CorrosionIntel
CorrosionIntelIndustrial AI Platform
Verified Deployments

Outcomes that
prove the science.

Every engagement is grounded in real asset data, verifiable field outcomes, and measurable improvements to reliability, cost, and safety. Nine active deployments across India's most demanding industrial environments.

9
Active Deployments
99%+
Model Accuracy
₹100+ Cr
Value Generated

Browse case studies:

Sectors covered:Oil & GasRefinery / CDUAerospace & DefenceBoiler & UtilitiesAutomobile & FleetMarine & NavalPressure VesselsPlant AutomationNaval Stealth
01Oil & Gas2024
Crude Oil Storage

Indian Oil Corporation Limited (IOCL)

Physics-Driven AI Corrosion Monitoring for Crude Oil Storage Tank

Large vertical crude oil storage tank — 79.5 m diameter, 89,800 m³ capacity

0
Inspection Area Reduction
Risk-based zone targeting vs. full surface treatment
0
Failure Prediction Accuracy
AI model identifies high-risk zones before leakage
0
Safety Risk Eliminated
Drone-assisted survey replaces manual high-altitude inspection
0
Maintenance Planning
Emergency shutdowns replaced with scheduled interventions
02Refinery2024
Crude Distillation

Bharat Petroleum Corporation Limited (BPCL)

Real-Time Corrosion Visibility in CDU Overhead Columns

Crude Distillation Unit overhead systems — HCl, CO₂, and acid condensate environments

0
Potential Annual Losses Mitigated
Energy efficiency, yield, and reliability combined
0
Response Time
vs. weeks–months with periodic inspection
0
Unplanned CDU Shutdowns
Early warning enables proactive corrective action
0
Corrosion Rate Control
Treatment optimization maintains target corrosion rates
03Aviation & Defence2023
Aerospace

Aerospace Manufacturer

Turbine and Airframe Component Integrity — Predictive Monitoring

Turbine blades, combustion chambers, fuselage structures, and wing spar joints

0
Component Failures Reduced
Unexpected failures eliminated through predictive scheduling
0
Maintenance Cost Reduction
Data-driven scheduling replaces time-based overhaul
0
Turbine Blade Life Extended
20,000 → 27,000 flight hours per blade set
0
Aircraft Availability Gain
Less downtime through early fault detection
04Boiler & Utilities2024
Power Generation

Process Plant — Horizontal Fire-Tube Boiler

Digital Twin-Based Safety Analysis of a Horizontal Fire-Tube Boiler

Horizontal fire-tube boiler critical for plant steam supply — real-time digital twin for blast prevention and predictive health monitoring

0
Tube Leak Reduction
Proactive corrosion management reduced tube leaks significantly
0
Failure Prediction Accuracy
vs. 75% accuracy with traditional methods
0
Repair Cost Reduction
Lower repair costs and reduced unplanned shutdowns
0
Boiler Uptime
Achieved through continuous predictive maintenance
05Automobile & Fleet2024
Automotive

Automotive Manufacturer & Fleet Operators

Smart Coating Control via AI Corrosion Intelligence

Zinc-coated automotive steel — galvanized & zinc-magnesium systems for car bodies, underbody structures, and chassis components

0
Warranty Rust Claims
Galvanized & Zn-Mg coatings eliminate perforation claims
0
Vehicle Life Target
High-strength galvanized steel enables decade-long warranty
0
Fleet Maintenance
Real exposure data replaces fixed schedule interventions
0
Emission Reduction
Lighter galvanized structures cut fuel use and CO₂/km
06Marine & Naval2024
Naval Defence

Naval Materials Research Laboratory (NMRL) — Defence Sector

AI-Augmented ICCP for Ship Hull Corrosion Control

Impressed Current Cathodic Protection with dual-objective AI control — uniform hull protection and electromagnetic signature reduction for naval vessels

0
Protection Objective
Uniform hull potential + electromagnetic signature reduction
0
Control Architecture
Model Predictive Control with ML anomaly detection
0
Human Intervention
Automated adaptive response replaces manual adjustment
0
Maintenance Posture
Failure alerts replace time-based inspection schedules
07Refinery / Pressure Vessels2024
Delayed Coking

Refinery — Delayed Coking Unit

Structural Integrity Assessment and Digital Twin for Coke Drums

Large pressure vessels in delayed coking units — extreme thermal cycling, fatigue, corrosion, and fitness-for-service under API/ASME standards

0
Failure Risk Reduction
Early crack precursor detection before propagation
0
Maintenance Approach
Condition-based scheduling replaces calendar-based overhaul
0
Asset Life Extension
Root-cause mitigation slows fatigue and corrosion degradation
0
Regulatory Readiness
Standards-aligned fitness-for-service and compliance reporting
08Plant Automation & Reliability2024
Industrial IoT

Process Industries — Multi-PLC Plants

ADAPT — Real-Time Equipment Efficiency and Health Monitoring Platform

Centralised industrial monitoring platform converting raw PLC data into actionable intelligence — predictive maintenance, unified visibility, and automated alarm management

0
Equipment Downtime
Predictive detection eliminates reactive emergency repairs
0
Plant Efficiency
Centralised visibility unlocks continuous performance gains
0
Maintenance Cost
Condition-based parts replacement lowers overall OPEX
0
Operational Visibility
All PLCs and parameters on one real-time dashboard
09Marine & Naval2024
Naval Stealth

Naval Materials Research Laboratory (NMRL) — Defence Sector

Optimisation of EM Signature in Ship Hull via Intelligent ICCP

Intelligent ICCP-based dual-objective system — corrosion protection and real-time electromagnetic signature reduction for naval stealth

0
Electric Dipole Reduction
vs. 100% baseline with conventional ICCP
0
Harmonic Energy Suppression
FFT-based ripple and switching emission control
0
UEP Signature Reduction
Underwater Electric Potential vs. conventional baseline
0
Corrosion Protection
No trade-off between stealth and hull protection

Start Your Engagement

Your facility. Your asset class.
Your corrosion model.

Every deployment begins with understanding your specific asset configuration, data sources, and risk priorities. Write to us and we'll respond within 24 hours.

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