Why oil and gas companies should invest in ruggedized edge computing

STACI KONO and DUSTIN MCINTIRE, Crystal Group  

In the oil and gas industry, a single day of downtime can cost millions of dollars for large-output platforms. Costs include lost production revenue but may also include contract penalties, restart costs, and deferred maintenance. As a result, investing in reliable, edge-based computer systems isn’t just a technological choice. It’s a strategic and financial imperative.  

Fig.1. Crystal Group manufactures rugged computing solutions in their U.S.-based facility, delivering vertically integrated design, build, and testing capabilities that ensure every system meets the highest standards for performance and reliability in harsh environments.

Ruggedized servers and computers can maximize your uptime and reliability anywhere corrosion, salt fog, dust, shock, vibration, thermal cycling, EMI interference, or unstable power might compromise operations. Edge-based computing devices can also produce and compile data instantaneously on-site without the lag time or latency associated with cloud computing. 

In 1987, Crystal Group began manufacturing ruggedized computer components for the military and defense industries Fig. 1. That’s how our team learned what it takes to build systems that function dependably in harsh environments—engineering solutions for equipment ranging from fighter jets and drones to submarines. More recently, the company has leveraged this expertise to build custom computer hardware and devices for oil and gas, construction, energy and utilities, and autonomous vehicles and equipment industries.  

Looking for computer equipment that can excel in the oil and gas arena? Let’s go through the most common challenges and explore what you need to know, to make the best possible decision when spec’ing your hardware.  

VIBRATION 

The ocean pummels offshore drilling platforms with ceaseless wind and wave action. Constant vibration from rotating machinery, diesel generators, and gas turbines also attacks the structural integrity of digital equipment and electronics.

To overcome the vibration challenges, you want systems designed with rugged engineering techniques like precision-milled aluminum chassis with custom bracketry and vetted electronics that receive special processes to enhance the durability and longevity in the unique environment that vibration stress creates. Customized, application-specific component designs can also go a long way in preventing damage caused by vibration. What might work just fine in a land-based operation may not last long in a more kinetic, 24/7 offshore application, Fig. 2. 

Fig. 2. Offshore drilling platforms operate in relentless conditions that demand computing systems built for continuous, reliable performance.

In those harsher environments, experts recommend not just isolation mounts, but a box-within-a-box solution. For example, if an expansion board and a motherboard move independently of one another, it can rub through the connective surface and create a discontinuity. The solution is to understand your operating environment and configure components, so they move together, rather than apart.  

UNSTABLE POWER  

Grid power in the U.S. is generally stable and clean. This is not the case in many other countries or for offshore oil and gas operations, where power is supplied by diesel generators or gas turbines. The military faces the same challenge in forward operating bases established in hot spots all over the world.  

In these environments, voltage drops, brownouts, power sags, and spikes can wreak havoc on sensitive computer components. It is critical to design the front end of that power supply to filter out noisy power. Custom-designed EMI filters and noise suppression filters on the equipment can maintain appropriate operations and accurate timing. 

Use cases will vary widely, but computers have precise voltage requirements. These voltages can’t vary. Components must be right in the middle of their sweet spot and responsive to unique mission sets. That can be a hard problem to solve, and operations may not be able to meet those specific needs with high-volume, off-the-shelf products. 

THERMAL CYCLING 

When it comes to managing heat, unique environments require unique solutions. Over time, thermal changes can lead to latent failures. Expansion and contraction of the printed circuit board (PCB)—as well as components and solder connections—can lead to PCB delamination, component failures, and intermittent solder connections.  

Engineering a solution to account for this expansion and contraction is imperative and should include the following: 

• An understanding of susceptible components and mitigation techniques to ensure reliability.
• Lifecycle analysis done with in-house thermal chambers to expose potential latent failures. A root-cause analysis team can quickly find the issue, while a vertically integrated business model allows your vendor to engineer a solution onsite and implement it.
• A partnership with consistent client communication that creates a feedback loop to understand a system's shortcomings and provides a clearer path to engineering a solution.

With this comprehensive approach to thermal management, custom heatsinks and water-cooled solutions have been able to keep servers operational in environments that are not fit for human personnel, while ensuring a long service life.   

SEALING FOR DUST AND MOISTURE  

Dust and moisture wreak havoc on electronics, producing corrosion and component failure within the computer’s circuitry. Coatings specifically designed to protect electronics can be applied to increase reliability in environments with dust and moisture. In most cases, this can be done without a fully sealed chassis. Not having to seal the computer keeps costs down while increasing reliability. 

Salt fog is a highly corrosive and conductive electrolyte of particular concern to the oil and gas industry. It can destroy electronics. In-house testing with a salt fog machine ensures that coatings can keep circuitry functional when exposed to the elements. When the environment requires it, these coatings can be coupled with sealed chassis and connections to create a server that will run nearly anywhere. In one example, we received feedback from a customer that our piece of electronics was the only unit operational after being pulled from a sunken vessel on the sea floor.  

COMPUTING ON THE EDGE 

Edge computing brings data processing and analytics directly to where data are generated—whether that’s the rig, refinery, or pipeline. This gives users precise control of drilling operations in extreme environments, allowing them to monitor pipeline integrity, detect leaks, and process and securely store exploration data in real time. High-density data sets are used to make high-dollar investment decisions, emphasizing the importance of high-performance edge computing. 

Unlike traditional cloud systems that depend on unreliable connectivity and long latency times, edge devices are connected to edge computers and operate locally, delivering real-time insights for predictive maintenance, process optimization, and safety monitoring. By detecting anomalies before failures occur, these systems prevent costly shutdowns and improve operational uptime. Edge device vibration sensors can help monitor the health of rotating equipment. Pressure and heat sensor monitoring ensures safety, and CCTV devices are used for personnel safety, as well as thermal imagery for leak detection. 

Fig. 3. Crystal Group is a trusted partner committed to long-term success, providing proactive lifecycle management, dependable supply chain support, and responsive service to keep critical operations running without interruption.

To take advantage of these new data processing capabilities, operations need a vendor that specializes in edge computing hardware and can support other edge devices, such as workstations, network switches, displays, storage devices used in blowout prevention, closed-circuit TV, and other system monitoring networks.   

RELIABLE PARTNERS  

Meeting the technical challenges of building ruggedized computer equipment for the oil and gas industry is important. It is equally important to partner with a company that offers customer-focused logistics and adequate inventory management, Fig. 3.   

Offshore platforms typically operate for 20 to 40 years. The lifecycle of the computer systems may run for five to 10 years. Meanwhile, consumer-grade, mass-market components may become obsolete without notification and lack viable replacements. Customers don’t get any feedback on, or insight into, when changes go into effect. 

When this equipment is on a platform miles away from shore, sourcing components that are backward-compatible with the existing systems requires a close relationship between vendor and customer. It’s all about avoiding shutdowns or control systems upgrades that can cost millions of dollars per day in lost production. A manufacturer that designs custom, mission-specific components and holds a strategic inventory with vendor roadmaps to stay ahead of changing market trends can help oil and gas operations mitigate this downtime danger. To proactively plan technology upgrades and minimize extended downtime costs, here are crucial questions to ask in selecting a vendor for your systems: 

• Do they have a spare parts program with sufficient product on hand to meet future needs?
• Do they proactively manage and notify clients when components are nearing the end of their lives or need to be upgraded to the newest generation of offerings?
• How good is their warranty, and do they provide extended warranties? 
• Do they work with their vendors to ensure an adequate supply of critical components like microchips?
• If they offer custom or one-of-a-kind products, can they quickly manufacture additional versions of that design?
• Will they let customers know with sufficient lead time if a specific type of product will be phased out, thus enabling the customer to order additional units?
• Does the vendor offer a proprietary system or customization?
• Do they have 24/7 tech support?

The importance of spare parts programs and inventory management was demonstrated in 2011, when a tsunami caused the Fukushima nuclear plant in Japan to melt down. Many, if not most, of the precision-engineered parts the Japanese were famous for were suddenly no longer available. Supply chain disruptions rippled across the world. Likewise, when Covid-19 hit in 2020, many of the world’s manufacturing plants ground to a halt. Even today, the struggle to find and acquire microchips is an ongoing concern throughout the industry.  

Fig. 4. Crystal Group partners closely with customers to engineer advanced computing solutions, aligning system design with real-world demands to deliver precision performance where it matters most.

A vendor that has a complete record of your installed products, which has accurate projections of your future needs, and who keeps your spares on hand for immediate shipment—without charging you for those products until they are shipped—is ideal. 

Operations should also be aware of “vendor lock.” Many high-volume/mass market computer component manufacturers offer an entire ecosystem of products as an all-in-one package. But if you decide later that you need something extra or some functionality that can’t be replicated inside their ecosystem, you could be out of luck. Custom-designed systems can offer a much broader range of applications to fit one-of-a-kind needs, Fig. 4.   

Technology is changing so rapidly that things that were compatible on a motherboard five years ago are not compatible with many current motherboard systems. And the effects of one part can ripple through a whole system. However, the ability to create custom circuit board solutions can often bridge the gap between legacy hardware and current technology.  

POTENTIAL FOR AI 

The oil and gas field industry has not demonstrated a huge demand for AI-capable solutions, but your computer system vendors should have a lot of AI experience in the military and autonomous commercial industries and be comfortable playing in the AI space. Once ROI is more firmly established, AI could be a benefit in the oil and gas industry.  

To a degree, A.I. is being used to monitor thermal cameras, look for gas leaks, and monitor safety equipment on personnel. It’s also being used to enhance preventive maintenance. Most of the AI functionality is handled by the software, rather than the hardware. But in terms of computing, the right solution involves high-powered GPUs that can withstand the thermal loads and other conditions.   

FINAL THOUGHTS 

It’s important to focus on two things. First: How painful will it be when one of these systems goes down?  

And second: What are the safety implications of a computer system failure? Everybody knows—but it bears repeating—that safety protocols must be integrated into every part of an offshore oil drilling and production program, from PPE to the servers, circuit boards, and sensors that control these massive platforms. 

You can buy a $3,000 or a $5,000 server. But if you're replacing that every three to six months, because the equipment isn’t designed to withstand these conditions, you have to ask how much time and energy is needed to continually replace one or more of these components. How many people do you have to pay to go out to the rig on a helicopter or a boat? How much money could you save by investing in a configurable server and a reliable solution that doesn’t need continual maintenance?  

STACI KONO is the Oil and Gas senior program manager for Rugged Technology at Crystal Group, Inc., in the Iowa City-Cedar Rapids area of Iowa. She has served in this position since October 2021. Before that, Ms. Kono was sales support manager for Crystal Group from October 2016 to October 2021. Previously, she worked 17 years at Verizon in positions of increasing responsibility. Ms. Kono is a graduate of Iowa Northern University.   

DUSTIN MCINTIRE is a senior systems architect for Crystal Group, Inc. He has served in this position since August 2025.