

Wireless Communication Channels:

LTE (2G, 3G, 4G networks)
WiFi
Satellite communication
Fiber optic communication (FOCL)

RS-485 Channel for Transformer Rectifier Units (TRUs)

All cathodic protection power supplies (TRUs) produced by PSS Corporation, equipped with digital control units, have an integrated wired RS-485 interface for communication with dispatch points or integration with devices supporting other data transmission methods. RS-485 is the most widely used industrial standard with bidirectional balanced transmission lines.

CAN/4-20 mA Converter

The B-4-20mA-01 converter transforms data (TRU output voltage, output current, polarization, and total potentials) received via a CAN digital interface into an analog 4-20 mA signal. All transformer rectifiers with digital control units from PSS Corporation can be equipped with these converters. This solution is employed when the user's dispatch point receives signals of this type.

Ethernet Communication Channel

Transformer rectifier units are equipped with standard RS-485 to Ethernet converters for data exchange between dispatch points and TRUs via Ethernet (Modbus TCP protocol).

Easy to implement and configure
Ideal for sites with existing network infrastructure
Reliable and interference-protected data transmission
No communication fees, unlike GSM and satellite

Data Transmission via Power Lines

For establishing wired communication between dispatch points and TRU using 220V, 380V, or high-voltage power lines, modems based on Power Line Communication (PLC) technology are used. PLC technology enables digital signal transmission via Modbus RTU protocol through building electrical wiring and power lines. Special connectors are used for high-voltage power lines from 6 kV to 220 kV.

No need for additional cable installation; electrical wires are widely available
No equipment registration required as radio frequency devices
PLC equipment includes mechanisms to suppress signals in specified frequency ranges
No data transmission fees

LTE Modem with Dual SIM

The LTE-2SIM-RA-01 modem has an RS485 interface for connecting to TRU control units and telemetry units BT-3-RA.

Supports data networks: 2G, 3G, 4G
USB port for configuration
Supports configuration via USB or remotely via SMS
Can operate as a client and server
Wide coverage area
Possibility of remote firmware updates

WiFi Communication with TRU

At industrial sites with transformer rectifiers installed within WiFi coverage areas, transformer rectifier units can be connected to dispatch software using WiFi.

Communication and control of TRU via WiFi using smartphones, laptops, or tablets through a WEB interface without specialized software
No cable installation or cellular/satellite communication required

Satellite Communication Channel

For TRU dispatch communication where other communication types are unavailable, stations can be equipped with the adapters for satellite communication via Globalstar. The adapter transmits TRU parameters, monitors unauthorized access, and manages TRU output parameters. Transformer rectifier monitoring occurs through Internet data exchange between the adapter and dispatch point via Globalstar.

Maximum coverage area
Data transmission possible in areas without cellular coverage

Fiber Optic Communication

For data exchange via Fiber Optic Communication Line (FOCL) between dispatch points and TRU, stations are equipped with standard RS-485 to optical converters. This channel is selected during new pipeline installation.

Capable of data transmission without a power supply
Allows construction of uninterrupted long network lines
Enhanced information security
Connectivity with existing fiber optic lines on the pipeline

Video Surveillance for Cathodic Protection Sites

Temporary or permanent surveillance employs an outdoor camera operating in 3G/4G networks, supporting SIM cards from any operator. A 60W solar panel ensures autonomous operation in central and southern Russia. At night or in adverse weather, power is supplied by a backup battery (40 Ah). Camera settings and remote viewing are managed via a smartphone app. The camera supports memory cards up to 128GB with remote archive access.