Operating a midstream gathering system comes with all the challenges of upstream wellhead production, just spread across a much larger map. From compressor sites to sales meters, pipelines stretch across counties, states, and sometimes countries. That geographic reality means you can’t be everywhere at once, but you still need to respond like you are. In this environment, waiting for accounting reconciliation to figure out fuel loss or imbalances is a thing of the past.
Operators need real-time visibility. With a system like zdSCADA, they can spot issues as they happen and be alerted to potential leaks or performance issues in minutes, not weeks. That kind of speed saves money, keeps production flowing, and limits risk.
The Balancing Act
Your system balance is only as good as the quality and completeness of your measurement. That includes not just receipt and sales meters, but also compressor fuel, vapor recovery, flares, and any other gas-consuming components. Without full coverage, operators are forced to guess. And that guesswork is where mistakes get made.
When zdSCADA is fully utilized, it surfaces imbalances early and ties them back to measurement issues before they turn into operational headaches. Something as small as an unrecorded plate change or liquids sneaking through an orifice plate can throw off the system. Spotting those problems early is the difference between a routine correction and a major investigation.
Leak Detection
Definitive leak detection on pipelines is, in most cases, not possible. But the emphasis here is on “definitive.” With SCADA in place, operators can quickly spot signs of trouble, like strange pressure behavior or growing imbalances. Graphs and trending tools make it easier to visualize the data and flag what needs inspection.
One zdSCADA customer recently caught a gas imbalance and traced it back to a dump valve stuck open on a vertical separator. Gas was venting into condensate storage tanks, but because the alert came within hours, not days, the financial and environmental cost was minimized.
Gas pipelines can mask problems due to compressibility. Liquids lines are less forgiving. Either way, good leak detection depends on solid measurement and accurate timekeeping. All meters need to be functioning properly and clocks need to be synced. Most pipeliners would probably support abolishing Daylight Saving Time just to make this easier.
Segmenting pipelines helps too. The more you can isolate pieces of the system, the faster you can zero in on the problem. A gathering system with dozens of inlets and multiple outlets becomes much easier to manage when upstream laterals and mainlines are segmented clearly.
Keeping an Eye on Things
Tank levels are another common chokepoint. Whether it's condensate tanks at a compressor or saltwater tanks at a disposal facility, full tanks can mean shutting in production. SCADA systems let operators track levels in real time and call in loads before a shutdown is required.
Equipment downtime is just as costly. Cry-out alarms delivered via text or phone call allow operators to respond immediately. And when properly configured, the system won’t stop alerting until someone acknowledges the alarm. That kind of accountability is what makes alarm systems actually work.
Midstream operators also have a customer to keep in mind: the upstream producer. If pressure starts to build, it's better for the pipeline operator to catch the issue first. That gives them a chance to fix the problem before the customer notices.
On the flip side, SCADA reports showing declining throughput can help the upstream operator identify and resolve production issues, which benefits everyone involved. SCADA can also monitor for signs that fluids are entering the line. H2S and CO2 alarms can close valves before corrosive substances get into the system.
A Pig in a Poke (or Pipeline)
Pigs are another area where SCADA adds value. Most operators use pigs to clear out liquids in gas lines. SCADA makes it easier to know when to run them. Rising upstream pressure is usually a sign that liquids are building up. Graphing those pressure changes helps teams decide when to launch a pig before the issue becomes disruptive.
Lost or slow pigs are a well-known frustration. SCADA can detect pressure changes or use pig sensors to confirm movement and arrival. That saves operators time and allows them to focus on other work without second-guessing where the pig is.
Playing Defense
Try as we might, upstream operators are going to complain from time to time. When they do, midstream teams need to respond quickly. A customer may question a volume statement, meter test, or gas analysis. With zdSCADA, all the relevant data can be stored together and retrieved in seconds.
If a customer calls with a complaint, you can have the documentation in front of them before they hang up. That kind of response builds trust, prevents back-and-forth, and keeps operations moving.
The Future is Here
The digital age of pipeline operation is already here. Tools like SCADA aren’t luxuries. They’re essential systems that give operators the visibility and responsiveness required to manage sprawling, high-stakes infrastructure. When configured properly for a specific gathering system, zdSCADA can help operators move faster, act earlier, and make smarter decisions—saving both time and money along the way.
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