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Technology

Ultrasonic Crack Detection
& Wall Measurement

PIPECARE ultrasonic in-line inspection combines crack detection and direct wall-thickness measurement for liquid pipelines. UTCD uses pulse-echo shear-wave technology to detect and size axial and circumferential cracks, while UTWM measures remaining wall thickness to size corrosion and metal loss. Covering pipelines from 2″ to 56″, both deliver reliable, POF-compliant, ATEX-certified inspection data.

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PIPECARE UTCD and UTWM ultrasonic inspection tool

Description

ACCURATE CRACK DETECTION & WALL MEASUREMENT

Liquid pipelines are exposed to both crack-like defects and progressive metal loss. Axial and circumferential cracks develop from internal pressure, bending forces, and geotechnical movement, while general and pitting corrosion steadily reduce wall thickness. Detecting and sizing both threat types early is essential to managing pipeline integrity and preventing failures.

PIPECARE deploys two complementary ultrasonic technologies. Ultrasonic Crack Detection (UTCD) uses the pulse-echo shear-wave method to detect and size axial and circumferential cracks, SCC, and lamination, with crack depth measured directly to ±1 mm. Ultrasonic Wall Measurement (UTWM) uses the time-of-flight principle to measure remaining wall thickness directly, sizing general corrosion, pitting, and metal loss to ±0.3 mm. Both run in liquid product, are POF-compliant, and ATEX certified.

Specifications

Pipecare tool specifications

Description	Value
Tool sizes	3″ to 56″
Pipeline product	Liquids
Tool velocity range	0.3 to 2 m/sec (4 m/sec optional)
Axial sampling interval	3 mm (1.5 mm optional)
Maximum circumferential sensor spacing	4 to 5 mm
Operating pressure range	0 to 8 MPa
Operating temperature range	−20 to +75° C
Wall thickness range	4 to 25 mm
Min. pipeline bend radius	1.5D
Min. passage bore	80-85% of OD
Certification	ATEX certified

Detection & Sizing	Axial Crack	Axial Colony	Circumf. Crack
Depth at POD 90% (L = 25 mm)	0.5 mm	1 mm	0.5 mm
Minimum crack opening	0 mm	0 mm	0 mm
Depth sizing accuracy at 90% certainty	+/- 1 mm (1–4 mm)	+/- 1 mm (1–4 mm)	+/- 1 mm (1–4 mm)
Length sizing accuracy at 90% certainty	+/- 10 mm	+/- 10 mm	+/- 10 mm
Orientation limits for detectability	+/- 15°	+/- 15°	+/- 15°

Location Accuracy	Value
Axial position from upstream girth weld at 90% certainty	+/- 0.05 m
Accuracy of distance from pig trap valve at 90% certainty	+/- 0.2%
Accuracy of circumferential position at 90% certainty	+/- 5°

Description	Value
Tool sizes	2″ to 56″
Pipeline product	Liquids
Tool velocity range	0.3 to 2 m/sec (4 m/sec optional)
Axial sampling interval	3 mm (0.75 mm optional, at 1 m/s)
Maximum circumferential sensor spacing	4 to 5 mm
Wall thickness range	3 to 40 mm
Operating pressure range	0 to 8 MPa
Operating temperature range	−20 to +75° C
Min. pipeline bend radius	1.5D 90°
Min. passage bore	80-85% of OD

Detection & Sizing	Value
Detection (not sizing) at POD 90% — Minimum diameter	5 mm
Detection (not sizing) at POD 90% — Minimum depth	0.8 mm
Detection and sizing at POD 90% — Minimum diameter	10 mm
Detection and sizing at POD 90% — Minimum depth	0.4 mm
Depth sizing accuracy at 90% certainty	+/- 0.3 mm
Length sizing accuracy at 90% certainty	+/- 4 mm
Width accuracy at 90% certainty	+/- 5 mm

Location Accuracy	Value
Axial position from upstream girth weld at 90% certainty	+/- 0.05 m
Accuracy of distance from pig trap valve at 90% certainty	+/- 0.2%
Accuracy of circumferential position at 90% certainty	+/- 5°

Advantages

Direct crack detection & sizing (UTCD)

Ultrasonic shear-wave technology detects and sizes axial and circumferential cracks, SCC, and lamination. Crack depth is measured directly to ±1 mm — the tightest crack-sizing tolerance available in in-line inspection.

Direct wall measurement (UTWM)

The time-of-flight ultrasonic method measures remaining wall thickness directly, sizing general corrosion, pitting, and metal loss to ±0.3 mm accuracy in liquid pipelines.

Combined inspection capability

UTCD and UTWM sensors run on one modular platform, delivering crack detection and wall-loss measurement in a single inspection — POF-compliant and ATEX certified.

How we work

Technologies

PIPECARE provides In-Line Inspection Services to locate, identify and size these threats and support your integrity management requirements.

We use a whole range of measuring instruments that allow us to detect corrosion, cracks, weld anomalies, and deviations in the shape of pipelines and determine their dimensions.

Electromagnetic Acoustic Transducer

Ultrasonic Crack Detection & Wall Measurement

Magnetic Flux Leakage

Transverse Field Inspection

Caliper - Geometry & Deformation Detection

Combination Tools – Multi-sensor capability

We use a whole range of measuring instruments that allow us to detect corrosion, cracks, weld anomalies, and deviations in the shape of pipelines and determine their dimensions.

AquaScan™

Crawler Systems

Tubing Inspection Tools

We use a whole range of measuring instruments that allow us to detect corrosion, cracks, weld anomalies, and deviations in the shape of pipelines and determine their dimensions.

PredictaTM

CyclopTM

Ultrasonic Crack Detection& Wall Measurement

ACCURATE CRACK DETECTION & WALL MEASUREMENT

Pipecare tool specifications

Technologies

Ultrasonic Crack Detection
& Wall Measurement