TOPAGENT IC – CORROSCAN: Sovereign AI solution for corrosion forecasting and protection of pipelines and equipment
Learn about the CORROSCAN solution on the TopAgent IC Platform (in collaboration with AIQ) that helps predict corrosion, optimize inspection schedules, and keep equipment and pipelines in the energy sector safe.
The combination of TopAgent IC Platform and AIQ has brought the CORROSCAN solution, opening an advanced direction in corrosion forecasting, optimizing inspection schedules, and ensuring absolute safety for equipment systems and pipelines in the energy sector.
- Challenges in inspecting pressure vessels and static piping systems
In addition to oil and gas pipeline systems, energy infrastructure assets such as petrochemical plants, gas processing plants, and offshore rigs also possess a massive static equipment system, including pressure vessels, distillation columns, heat exchangers, and internal piping networks.
These pieces of equipment operate under extreme conditions: elevated temperatures, high pressures, and highly corrosive fluids. According to international standards such as API 510 (for pressure vessels) and API 570 (for piping), enterprises must establish tens of thousands of Condition Monitoring Locations (CML) or Thickness Monitoring Locations (TML) across the entire plant.
Under traditional methods, maintenance engineers must periodically bring Ultrasonic Testing (UT) gauges to each point to measure metal wall thickness. This process not only consumes significant human resources and requires erecting scaffolding to access hazardous locations, but it is also highly passive. Engineers typically only know the equipment’s condition at the exact moment of measurement, making it difficult to predict when the pipe wall will thin down to a critical threshold, leading to untimely component replacements or emergency shutdowns due to failures.
- CORROSCAN – Data-driven intelligent predictive maintenance solution
CORROSCAN is an intelligent system built on the TopAgent IC Sovereign AI Platform, ensuring that all data regarding plant process diagrams and core asset conditions are strictly protected on internal servers (on-premise).
Instead of measuring every TML point indiscriminately, CORROSCAN uses artificial intelligence algorithms to analyze historical time-series data, fluid dynamics, and material properties to accurately forecast corrosion. The solution operates based on 3 core functions:
2.1. Next Inspection Forecasting: The AI system continuously monitors tens of thousands of Thickness Monitoring Locations (TML) on pressure equipment. By analyzing historical ultrasonic data combined with material degradation models, CORROSCAN automatically calculates the current corrosion rate and predicts the optimal next inspection date. Instead of setting rigid fixed inspection schedules every 1 or 2 years for the entire plant, the system proposes tailored inspection intervals for each specific piece of equipment.
2.2. Inspection Schedule Prioritization: Maintenance resources and equipment in any plant are limited. This module helps managers prioritize inspection schedules based on risk assessment results predicted by AI. Pipelines carrying hazardous fluids with high corrosion rates are prioritized to the top of the list for immediate inspection. Conversely, low-risk locations can have their inspection schedules deferred, optimizing manpower and material resources.
- 2.3. Corrosion Advisor: Integrated with generative AI technology, Corrosion Advisor acts as a virtual RBI expert. This assistant helps engineers plan, track end-to-end inspection campaigns, and evaluate risks. Engineers can interact with the virtual assistant to inquire about resource allocation scenarios to minimize downtime. Furthermore, this centralized expert knowledge base preserves the plant’s entire maintenance experience, preventing knowledge loss during personnel turnovers.
- Operational benefits and economic efficiency
Shifting from periodic maintenance to proactive maintenance with the CORROSCAN solution delivers tangible values and efficiency:
- 20% reduction in annual routine inspections: Eliminating unnecessary inspection routines on safe equipment saves significant costs on hiring third-party inspection personnel and equipment.
- 40% reduction in ultrasonic testing (UT) tasks: Thanks to high-confidence forecasting of remaining wall thickness, engineers only conduct UT measurements at critical locations, reducing manual labor in hazardous environments.
- Enhanced productivity and asset lifecycle management: The system automatically flags assets nearing End of Life (EOL) so management has ample time to order materials and prepare repair or replacement budgets, avoiding passive downtime.
- >85% accuracy in real-world corrosion forecasting: Complex AI algorithms verified in field conditions have proven their capability to closely follow material degradation under thermal and pressure impacts, far surpassing traditional linear interpolation methods.
- Fast and intelligent decision-making: Powered by a centralized knowledge base and early warning systems, executive management can confidently approve major overhaul plans, saving millions of dollars in downtime costs.
By leveraging the power of Big Data and Sovereign AI, the intelligent corrosion prediction model has transformed massive volumes of legacy inspection reports into logical, highly predictive insights. This is the key to helping oil refineries and gas processing plants maintain smooth operations, extend asset life, and optimize costs.
Contact ADT for in-depth consultation on Sovereign AI Solutions in the Energy Industry, or visit the AI/Physical AI section to stay updated with the latest technology trends!
