Pipeline Integrity & Leak Detection
Maintaining pipeline integrity and detecting leaks early are critical to the safety, environmental compliance, and operational efficiency of oil and gas, petrochemical, water, and energy infrastructure. Undetected pressure anomalies, whether from corrosion, mechanical damage, weld failures, or third-party interference, can lead to catastrophic failures, environmental contamination, and significant financial loss.
Stork Solutions supplies a comprehensive range of industrial pressure transmitters, differential pressure sensors, electronic pressure switches, and wireless monitoring systems specifically suited to pipeline integrity management and leak detection programmes. All products are available with ATEX, IECEx, and UKEX certification for hazardous area deployment, with SIL 2 functional safety compliance to IEC 61508 and IEC 61511.
Product Spotlight for Pipeline Integrity & Leak Detection
Why Pipeline Pressure Monitoring Matters
Continuous and accurate pressure measurement along pipeline networks enables operators to:
Detect leaks in real time — identify pressure drops indicative of ruptures, pinhole leaks, or joint failures before they escalate
Monitor pipeline integrity — track long-term pressure trends to identify corrosion, fatigue, or degradation
Comply with regulations — meet requirements under PSSR (Pressure Systems Safety Regulations), API 1160, ASME B31.8S, PD 8010, and IGEM standards
Support pipeline pigging operations — monitor pressure differentials during intelligent pigging and cleaning runs
Enable SCADA integration — feed real-time pressure data into centralised pipeline management and leak detection systems (CPM/LDS)
Reduce environmental risk — minimise the volume and impact of hydrocarbon or fluid releases through early detection
Pressure Transmitters for Pipeline Monitoring
Standard Pipeline Pressure Monitoring (up to 600 bar)
For transmission pipelines, distribution networks, and process piping operating at standard pressures:
DMK 331 Industrial Pressure Transmitter
Pressure range 0–400 mbar to 0–600 bar. Capacitive ceramic sensor (99.9% Al₂O₃) resistant to corrosive pipeline media including H₂S, CO₂, and produced water. ATEX/IECEx (Ex ia) certified, SIL 2 compliant. Flush-mounted PVDF option for aggressive or fouling media. Ideal for inline pipeline pressure monitoring, pig launcher/receiver pressure, and pipeline station metering.
XMP i Precision Pressure Transmitter with HART® Communication
Pressure range 0–400 mbar to 0–600 bar. HART® protocol enables remote configuration, diagnostics, and seamless integration with pipeline SCADA and leak detection systems. ATEX/IECEx certified with intrinsically safe (Ex ia) and flameproof (Ex d) options. Hastelloy® and Tantalum wetted parts for sour gas and corrosive pipeline fluids. Cooling element rated to 300°C for high-temperature pipeline applications. The XMP i is the primary choice for computational pipeline monitoring (CPM) leak detection systems requiring HART connectivity.
DMP 333 Industrial Pressure Transmitter
Pressure range 0–100 bar to 0–600 bar. Excellent long-term stability under high dynamic pressure loads — critical for pipelines subject to pressure surges from valve operations, pump starts, and water hammer events. ATEX (Ex ia) certified, SIL 2 compliant.
DMP 331 Industrial Pressure Transmitter
Pressure range 0–100 mbar to 0–60 bar. ATEX (Ex ia) certified, SIL 2 compliant. Suitable for low-pressure gas distribution pipelines, vent lines, and atmospheric pipeline monitoring where high sensitivity at lower ranges is required.
DMP 331i / DMP 333i Precision Pressure Transmitters
Pressure range 0–400 mbar to 0–600 bar. Digital electronics with 16-bit ADC and 1:10 turn-down ratio. Communication interface allows remote span and zero adjustment — reducing the need for technician visits to remote pipeline sections. ATEX (Ex ia) certified.
High-Pressure Pipeline Monitoring (600–2,200 bar)
For high-pressure transmission lines, subsea flowlines, and injection pipelines:
DMP 334 Industrial Pressure Transmitter
Pressure range 0–600 bar to 0–2,200 bar. Thin-film strain gauge sensor welded directly to the pressure port for maximum durability under sustained high-pressure pipeline conditions. ATEX (Ex ia) certified with adjustable span and offset. Designed for high-pressure gas transmission lines, water injection pipelines, and subsea tie-back monitoring.
DMP 334 i Precision Pressure Transmitter
Same pressure range as the DMP 334 (up to 2,200 bar) with enhanced digital electronics and active temperature compensation. Turn-down ratio of 1:10 allows a single transmitter to cover a wide operating range — reducing inventory requirements for multi-section pipeline networks.
Ultra-High-Pressure Pipeline Applications (2,000–6,000 bar)
For the most demanding pipeline environments including hydraulic testing, hydrostatic pressure testing, and ultra-high-pressure injection lines:
SHP 1000 High Pressure Transmitter
Pressure range 2,000–5,000 bar. Silicon-on-Sapphire (SoS) sensing element with titanium alloy wetted parts provides exceptional resistance to corrosion and hydrogen embrittlement. Accuracy <±0.25% (optional <±0.10%). Purpose-built for hydrostatic pipeline testing, high-pressure injection monitoring, and pipeline commissioning.
DMP 304 Ultra High Pressure Transmitter
Pressure range 0–2,000 bar to 0–6,000 bar. ATEX (Ex ia) certified. The highest pressure rating in the Stork Solutions range — suitable for extreme pipeline pressures encountered during hydrostatic testing, pipeline pre-commissioning, and high-pressure gas transmission.
Differential Pressure Transmitters for Leak Detection
Differential pressure measurement is one of the most effective methods for detecting pipeline leaks. By monitoring the pressure difference between two points along a pipeline, operators can identify anomalies that indicate fluid loss, blockages, or integrity failures.
DMD 331 Differential Pressure Transmitter
Differential pressure range 0–20 mbar to 0–16 bar. Piezoresistive stainless steel sensor. Compact design with mechanical robustness under dynamic pressure, shock, and vibration. Withstands one-sided static pressure up to 30× the differential range. IS-version (Ex ia) available. Ideal for pipeline segment differential pressure monitoring, filter condition monitoring at pipeline stations, and flow-based leak detection.
DMD 831 Differential Pressure Transmitter with Display
Differential pressure range 0–1 bar to 0–70 bar. Dual piezoresistive stainless steel sensors with selectable display mode (P+, P-, or ΔP). Rotatable 4-digit LED display and configurable switching contacts. IP65 rated. Suitable for higher-pressure pipeline differential monitoring, pig tracking pressure differentials, and pipeline station filter monitoring where local display and alarm contacts are required.
DPT 100 Differential Pressure Transmitter
Differential pressure range 10 mbar to 20 bar. Static pressure up to 400 bar. Fast response time and high sampling rate — specifically optimised for leak testing and rapid pressure decay measurement. RS485 Modbus RTU interface for direct SCADA integration. Compact aluminium die-cast case with zero adjustment via button. The DPT 100 is purpose-designed for pipeline leak testing and integrity verification.
DPT 200 Differential Pressure Transmitter with HART®
Differential pressure range 1 mbar to 20 bar. Static pressure up to 400 bar. HART® communication for integration with pipeline SCADA and computational pipeline monitoring (CPM) systems. Rangeability up to 100:1 for exceptional flexibility across varying pipeline conditions. ATEX (Ex ia and Ex d) certified. LC display and stainless steel housing options. Hastelloy® diaphragm available for sour service pipelines. The DPT 200 is the premium choice for HART-connected pipeline leak detection systems.
Electronic Pressure Switches for Pipeline Alarm & Protection
Electronic pressure switches provide independent high/low pressure alarm and emergency shutdown (ESD) functionality for pipeline protection:
DS 201 Electronic Pressure Switch
Pressure range 0–400 mbar to 0–600 bar. 1, 2, or 4 independently configurable PNP contacts with analogue output (4–20 mA / 0–10 V). Rotatable 4-digit LED display. IS-version (Ex ia) available. PVDF pressure port option for aggressive media. Ideal for pipeline overpressure/underpressure alarms, pump protection, and emergency shutdown initiation at pipeline stations.
DS 201 P Electronic Pressure Switch
Pressure range 0–60 bar to 0–400 bar. Flush stainless steel diaphragm for viscous, pasty, or contaminated pipeline media. Cooling element option for media temperatures up to 300°C. IS-version (Ex ia) available. Suitable for pipeline applications involving heavy crude, wax-laden fluids, or high-temperature process lines where conventional pressure ports would foul.
DS 200 Electronic Pressure Switch
Pressure range 0–100 mbar to 0–600 bar. Welded pressure sensor for enhanced durability. 1, 2, or 4 independent PNP contacts. IS-version (Ex ia) available. A robust, general-purpose pipeline pressure switch for alarm and control applications across gas and liquid pipelines.
DS 210 Electronic Pressure Switch
Pressure range 0–10 mbar to 0–1,000 mbar. Designed for low-pressure and vacuum pipeline applications. IS-version (Ex ia) available. Ideal for low-pressure gas distribution networks, vent line monitoring, and vacuum pipeline integrity checks.
Certifications & Compliance
All Stork Solutions pipeline pressure instruments are available with the following certifications to meet international pipeline safety standards:
ATEX (EU Directive 2014/34/EU) — Zone 0, 1, 2
IECEx — international explosive atmospheres certification
UKEX — UK post-Brexit equivalent of ATEX
SIL 2 — IEC 61508 / IEC 61511 functional safety
IP65 to IP68 ingress protection ratings
CE marking and EMC compliance