PipeSense delivered a new dynamic pressure analysis-based leak detection system to a Texan sCO₂ pipeline

Having proven its capabilities in monitoring and detection leaks in oil and gas pipelines, PipeSense, a leading midstream technology provider, is now expanding its support to emerging CO₂ applications and networks.

Successfully designing, implementing, and testing a new dynamic pressure analysis-based leak detection system, PipeSense proved the capability of the technology on a South Texas pipeline transporting dense phase and supercritical carbon dioxide (sCO₂) at approximately 2,000 psi. Deploying its team on-site for testing, PipeSense was responsible for a 12-mile stretch from a compressor station to a client's handoff point within the state.

Applying a Dynamic Pressure Analysis method (DPA), the leak detection system utilized two Field Processing Units (FPU) equipped with high-sensitivity pressure sensors and positioned at each end of the pipeline segment.

Installation commenced in Q3 2025, while tests continued throughout Q4 2025.

Upon completion of the project, the system capability detects leak events within 2-3 minutes and with location precision down to <20 ft. One false positive and zero downtime was observed over a 5-month period, with the system achieving sensitive, accurate detection and addressing key pipeline network challenges like such as speed of sound variability, unplanned compressor station shutdowns and changes between dense and supercritical phases.

Demonstrating the efficacy of a Machine Learning-enhanced Dynamic Pressure Analysis system for leak detection in sCO₂ pipelines, the project could prove a crucial milestone for supporting growing demand for Carbon Capture and Storage (CCS) infrastructure. With U.S. CO₂ pipelines expected to grow 20x by 2050, the availability of PipeSense’s technology will help to enhance safety and minimize environmental risks from undetected leaks.

PipeSense’s leadership team is planning for further testing and implementation within CO₂ networks and infrastructure in the U.S. and globally.

Stuart Mitchell, President & CTO of PipeSense, commented: “Supercritical CO₂ pipelines operate near the critical point, where fluid properties such as density and compressibility exhibit highly nonlinear and rapid variations. Standard Real-Time Transient Models (RTTM) and statistical models, which rely on simplified equations of state and linear assumptions, struggle to accurately predict pressure and flow transients during operational fluctuations. These modeling inaccuracies produce persistent discrepancies that appear as false leak signatures when residuals or pressure anomalies are misinterpreted.  Our dynamic pressure analysis method offers a superior, mass-flow-independent alternative, paving the way for reliable monitoring in expanding CCS infrastructure.

The simplicity of our system was on full display during this recent implementation. Through just two FPU connected pressure sensors and a flexible dashboard interface, the system demonstrated its effectiveness and highlighted its potential to scale to larger CCS networks, many of which will be required by the expected growth in CO2 pipelines.”

About PipeSense: Representing the future of pipeline leak detection and monitoring, PipeSense has been established under the umbrella of pipeline construction and maintenance specialist Charps. Led by a team of engineers, operators, and problem-solvers with over a century of industry experience, PipeSense is driven by a shared passion for protecting communities and the environment.

Applying ultra-high-frequency pressure sampling and advanced machine learning to detect, pinpoint, and validate pipeline anomalies and leaks with unparalleled precision and speed, PipeSense is committed to ending false positives through relentless innovation. Technical excellence is the base line of every solution and service provided.

With a growing team operating across the United States, backed by development and testing facilities in Houston, Texas, and Clearbrook, Minnesota, PipeSense works closely with an international clientele to understand their unique operational challenges before developing individually tailored solutions. Maximizing efficiency and the service life of a pipeline asset, PipeSense offers assurance that pipelines are monitored in real-time, providing fully integrated services without compromising ease of installation and operation.

Issued on behalf of PipeSense by ThinkPR. For further information contact Matthew Forsyth at [email protected] / +44 1224 623 960