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Manufacturing & R&D

Engineering the Next Generation of Pipeline Inspection Technologies

PIPECARE develops, manufactures, tests, and improves advanced inspection technologies in-house. From mechanical design and sensor integration to prototype validation and field-ready tool assembly, our R&D capability helps operators access reliable inspection solutions built for complex pipeline conditions.

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PIPECARE manufacturing and R&D facilities

Introduction

Built in-house, tested for the field

PIPECARE owns every step of the inspection-tool lifecycle. Mechanical engineering, sensor development, electronics, firmware, software, and field testing all happen inside the same organisation — under the same quality system, in coordination with the field crews who deploy the tools.

This control is what allows us to qualify custom tools for non-standard pipelines, respond quickly to field-condition surprises, and continuously improve every technology in the portfolio based on real inspection data.

Tool design and integrationMechanical, electronics, and firmware engineered together — no third-party hand-offs.

Sensor research and validationHall-effect, ultrasonic, EMAT, and caliper sensors developed and qualified in-house.

Calibration and softwareControlled-defect test loops and proprietary analysis software keep tool and data quality aligned.

Field readinessEvery tool is built and pre-tested by the same operating group that runs it in the pipeline.

R&D capabilities

Engineering and inspection technology, designed as one

Built for real operating conditions

PIPECARE develops inspection technologies through in-house engineering, workshop integration, and practical field-driven validation.

PIPECARE Engineering

PIPECARE

Inspection technology engineered for performance

High detection accuracy
Verified sizing tolerances and POD targets.

Designed for harsh environments
Operating envelope tested against real conditions.

Built, tested, validated in-house
One team from concept to deployment.

Detection built into every layer

Sensor architecture, signal quality, and mechanical design developed together for reliable inspection performance.

Development process

From concept to field-ready inspection tools

01 — CONCEPT & ENGINEERING DESIGN

Define the inspection objective

Pipeline parameters, threat profile, and detection targets translated into mechanical, sensor, and electronics requirements.

02 — MECHANICAL DEVELOPMENT

Build the tool body

Drive modules, sensor mounts, seal configurations, and structural components designed for the operating envelope.

03 — SENSOR INTEGRATION

Integrate detection technology

Hall-effect, ultrasonic, EMAT, or caliper arrays assembled, wired, and signal-conditioned for the target anomaly types.

04 — PROTOTYPE ASSEMBLY

First-article build

Full tool assembly with firmware, data acquisition, and onboard processing — ready for laboratory qualification.

05 — TESTING & CALIBRATION

Qualify against controlled defects

Pull-through trials and controlled-defect samples confirm sensor response, sizing accuracy, and POD targets.

06 — FIELD VALIDATION

Prove the tool on real pipelines

Pilot deployments and customer-witnessed runs verify performance under live operating conditions before production rollout.

Global R&D footprint

Research and development across multiple countries

PIPECARE operates engineering and R&D centres in more than one country — close to the operational regions our tools serve. Distributed expertise allows us to develop, test, and improve inspection technologies in parallel, drawing on field signatures from every continent.

Multi-country engineering

R&D and manufacturing facilities located across operational regions.

Field-driven innovation

Signatures from 90+ project countries feed back into every new build.

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Technologies supported

Every PIPECARE inspection technology originates here

Designed, manufactured, qualified, and continuously improved by the R&D and manufacturing teams.

Metal Loss

MFL

Magnetic Flux Leakage

Industry-standard metal-loss detection. Standard- and high-resolution MFL configurations across 4″–56″.

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Metal Loss

TFI

Transverse Field Inspection

Circumferential magnetization for longitudinal cracks, ERW seam-weld defects, and axial grooves.

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Cracks & Wall Loss

UTCD / UTWM

Ultrasonic Crack Detection & Wall Measurement

High-resolution crack sizing and direct wall-thickness measurement for liquid pipelines.

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Cracks

EMAT

Electromagnetic Acoustic Transducer

Ultrasonic crack detection without liquid couplant — the standard for SCC programs in gas pipelines.

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Geometry

Caliper

Geometry & Deformation

Mechanical-sensing tools for dents, ovality, bends, buckles, bore restrictions, and IMU mapping.

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Leak Detection

AquaScan™

Acoustic Leak Detection

Free-swimming acoustic sphere for water pipelines — detects leaks as small as 0.04 LPM.

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Specialized

Crawler

Unpiggable Pipeline Inspection

Self-propelled platforms for unpiggable lines, facility piping, offshore risers, and urban networks.

2″–4″ specialized tools for refinery tubing, boiler coils, fired heaters, and downhole production wells.

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Pipeline Conditioning

Cleaning Tools

Foam, Mandrel, Brush, Magnetic

Custom cleaning pigs designed in-house — from foam runs to magnetic recovery — matched to ILI envelopes.

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What are we doing

Our Solutions

For clients operating challenging or unpiggable pipelines, we provide tailored inspection solutions designed to overcome any technical limitations -
ensuring reliable data, minimized downtime, and complete pipeline integrity.

In-Line Inspection (ILI)

Advanced inspection tools for detecting corrosion, cracks, wall loss, geometry changes, and other pipeline anomalies.

Data Analysis & Integrity Assessment

Technical analysis, defect classification, sizing, reporting, and integrity assessment to support maintenance decisions.

Cleaning & Calibration

Pipeline preparation services that remove internal deposits, verify tool passage, and improve inspection readiness.

Pipeline Repair & Maintenance

Repair and maintenance support to restore integrity, reduce operational risk, and extend pipeline service life.

Special Solutions & R&D

In-house engineering, manufacturing, testing, and development of inspection technologies and specialized pipeline tools.

Why Choose PIPECARE

Technology built by experts who use it

By combining R&D, manufacturing, and field experience under one roof, PIPECARE delivers unmatched tool reliability, data quality, and operational flexibility. Our engineering teams don’t just build tools - they refine them through every run and every dataset.

In-House Manufacturing

Tools built and calibrated in our facilities

Certified Processes

API 1163, ISO 9001, 14001, 45001 compliance.

Global Experience

Proven across oil, gas, and water pipelines in 40+ countries

Partner with PIPECARE to shape the future of inspection

Work with our R&D and engineering experts to design your next inspection solution - from concept to commissioning.

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