Corrosion is slow, patchy and easy to underestimate. One low point holds free water, one tank floor sits on damp sand, one crossing picks up stray current, and the evidence sits in an ILI report, a coupon spreadsheet and a CP survey file that nobody reads together. AI corrosion monitoring pulls those sources into one view, trends the rate for every segment and tank, and tells your integrity team where to look next. See it on sample segment data in a short integrity demo.
Predict Wall Loss on Pipelines and Tanks Before It Becomes a Repair
iFactory combines ILI, coupons, ER probes, CP surveys and sampling into one corrosion rate per segment and per tank. It ranks where to inspect next, grades MIC risk and shows whether your inhibitor dose is doing its job.
Two Attack Fronts, Different Evidence for Each
Internal corrosion needs liquid water. Dissolved CO2, H2S and oxygen and microbial activity set how fast it moves, and it collects at low points, dead legs and tank bottoms. External corrosion depends on coating condition and cathodic protection, and on stray current from power lines or other pipelines nearby. The two need different data and different fixes, so iFactory scores them separately for every segment. Ask our integrity support team how your segments are split today.
What Each Source Measures, and What It Misses
No single method sees everything. ILI gives a full-length snapshot every few years, probes and coupons give a local rate between runs, surveys show protection levels and sampling shows whether the conditions for corrosion are present. The value comes from reading them together. Compare your current sources with ours in a data mapping call.
Turning Scattered Readings Into One Rate per Segment
A rate is only useful if you know where it came from. iFactory keeps the long-term rate from comparing successive ILI runs and the short-term rate from probes and coupons side by side, and plans on the more conservative one unless an engineer records why not. When the short-term rate jumps, the model looks for a cause in flow, water and inhibitor data. Review a rate history with our corrosion engineers.
Remaining Life Is Simple Arithmetic on Honest Inputs
The core sum is (actual thickness − minimum required thickness) ÷ corrosion rate. The hard part is the inputs: a measured minimum, a defensible required thickness and the right rate. API 570 limits the next thickness check on in-service piping to half the remaining life. On transmission pipelines, a pit is judged on remaining strength, for example with ASME B31G methods, not on thickness alone. Check the sum on your own data in a remaining life walkthrough.
Scoring MIC Risk Without Pretending to See Microbes
Microbiologically influenced corrosion cannot be seen from a control room. What can be scored is the likelihood: water that sits still, temperatures microbes like, nutrients, sampling results and the shape of past pits. iFactory combines these into a risk grade and names the sample or dig that would confirm or clear it. NACE TM0212 describes how to test for MIC on internal pipeline surfaces. Set up MIC scoring rules with our integrity team.
A grade is a prompt for sampling, not a finding. Only lab results and pit examination move a segment to confirmed.
Know Which Segment to Dig First, and Why
iFactory ranks segments and tanks by predicted wall loss and explains each rank in plain words. Your integrity engineers check the reasoning and make the decision.
Closing the Loop Between Dose, Residual and Rate
Inhibitor programs often run on a fixed pump rate set years ago. The better test is whether the residual reaches the far end of the line and whether the measured rate responds. iFactory links pump rate, flow, residual tests and probe data, and suggests dose changes that a person approves with your chemical supplier. Walk through an inhibitor loop in a dosing review session.
Why Gathering Lines Corrode Differently
Gathering lines carry wet, untreated gas and produced water, often at low and changing flow, so water and solids settle where a dry transmission line stays clean. PHMSA's 2021 gas gathering rule brought many Type C lines under corrosion control and other Part 192 requirements, and extended incident and annual reporting to Type R lines. Ask our support team how gathering segments are scored.
Tank Floors Under API 653: Where the Loss Hides
On aboveground tanks, the floor is the hard part: product-side pitting from water bottoms and soil-side corrosion you cannot see from inside. API 653 sets a minimum floor thickness at the next internal inspection, generally 0.10 in., or 0.05 in. with a release prevention barrier or a qualifying lining. It caps internal inspection intervals at 20 years, or 30 with a barrier, though RBI under API 580 can support other intervals where API 653 allows. MFL floor scans with UT follow-up feed iFactory's floor model. Review a floor scan with our tank integrity specialists.
What the 2022 Gas Transmission Rule Changed for Corrosion
PHMSA's gas transmission final rule, published in August 2022 and effective May 24, 2023, tightened several corrosion requirements in 49 CFR Part 192. The summary below is a guide, not the legal text, so check the current regulation before acting. Map these duties to your records with our compliance support team.
Plan Inspections and ILI Runs by Risk
Risk-based inspection under API 580 (4th edition, 2023) and the API 581 methodology (4th edition, 2025) applies to station piping, vessels and tanks, and yard piping also falls under API 570 (5th edition, 2024). Pipelines follow integrity management under 49 CFR Part 192 subpart O or §195.452, guided by ASME B31.8S for gas and API RP 1160 (3rd edition, 2019) for liquids. iFactory feeds both with the same corrosion rates, so the next run, dig or tank entry goes where risk is highest. See a ranked plan in a risk ranking demo.
Integrity Models on a Server You Rack Yourself
iFactory delivers a pre-configured NVIDIA AI server racked and ready. Corrosion rate, MIC risk and tank floor models come pre-loaded, along with importers for ILI listings, probe data, CP survey files and lab results. You rack it, plug in power and Ethernet, and the AI is live. For a project scope sheet, contact our deployment engineers.
- Pre-configured NVIDIA AI server, racked and ready
- Importers for ILI listings, CP survey files and lab results
- Links to probe, coupon and SCADA data
- Corrosion rate models for segments and tanks
- MIC risk grading and inhibitor loop tracking
- Ranked inspection plan with the reasons shown
- Remote help with model tuning and hardware
Past ILI runs, coupon and probe data, surveys and dig reports loaded and matched to segments.
Rates and ranks checked against known dig results with your integrity engineers.
Ranked plan, alerts and a weekly integrity review switched on.
AI Integrity Analytics That Supports Your Integrity Program
iFactory sits beside your integrity management program and records. It ranks and explains, and your engineers decide. Watch it work in a live integrity walkthrough.
What Integrity Managers Ask About AI Corrosion Monitoring
See Every Segment and Tank Floor Ranked by Risk
Combine ILI, probe, coupon, CP and sampling data, trend one honest corrosion rate and send the next dig, run or tank entry where it counts. Delivered turnkey and live in 6 to 12 weeks.
