Faced with mounting challenges and an inspection backlog in their pipeline inspection program, a client needed a smarter, safer, and more cost-effective solution than smart pigs.
We introduced an alternative that reduced inspection risks and costs, streamlined operations, and enabled the client to maintain pipeline integrity with greater confidence, efficiency, and reliability. This alternative inspection technology enabled the client to achieve their goal of getting their inspection schedule back on track while reducing risks and improving the reliability of pipeline integrity assessments.
The client’s pipeline inspection program fell behind schedule across a large oil concession field in offshore southern Africa.
The logistical complexity of coordinating inspections between multiple facilities presented a serious operational bottleneck. However, several deeper challenges further compounded the issue.
- Pipeline design constraints: Many pipelines in the concession were of small diameter, limiting compatibility with conventional smart pigging tools.
- High wax buildup: Infrequent and irregular pigging led to heavy wax accumulation, increasing the risk of obstructions during inspection.
- Lack of operational history: With limited historical data available, the likelihood of intelligent pigs becoming stuck or causing damage was significant.
- Safety and downtime risks: Combined, these factors introduced elevated risks to personnel and infrastructure, while also extending downtime windows during each inspection attempt.
These challenges demanded a solution that could adapt to physical constraints, streamline logistics, and minimize operational hazards.
We worked with a third-party inspection technology provider to implement a smarter, non-intrusive solution designed specifically for complex pipeline environments.
The inspection technology included a tennis ball-sized inspection sphere equipped with:
- Magnetometers to detect metallic anomalies and welds
- Accelerometers for spatial mapping and feature location
- Acoustic sensors to identify leaks and flow irregularities
Our inspection teams floated the spheres through crude oil pipelines, where they confirmed wall condition, deposits and leaks, and were retrieved at designated trap points.
For gas lines, the spheres were embedded in foam cleaning pigs to ensure safe transit without disrupting operations. Operations were supported by a full inspection suite including:
- A sensor deployment strategy tailored to the client’s pipeline specifications
- A complete feature map with timestamps, spatial data, and anomaly categorization
- Risk assessments for stuck-pig scenarios—reduced to near zero with the technology
- Clean, visual inspection reports for client use in asset integrity management systems
In total, the campaign successfully inspected 563 km of pipeline across 21 assets in a three-month campaign.
We played a critical role in customizing the deployment strategy for the client.
- Tailored sensor configuration based on pipeline diameter, wax buildup severity, and fluid type.
- Adjusted inspection protocols for pipelines with historically difficult pigging conditions.
- Developed a low-risk deployment workflow to accommodate tight maintenance windows and mitigate stuck pig scenarios.
Because of their compact size, the spheres eliminated the risk of getting lodged in pipelines, particularly in segments with severe wax accumulation or limited pigging history. This innovative approach solved a longstanding operational challenge that conventional intelligent pigs simply could not overcome.
Using this innovative inspection technology and strategy unlocked new operational capabilities for the client, transforming pipeline management from a high-risk activity into a streamlined, data-driven process.
- Cost savings: Inspection costs reduced by up to 40%, largely due to lower deployment overhead, reduced downtime, and faster execution.
- Downtime reduction: We executed the pigging process with minimal
logistical overhead, eliminating the need for cranes, pig transportation,
and complex scheduling. Inspection runs were completed at short notice, significantly reducing downtime compared to traditional pigging methods. - Competitive advantage: By replacing traditional smart pigs with this
technology, the client gained access to previously unreachable pipeline
segments—restoring compliance, reducing safety risks, and ensuring asset integrity across their entire network. - Compliance restoration: Pipelines that had not been inspected for years due to elevated risk—such as small diameter segments and wax-heavy lines—were confidently assessed.
- Risk elimination: The compact, non-intrusive nature of the spheres cut
the danger of tool obstructions, particularly in areas with challenging flow dynamics. - Operational certainty: With accurate anomaly mapping and spatial feature tracking, the client can plan maintenance proactively instead of reacting to unplanned events.
This project demonstrates how the right mix of technology, collaboration, and
execution can overcome entrenched challenges and transform operational
outcomes. Pipelines were back into compliance, inspection efficiency
improved, and the client gained a new level of confidence in their asset
integrity management strategy
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