PipePatrol NEO

Precise, reliable pipeline information in real time

Pipeline operators depend on leak detection and monitoring systems to protect assets, people and the environment. However, many conventional systems remain static while pipeline conditions continuously change. As operating modes evolve, products vary and equipment ages, detection performance often degrades, false alarms increase and operator confidence declines.

PipePatrol NEO changes this approach. Developed by KROHNE, it integrates artificial intelligence into proven multi‑method pipeline monitoring, enabling the system to evolve together with the pipeline. Instead of stopping optimisation after commissioning, PipePatrol NEO continuously learns from real operational data and adapts automatically to changing conditions.

By combining physics‑based hydraulic models with advanced machine learning, PipePatrol NEO delivers precise pipeline information in real time — and improves performance over time rather than degrading. Intelligent model tuning automatically optimises sensitivity, detection speed and stability, without the need for additional hardware or sensors. The result is consistently high detection performance, minimal false alarms and a monitoring system that actively protects the pipeline throughout its entire lifecycle.

1. Leak Detection: PipePatrol NEO includes a state-of-the-art system for leak detection and localisation on pipelines. It sets a new benchmark for internal leak detection by combining highly sensitive measurement data with intelligent, data‑driven decision-making. A unique multi‑method approach ensures fast, reliable detection – even under challenging operating conditions and evolving risk scenarios. As the most sensitive internal leak detection system on the market, it provides precise information on pipeline integrity, leak rate and position for maximum safety.

2. Theft Detection: PipePatrol NEO can detect unusual activity around pipelines, which is particularly relevant in regions with a high risk of theft. The measurement solution is based on advanced pattern recognition to quickly and precisely identify and locate unauthorised or illegal product withdrawals. Even small quantities trigger an alarm within minutes, allowing operators to respond immediately and minimise financial, safety and environmental risks.

3. Line Break Detection: PipePatrol NEO Line Break Detection is designed to protect people, the environment and critical assets by enabling immediate recognition of sudden pipeline ruptures. Especially in high-consequence areas (HCAs), the solution supports operators in meeting regulatory expectations through fast, reliable detection and robust emergency response, and initiating the emergency shutdown procedure for pipeline operations, all in compliance with API 1175 & API – Association of Oil Pipelines (AOPL) Liquid Pipeline Rupture Recognition and Response. 

4. Predictive Modelling: This simulation tool runs in parallel with pipeline operation and represents the thermodynamic and fluid-mechanical conditions. PipePatrol NEO Predictive Modelling enables pipeline operators to anticipate future hydraulic conditions and act before operational or commercial risks arise. By combining traditional monitoring with forward-looking analysis, the solution supports safe, reliable, and efficient pipeline operation across complex networks. 

5. Batch Tracking: PipePatrol NEO Batch Tracking provides complete transparency for sequential pipeline transport of different products, ensuring the right product reaches the right destination at the right time. Accurate batch tracking enables operators to prevent contamination, optimise capacity utilisation and support both operational and commercial decision‑making. 
   It is used directly in daily control room operations to coordinate dispatch, deliveries, and customer fulfilment. 

6. Tightness Monitoring: Small or gradual leaks, in particular, are often not detected by conventional systems, as environmental influences along the pipeline can mask the minor effects of small quantities of leakage on the process data being measured. However, PipePatrol NEO offers a way to identify even slow leaks with reliable tightness testing, such as testing hydrant networks with detection limits down to 0.02 l/m³/hr, ensuring maximum operational safety and reliability. 
   It is ideally suited for commissioning, periodic integrity verification and regulatory tightness testing of pipelines and hydrant systems. 

7. Stress Monitoring: PipePatrol NEO Stress Monitoring supports pipeline operators in understanding and documenting mechanical stress and pressure‑related ageing effects throughout the pipeline lifecycle. Continuous, automated analysis provides the foundation for regulatory‑compliant integrity assessments and informed decisions on remaining service life. 
   The solution runs continuously in the background, supporting long‑term integrity management, audits and lifecycle reporting rather than emergency response. 

8. Pig Tracking: This module provides continuous, real-time visibility of pig and scraper movements to support safe, efficient, and well-coordinated pigging operations. Accurate position information and arrival time predictions enable operators to plan maintenance activities with confidence and reduce operational risk. 
   This helps prevent unplanned downtime, stuck pigs and coordination issues between control rooms and field teams. 

The PipePatrol NEO uses various wireless communication technologies to transmit data from the sensors along the pipeline to the central monitoring unit. The transmission paths, e.g. secure Internet connections via VPN tunnels and SHDSL, mobile radio, Radiolink and WLAN connections, are adapted to the actual conditions on site. This ensures flexible and cost-efficient data transmission, even in remote or difficult-to-access areas. Another aspect is that PipePatrol can be seamlessly integrated into existing SCADA (Supervisory Control and Data Acquisition) systems and software. SCADA systems are widely used in the process and manufacturing industries and enable the centralised monitoring and control of plants. To ensure high availability and reliability of communication, the KROHNE Pipe Patrol NEO System relies on redundant communication paths and fail-safe mechanisms. This means that if a communication channel fails, the system automatically switches to an alternative channel.

The KROHNE PipePatrol NEO System is designed to function reliably even in the most demanding environments. A particular challenge is posed by hazardous areas, i.e. potentially explosive zones, which are found in many industries such as the oil and gas industry, the chemical industry and the petrochemical industry. Strict safety regulations and special technical requirements apply in these areas, which the system must fulfil.

One of the biggest challenges here is the safety of the devices used. All components installed in these zones must be explosion-proof and comply with the relevant ATEX or IECEx directives. In this environment in particular, the reliability of measurement data transmission is often a challenge. Due to the strict safety requirements, conventional communication methods may be limited. The KROHNE PipePatrol NEO pipeline monitoring system therefore offers special communication solutions that guarantee safe and reliable communication.