IoT pipeline monitoring and leak detection can save you millions in costs and fines.
Crude oil and brine (or produced water) is being pumped through 3.5m kilometres of pipeline around the world at any given moment.
A leak can have disastrous consequences on soil and flora, as well as the organization’s bottom-line, plus the remote nature of these assets exposes them to the risk of theft and makes visual monitoring of them time consuming, inefficient, and expensive. What’s more, poorly conceived monitoring algorithms may lead to false positives and an excessive number of maintenance callouts – further impacting their profitability.
These factors make an effective IoT Pipeline Monitoring and Leak Detection solution an ideal tool for Oil & Gas companies to reduce costs.
Real-time asset understanding and predictive insights
We designed our IoT Pipeline Monitoring and Leak Detection solution for our customer so that they could monitor the real-time flow and pressure of what was going through their pipelines and create alerts, based on custom-built predictive algorithms, that would fire when something was going awry, such as a pipe break, leak, abnormal pressure or consumption.
When faults are detected early, maintenance can take place quickly and reduce the environmental damage and minimize losses. The sensor installations also only require optical fibre, so no control of power system lines are needed, which means minimum ongoing maintenance will be needed.
Defining what data to collect is critical
In order to create this solution, we first identified the key data required to achieve the desired business objectives. In this solution, this included:
- Production schedule
- Pump status
Initial goals of the solution
Working with our partners, we installed optical fibre sensors to a 4G gateway, so that we could then:
- Monitor critical operational data received from the equipment via a web-based system
- Ensure device management monitoring was set in place
- Define business logic for the application in order to meet the business objectives
- Provide alarm and alert notifications via email or SMS messages
- Start collecting historical data to undertake leak detection modelling
- Provide the right dashboards to the right users with the right insights
- Test the application, making sure all of the above goals are met, based on the solution architecture
Before go-live, we tested four critical aspects of the solution:
The Rayven IoT platform is built with security as a top priority and our proprietary security architecture ensures that data is secure at all points of the IoT environment.
The solution includes data encryption in transit from device-to-cloud, as well as device authentication; security (Bearer) tokens; SSL, AES and RSA encryption; as well as additional device security checks done via automated polling.
As some areas had good 4G coverage, we utilized a 4G gateway, and then in other areas where there was no 4G, we used LoRa based connectivity.
Your ability to make the right decisions is entirely reliant on the integrity of the data you collect, therefore, making sure that a solution has reliable connectivity is key to ensuring your data is always up-to-date and that you can rely on it to make critical business decisions in real-time. In addition, it’s important to check that the data you’re seeing in your dashboard matches the data recorded in the field; this avoids any possibility of false positives with leak alerts.
Industrial data science
The objectives of the exploratory data analysis was to monitor pump-house performance and efficiency, which included:
- Calculating flow rate by minute, hour, day, and week
- Forecasting hourly and daily pipeline flows
- Leak detection with minimal false positives
We are continuing to improve our maintenance forecasting by leveraging machine learning across growing data sets, which will further enhance our leak detection results.
Data sources used to deliver our Oil & Gas IoT Pipeline Monitoring and Leak Detection solution
New and existing data was used to create the custom applications and business insights that come from our Oil & Gas IoT Pipeline Monitoring and Leak Detection solution.
Key features of our Oil & Gas IoT Pipeline Monitoring and Leak Detection solution
All of these features were customized to fit the customers specific business objectives, but can me modified to fit your organization and pipeline - no matter what you're transporting.
Real-time performance monitoring
Gain continuous real-time oversight of your pipelines’ performance, and asset health – no matter where the asset is and where you are.
Alerts and notifications
Receive SMS and email alerts as soon as an event (e.g. leak detection) or a critical threshold (e.g. low flow rate) occurs.
Real-time flow rate
Decrease risk by continuously monitoring the pipeline’s flow rate, allowing you to keep your fingers on the pulse of the health of your network
Get better predictability across your pipe network. Run production forecasting to ensure you’re always on-track to hit your performance KPI targets.
Algorithms have been used to build pipeline leak detection in the network, triggering immediate alerts so that your crew can react as fast as possible with the correct response.
Reduced false positives
Using smart machine learning algorithms, learn the patterns of flow and leaks, so that you don’t send crews to fix leaks that don’t exist.
Delivering real-time business outcomes from our Oil & Gas IoT Pipeline Monitoring and Leak Detection solution
Lower cost of maintenance
Old infrastructure has a tendency to fail and must be visually inspected. Sending crews out to check remote pipelines is costly and time consuming. Remote monitoring of your assets is a much more efficient.
Better resource utilization
Send crews to the right place and at the right time, with all the parts that they need to do an already understood job right the first time.
Continuous monitoring means you can move away from fix-as-fail to a more proactive predictive maintenance regimen, meaning less disruption and better productivity.
Fewer maintenance calls
Continuous real-time monitoring means fewer unnecessary truck rolls and ensures that the root cause of problems are addressed, reducing errors and additional call-outs.
Continuous monitoring means fewer surprises and greater predictability of pipeline availability.
False positives are not only inefficient, they can reduce a crew’s confidence in the system. You can achieve better issue management when your team knows they can rely on alerts and not ignore them.
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Pricing & plans
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