By: Kobus Vermeulen - Direct Sales Executive, Process Automation at Schneider Electric

At any given moment, thousands of kilometres of critical assets flow through pipelines that cross veld, mountainous areas, dense forests and even busy streets.  Surprisingly, many of these pipelines operate either unmonitored or with scant oversight, leading to missed opportunities for operational continuity and efficiency.

The result of ineffective pipeline monitoring can also be catastrophic. In Nigeria, an estimated 250 000 barrels of crude oil are stolen daily from pipelines whilst a few years ago, another global pipeline operator remained unaware of an oil leak for 17 hours, incurring nearly $177 million in cleanup fees and fines. 

Despite growing interest in leak detection across various industries, current market solutions often fall short. Traditional monitoring systems typically alert operators to the presence of a leak in a general location. Operators are then left to investigate the cause and determine the specific location of the leak, a process that can be time-consuming and ineffective.

To address these challenges, Schneider Electric partnered with Prisma Phototonics to offer an advanced monitoring solution designed to enhance the safety and efficiency pipelines. PrismaFlow employs Hyper-Scan Fiber Sensing technology which utilises fibre optic sensing technology and machine learning (ML) algorithms for accurate, real-time monitoring of pipeline systems.

In essence, Hyper-Scan analyses laser backscatter light from every location along the pipeline using pre-deployed fibre optics cables. As a practical example, tapping or hot tapping a pipeline is noisy. Thieves need to dig, drill, or weld; this mechanical work is easily detectable with PrismaFlow’s fibre optic sensing tools in place

Indeed, what sets PrismaFlow truly apart is its exceptional sensitivity, capable of detecting changes as minute as 0.025% of pipeline flow.  For instance, preventing a single leak can save oil and gas industries millions of dollars, while water industries can similarly benefit from reduced losses along transportation pipelines.

It also accurately tracks events such as manual digging, vehicle movement, inline inspections (PIG), and other suspicious activities near pipelines, ensuring rapid response to any potential issues. 

Moreover, PrismaFlow dramatically reduces nuisance alarms, which often plague monitoring systems located near busy roads or urban areas. By leveraging machine learning, PrismaFlow can characterise and differentiate between various events, alerting users based on their specific areas of interest.

Additional PrismaFlow benefits include:

• Instant Effectiveness: Unlike conventional systems, PrismaFlow can be deployed within hours, leveraging the existing optical fiber networks installed alongside pipelines. No additional sensors are required, reducing both the time and cost of deployment.
• Cost-Efficiency: PrismaFlow introduces a cost-effective, pay-as-you-grow business model, allowing operators to scale their monitoring capabilities as needed without heavy upfront investments. This flexible model ensures that both small and large pipeline operators can benefit from its advanced features.
• Scalable and Always-On: Designed to monitor thousands of kilometres of pipeline infrastructure, PrismaFlow provides around-the-clock monitoring in any condition—whether day or night, rain or shine.