Advancing the Inspection of Challenging Pipelines: Introducing Our New Odometer-Equipped Smart Pig

Last week, we explored how Cokebusters is helping operators eliminate integrity blind spots in tubes and pipelines once considered “unpiggable”. Building on that foundation, we’re pleased to share the next step in that journey: the development of a new odometer-integrated intelligent pig that delivers precise axial positioning within an ultra-compact single-bodied design.

This advancement gives operators an even clearer view of what’s happening inside their most challenging assets – not only detecting changes in wall thickness or geometry, but pinpointing the exact physical location of those findings with exceptional accuracy.

Taking Single-Bodied Ultrasonic Inspection Further

Our patented single-bodied Smart Pig was originally developed to navigate piping systems that traditional multi-carriage tools struggle to navigate. By housing all transducers, control electronics and power supply within one manoeuvrable assembly, the tool can pass through tight-radius bends, schedule changes, unbarred tees and configurations that would render conventional pigs unusable.

The latest enhancement adds a significant new capability: high-precision axial distance measuring device, enabling precise axial positions to be recorded during in-line inspection activities.

How the Odometer System Works

To retain the compact assembly of the Smart Pig, our engineering team developed a modular concept that allows the rear brush section to be replaced with a lightweight aluminium odometer assembly. This assembly incorporates:

• Three spring-loaded arms, each with separate sensors and data processing systems
• Hall-effect sensors, used to detect wheel rotation and therefore axial movement
• Rubber Wheel tread, to prevent slippage and avoid metal on metal contact
• Triple cross-verification, enabling cross referencing of recorded data to ensure accuracy

As the Smart Pig travels through the pipeline, each rotation reflects a certain axial distance, which is calibrated These measurements are logged continuously, giving us a reliable and traceable distance profile that correlates directly with every ultrasonic thickness (UT) reading.

This capability transforms inspection data into actionable integrity insight – enabling operators to locate anomalies quickly, plan targeted interventions and maintain a permanent positional record for future comparisons.

Field-Proven in Real-World Conditions

This year we were invited to apply this technology to a 2km subterranean multiphase pipeline in Europe, constructed from 6” carbon steel and featuring:

• Heavy-schedule bends
• Multiple line-size unbarred tee-pieces
• Sections running above and below ground
• No conventional launcher or receiver infrastructure

Our odometer-equipped Smart Pig successfully traversed the full system, providing a continuous axial log and a complete through-wall ultrasonic dataset. The Smart pig also benefitted from using our latest iteration of simultaneous firing electronics, this resulting in a sampling rate of over 60,000 measurements per linear meter, this giving excellent sampling density.

Deploying Through Existing Pig Valves

One of the standout advantages of our compact single-bodied tools is their compatibility with in-line pig valves commonly installed for cleaning or batching operations.

This capability allows us to:

• Launch and receive without modifying pipework
• Avoid construction of dedicated pig traps
• Reduce project cost and complexity
• Minimise downtime
• Reduce product loss
• Inspect assets that would otherwise remain out of reach

For many operators, this immediately expands the number of pipelines that can be brought into a structured integrity programme.

Why Precise Axial Positioning Matters

Accurate axial localisation is critical for effective integrity management. With the odometer system, every UT measurement is tied to an exact position within the pipeline, enabling:

• Swift pinpointing of defects
• Accurate excavation or access planning
• Repeatable long-term trend analysis
• Fitness-for-Service assessments
• Remaining life calculations in accordance with API 579
• Integration into digital integrity databases or RBI programmes

This transforms a dataset into a map – and a map into a confident decision-making tool.

Key Benefits of the Odometer-Enhanced Smart Pig

• Pulse-echo ultrasonic measurement for internal radius and wall thickness
• High-density UT data for unparalleled insight compared to handheld techniques
• Compatible with in-line pig launchers and pig valves
• No need for insulation removal, de-lagging or pipework modification
• C-Scan data output
• POF100 reporting format
• Suitable for oil, steam and petrochemical processing units, as well as transportation and distribution lines

Strengthening Our Capability for Previously Unpiggable Assets

This development represents a significant advancement in our mission to bring previously unpiggable assets into full integrity programmes. By combining compact geometry navigation with high-precision axial location, we’re giving operators the clarity they need to manage risk, extend asset life and plan interventions with confidence.

If you have pipelines or process systems that have been historically challenging to inspect, we’d be pleased to assess their suitability for this new technology.

Contact our team to learn more.