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Midstream Case Study
Achieved 100% Inspection Follow-Through Across 1,247 Miles of Pipeline

The Challenge
A regional midstream operator was completing pipeline inspections on schedule, but the data showed that only 71% of flagged issues were actually being resolved. Inspections were happening; resolution was not.
- Paper inspection forms were being filled out at the right-of-way, then transcribed back at the field office 2-5 days later. Critical findings could sit for nearly a week before anyone in operations saw them.
- No closed-loop workflow. When an inspector flagged a defect, there was no automated way to convert that finding into a work order, assign it to a technician, and track resolution.
- Compliance reporting was a fire drill. Each quarter, the integrity team spent 80-100 person-hours assembling PHMSA-required documentation from scattered sources.
- Audit risk. Two near-miss incidents in 18 months were traced back to inspections that had identified the issue but never triggered remediation.
The Solution
OpsFlo deployed in 12 weeks with a focused use case: every inspection finding must convert to a tracked, assigned, and resolved work order.
- Inspection & Checklists - digitized PHMSA-aligned inspection forms with photo capture, GPS-stamping, and offline capability
- Work Order Automation - every fail or warning on an inspection auto-generates a work order with severity classification
- Scheduling & Dispatch - automated technician assignment based on proximity, skills, and severity
- Compliance & Audit - automated PHMSA documentation with full audit trail
- Asset Intelligence - full history of every inspection and remediation per pipeline segment
The Results
After 16 months:
- Inspection follow-through rose from 71% to 100%. No flagged issue can be marked closed without documented remediation.
- Time from inspection to corrective action dropped from 14 days to 38 hours. Real-time data sync eliminated the transcription gap.
- Quarterly compliance reporting effort dropped from ~90 hours to under 6 hours. Reports are generated automatically from the audit trail.
- Zero PHMSA findings in the 2024 audit, compared to 7 administrative findings the previous year.
- Insurance premium negotiation: the company used the audit trail to negotiate a 9% reduction in their general liability premium.
Key Impacts
100%
Inspection Follow-Through Rate
38hrs
Time from Inspection to Action (was 14 days)
Zero
PHMSA Compliance Findings in 2024
“We weren't failing on inspections, we were failing on what happened after the inspection. OpsFlo turned a paper handoff into a digital workflow. The day a technician submits a checklist with a defect flagged, a work order is already in the assigned tech's queue. That gap used to be where things died. Now there is no gap.”
Director of Pipeline Integrity
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