AI-Powered Integrity Management System Detects Pipeline Corrosion, Prevents Leaks, and Cuts Operational Costs by 22%

Key Outcomes

Downtime Reduced From 1-3 Days to Under 5 Minutes

Pipeline corrosion detection dropped from 1-3 days to under 5 minutes, enabling uninterrupted operation across 150,000 miles.

22% Decrease in Annual Operational Costs

Significantly reduced unplanned downtime, emergency repairs, and costly environmental cleanups led to a 22% annual cost reduction.

Improved Risk Forecasting and Management

Real-time anomaly monitoring from telemetry data enabled early corrosion detection, helping prevent pipeline leaks and bursts.

18% Increase in Asset Lifespan

Data-driven insights identified weak points, enabling targeted maintenance that reduced wear and extended asset lifespan.

Challenges

The energy giant's Integrity Management team aimed to transition from manual pipeline inspection and maintenance to a modern, data-driven solution. They partnered with Aligned Automation to leverage AI, ML, and advanced analytics to overcome key operational challenges:

Safety Risks and Delays: The lack of real-time monitoring delayed leak detection, increasing safety risks and exposure to costly pipeline failures.
Unforeseen Downtime: Delayed maintenance caused costly and unexpected halts that led to weeks of production loss annually.
Inefficient Manual Process: The existing manual process was time-consuming, error-prone, and non-scalable, making it inadequate for real-time asset health monitoring.

Value Delivered

Aligned Automation developed a data-driven, AI-powered solution that enhanced the client’s legacy Integrity Management System by enabling early detection of pipeline corrosion. Through continuous analysis of telemetry data, the system supported proactive maintenance, helping to prevent pipe bursts and operational failures. The solution included:

Workflow Automation: Automated data collection and real-time monitoring along with integrated alerts and failure detection, streamlined maintenance workflows.
AI & Computer Vision: Intelligent classification of drone images for corrosion enabled early issue detection and safety enhancement.
Real-time Anomaly Detection: Enabled continuous asset health visibility, increasing asset lifespan with adaptive model tuning.
Predictive Models: Predicted corrosion rates and provided early warnings, reducing downtime through proactive maintenance.

Capabilities

Advanced Data Analytics

Process Transformation

AI & ML

About Client

A $300 billion oil and gas giant operating in over 70 countries relied on a manual system to oversee its extensive pipeline network. Safety inspections were conducted every 4 months to identify faulty pipelines, often taking 1-3 days to complete. This resulted in challenges related to managing operational downtime, maintaining pipeline integrity, optimizing maintenance, and ensuring safety and regulatory compliance.

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