Advanced In-Line Inspection Detecting Pipeline Integrity with Smart Pigging System
The smart pigging technology is revolutionising the pipeline industry, particularly in the sectors such as oil and gas, as well as water and wastewater management. The implementation of smart pigging in the pipeline industry grows at a rapid pace in recent years. For example, Grand View Research reported the global pipeline pigging market size was estimated at USD 2.18 billion in 2023 and is forecasting to reach USD 2.98 billion in 2030 at a CAGR of 4.6%.
This advanced in-line inspection (ILI) technique not only enhances safety for operators but also significantly reduces maintenance costs from advanced non-destructive technology. By identifying issues early on with smart pigging system as prevention maintenance, companies can mitigate risks associated with pipeline failures or severe accident. Regular inspections through smart pigging ensure that pipelines remain compliant with industry regulations while also prolonging the remaining lifespan of pressurised pipeline. The system employs sophisticated tools known as "smart pigs" equipped with various sensors to assess the integrity of pipelines effectively. The configuration of “smart pig” can vary depending on the specific requirements of the inspection. It is constructed with some common components:
- Body: The main structure houses the various sensors and technologies. It can be made of materials like polyurethane, steel, or composites.
- Sensors: Non-destructive sensors which can indicate defects such as corrosion or cracks.
- Power supply: Onboard batteries for electronic devices
- Data storage and transmission: Onboard data storage systems to record the data collected by the sensors, transmitting data in real-time or near real-time to a control centre or monitoring station.
Three non-destructive technologies are often found in the pipeline industry. The Magnetic Flux Leakage (MFL) stands out for its ability to detect metal loss due to corrosion with remarkable accuracy for ferromagnetic material. Meanwhile, ultrasonic technology offers precise measurements of pipe wall thickness and can spot anomalies that may not be visible externally. Eddy current testing is another valuable method that effectively identifies crack formations in conductive materials. Each method has its distinct advantages and drawbacks in terms of cost, accuracy, ease of use, and adaptability to various pipe materials.
Cost: The cost of smart pigging technologies can vary significantly based on the complexity of the equipment, the length and diameter of the pipeline, and the specific requirements of the inspection. MFL technology is generally considered one of the more expensive options due to the sensor array and data processing systems required. The initial investment in MFL smart pigging equipment can be substantial. The ultrasonic technology (UT), while also requiring a significant initial investment, is often more cost-effective than MFL for certain applications. The cost of ultrasonic smart pigging equipment can range from tens of thousands to hundreds of thousands of dollars, depending on the specific configuration and capabilities. Operational costs for ultrasonic inspections are typically lower than those for MFL, making it a more affordable option for some pipeline operators.
The eddy Current technology (ECT) is generally considered the most cost-effective among the three technologies discussed here. The initial investment in ECT smart pigging equipment is typically lower than that for MFL and ultrasonic technologies. Operational costs are also lower, making smart ECT pigging a more economical choice for many pipeline inspections.
The cost of the smart pig itself can range from tens of thousands to hundreds of thousands of pounds, depending on the sophistication of the technology and sensors and other electronic devices it carries. To use the system, the additional equipment is needed to launch and receive the smart pig, which can add to the overall cost. To obtain a better signals and results, a cleaning pig may be required to launch first to clean the pipe before ‘firing’ the smart pig for pipeline integrity inspection or defects detection. Additionally, the operational costs, including mobilisation, personnel, and data analysis, can add to the overall expense to use a smart pigging system for ILI.
Accuracy: The accuracy of smart pigging technologies is a critical factor in ensuring the reliability and safety of pipelines. MFL is particularly effective in identifying internal and external defects in ferromagnetic materials at highly accuracy, in detecting and measuring metal loss due to corrosion, pitting, and other defects. It can detect even small anomalies, providing detailed information about the pipeline's condition. For some applications, it’s a preferred choice for inspecting steel pipelines.
The UT is also highly accurate in detecting defects in pipelines. It uses sound waves to measure the thickness of the pipeline wall and detect internal and external defects. The UT inspections can provide detailed information about the pipeline's condition, including the size and location of defects. However, the accuracy of ultrasonic inspections can be affected by the pipeline's geometry, flow conditions, and the presence of debris or other obstructions.
The ECT is highly accurate in detecting surface and subsurface defects in pipelines. It uses electromagnetic fields to identify cracks, corrosion, and other anomalies. Eddy Current inspections can provide detailed information about the pipeline's condition, including the size and location of defects. However, the accuracy of eddy Current inspections can be affected by the pipeline's geometry, and the presence of debris or other obstructions.
Ease of use: The MFL systems typically require minimal training for technicians compared to advanced ultrasonic setups that necessitate more specialised knowledge. Eddy current tools also present a steeper learning curve because they require a solid understanding of electromagnetic principles.
Materials of pipe: The technology adaptability across pipeline materials must be taken into account. The MFL works well with ferromagnetic materials commonly found in oil and gas pipelines while ultrasonic technologies are versatile enough for non-ferrous pipes used in water systems. The eddy current inspection can be deployable to certain metallic surfaces but excels on conductive materials. This makes smart ECT pigging a good choice for various applications, including water, oil, and gas pipelines.
The smart pigging operation follows the same international in-line inspection standards. For example, NACE RP0102-2002, API 1163 and ANSI/ASNT ILI-PQ-2005 provide practical information about operation, qualification and certification. The IEC posted a blog article about views on smart pigs for explosive (Ex) areas. The device and equipment shall be tested and certified to IEC 60079 series on explosive atmospheres before the deployment.
The smart pigging technology plays a vital role in maintaining the integrity of pipelines through effective detecting or monitoring for corrosion or leakage issues. The choice of smart pigging technology for pipeline inspection depends on various factors, including cost, accuracy, ease of use, applicability, and pipe materials. With these factors in mind, pipeline operators can ensure the reliability and safety of their infrastructure, while optimising maintenance and repair activities.
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