IK Trax is heading back to Berlin for the Pipeline Technology Conference, taking place from the 6th to the 8th of May 2025. We’re proud to be exhibiting once again and supporting the event as a Silver Sponsor.
Now in its 20th year, PTC is Europe’s leading pipeline conference and exhibition, bringing together industry professionals from around the world to explore the latest innovations and developments in pipeline technology.
You’ll find us at Stand C15, where our team will be on hand to showcase our Intelligent Pipeline Technology and discuss how we support safer, more efficient operations.
The 4004S Magnetic Pig Signaller is a compact, self-contained, non-intrusive device designed for detecting the passage of magnetic pigs in harsh subsea environments. Unlike traditional subsea signallers, the 4004S is designed for permanent installation on subsea pipelines and can be externally powered through a subsea cable connected to a topside control system. This case study details the development of the 4004S Magnetic Pig Signaller and some of the challenges faced by the IK Trax team.
Project Objectives
The development of the 4004S Magnetic Pig Signaller was guided by three primary objectives. Firstly, the signaller needed to be externally powered via a subsea cable linked to a control system or station topside. Secondly, the device had to be designed for easy installation and removal by divers. Finally, the signaller and clamp assembly, required a minimum operational life of 20 years under subsea conditions. These objectives set the 4004S apart from other subsea pig signallers in the market, particularly those within IK Trax’s existing product range, because the unit could be installed permanently subsea and permanently powered if required.
Design and Development Process
The development process for the 4004S began when the IK Trax sales team identified a potential project that required a new pig signaller meeting the specific criteria mentioned earlier. The in-house R&D department quickly assembled a team of engineers who collaborated to create a concept design which went through multiple iterations and reviews to ensure it met all the necessary requirements. After refining the design, it was presented to the client, who expressed confidence in the unit. Following the client’s approval, a detailed quote was provided. And further refinements were made before the manufacturing phase commenced to ensure all specifications were met.
Meeting Technical Requirements
To meet the technical requirements, the 4004S signaller incorporated several key design features. Powering the unit externally was achieved using a Siemens wet-mate connector, which was permanently fixed to the signaller and designed to withstand external pressures of up to 300Bar. The requirement for diver deployability was addressed by designing a bespoke subsea clamp system that included a funnel mechanism. This system allowed divers to easily install and remove the signaller from the pipeline as needed. To ensure the device’s long-term durability, all metal components were made from super duplex stainless steel, a material known for its resistance to corrosion in subsea environments, ensuring that the signaller and clamp assembly could operate reliably for 25 years.
Client feedback was critical for refining the final design. Specifically, feedback regarding the pipe O/D tolerance allowed the engineering team to fine-tune the clamping mechanism, ensuring it could accommodate the large O/D tolerance of subsea pipelines.
Design Challenges and Solutions
The project’s most demanding design challenge involved creating a locking mechanism that could be easily operated by a diver while ensuring that the 4004S remained securely attached to the pipeline, even under strong currents and potential contact with trawlers. The engineering team tackled this by designing a compression-based locking slot. The mechanism was rigorously tested with various compression forces, leading to an optimised design that balanced ease of use with the necessary security.
Installation Process
The installation of the 4004S is straightforward and diver-friendly, primarily due to its well-designed clamp assembly. The clamp assembly, which is provided with the unit, can be pre-installed onto the pipeline topside, simplifying the subsea deployment process. The assembly includes a built-in funnel designed to accommodate and secure the 4004S signaller once it is deployed subsea. A diver can easily install the pig signaller underwater by using assembly tools to insert it into a locking slot on the funnel. Once the signaller is engaged in the locked position, it becomes securely fixed to the clamp assembly on the pipe. If necessary, the signaller can also be removed by a diver, making the installation both secure and reversible.
Testing and Validation
To ensure the 4004S would perform reliably in its intended environment, it underwent extensive testing. The prototype was subjected to a 22-hour pressure test at more than 1.25 times the operating pressure, which confirmed the signaller’s resilience, with no damage or defects observed. Additionally, the custom-designed electronic PCB was thoroughly tested to ensure it provided the correct voltages and currents for accurate signalling. Before shipping, each unit underwent Factory Acceptance Testing (FAT), which involved powering the unit from a 24V DC supply, monitoring the current loop in both ‘listening’ and ‘detect’ modes, and verifying that the signaller operated correctly.
Conclusion
The 4004S Magnetic Pig Signaller represents a significant advancement in subsea pig detection technology. By closely collaborating with the client and overcoming technical challenges, IK Trax successfully developed a durable, diver-deployable, and externally powered signaller suitable for permanent subsea installation. This project highlights the company’s commitment to innovation and client satisfaction, resulting in a product that meets the highest standards of subsea operation.
We’re excited to announce the launch of our new Technology Footprint page! This interactive map highlights where our technologies are making an impact across the globe.
Check back regularly for updates as we continue to expand and innovate worldwide!
Pig tracking and pig signallers have long been integral to pipeline operations, with each process relying on specialised equipment and methods. As technology has advanced, modern Apps have emerged that significantly enhance these tasks. By integrating the latest Apps into your pig tracking and signalling operations, you can streamline processes, improve data accuracy and achieve great operational flexibility.
Streamlined Operations with Real-Time Data
Modern Apps for both pig tracking and signalling offer real-time monitoring capabilities that simplify operations. Pig Tracking Receiver Apps provide a graphical representation of signals, helping to identify individual and multiple pigs with greater accuracy. Similarly, our latest Pig Signaller App allows you to view real-time pig passages directly on your phone or tablet via Bluetooth, eliminating the need to be situated in view of the signaller. The Apps also allow you to detect your pigs from the comfort of your vehicle which can be advantageous if working in a remote area whilst experiencing inclement weather.
Enhanced Flexibility and Convenience
Traditionally, changing settings on pig tracking equipment involved sending units back to the manufacturer, causing delays and additional costs. IK Trax’s EMTx Config App allows operators to adjust transmitter settings such as pulse length, frequency and power output directly on-site. This increased flexibility is mirrored in our receiver and pig signaller apps, which enables users to adjust settings in real time from their device, making the process more convenient and reducing the need for direct equipment handling.
Comprehensive Data Review and Analysis
Both pig tracking and pig signalling apps offer advanced data review features. Receiver apps let users pause, zoom and scroll through past tracking data, facilitating detailed analysis without the need for constant monitoring. Similarly, our pig signaller app provides a live graphical representation of gauss readings from the 4003 Pig Signaller and allows users to download up to 100 stored events. These features enable thorough review and analysis.
Exportable Records and Client Support
One significant advantage of these apps is the ability to generate detailed records of operations. Pig tracking apps enable users to mark areas of interest and create comprehensive logs of received signals, which can be exported for client reporting and supporting data. Our pig signaller apps also supports exporting records, providing clients with valuable data and ensuring a thorough documentation of pig passages.
Discover the Benefits
Explore how these advanced apps can transform your pig tracking and signalling processes. Our Apps are available to download from our website – for more information on integrating these technologies into your operations, contact us today.
We’re pleased to announce that John Macinnes has joined us as our new Finance Manager!
With over 14 years of experience in the Oil & Gas industry across multiple countries and continents, John brings a wealth of knowledge in International Finance and Project Management to IK Trax.
Outside of work, you’ll often find him at the gym, on the golf course, or trying his hand at training his puppy—though he admits the puppy training is still a work in progress!
This month, we caught up with Andrew Donnelly our Mechanical Engineer.
Tell us about yourself.
My name is Andrew Donnelly, and I work as a mechanical design engineer at IK Trax. I earned my master’s in mechanical engineering at RGU. Throughout university, I had various work placements, and after graduation, I was lucky enough to be accepted as a graduate mechanical engineer at a start-up oil and gas company and that is where I learned my trade. I now have 6 years of experience in mechanical engineering.
Outside of work, I enjoy spending time with my family, whether it’s dog walks on the weekends or dinner dates with my fiancé. I am getting married next April, so wedding planning is currently taking up a lot of our time.
Can you tell us about the mechanical capabilities we have at IK Trax and how they are integrated with our electronics engineering capabilities?
At IK Trax, our CAD software allows me to create 3D working assemblies of all our products and prototypes. We also use finite element analysis software and an in-house design calculation package to ensure our prototypes pass the necessary pressure tests before moving to production.
Our electronic engineers can create a 3D model of a PCB, which I can import into my CAD software. I then design an enclosure to house and secure the PCB and other internal components. These components are often subjected to harsh vibratory conditions, so we work together to create an optimal and mechanically robust PCB mounting method.
What projects have you been involved in at IK Trax, and what have been some key highlights and challenges?
One of my favourite projects was the EMTx50, the largest EM transmitter we’ve ever designed. You can read about the design process in the EMTx50 case study.
The EMTx40 EM transmitter is a product I have worked on from conception. This was my first major project at IK TRAX, in which I was the lead mechanical design engineer. This was also my first project that involved designing enclosures for ATEX certification and while it was challenging learning all the requirements, our prototype type successfully passed all ATEX requirements and testing on our first attempt.
What do you find most rewarding about your role, particularly in the context of developing innovative products like we do at IK Trax?
For me, the most rewarding part of the job is talking to other engineers and seeing a concept design become a working production unit. At IK Trax, I can observe and participate in the production of units I’ve designed. It’s exciting to see something that started as a sketch in a notepad get packed into a crate for a job halfway across the world.
Finally, what are your career goals in the area of mechanical engineering?
My career goal is to apply for and achieve chartered engineer CEng status. This will be an important milestone in my engineering career.
The EMTx50 electromagnetic transmitter is a ground-breaking innovation that represents a significant leap forward in pig tracking technology. With unmatched power and a robust design, it is suitable for larger-diameter pipelines where signal strength and reliability are key to precise and quick detection.
This case study will explore the development of the EMTx50, showcasing the collaborative effort of the IK Trax design, production and sales teams and the innovative technology which made this standout product possible.
Background and Objectives
Developing electromagnetic transmitters for larger pipelines is not new to IK Trax – for years, we have led the market with our 3007 EM transmitter. However, digitalisation has led to demands for further flexibility and customisation and an enhanced user experience. To meet these demands, upgrades were required for the transmitter to be compatible with our EMTx Config Android and Windows Apps.
These Apps enable customers to modify transmitter parameters and gain insights into expected battery life, offering them customisation options and an improved user interface that they now expect. Thanks to the composite housing, this can be done in the field without removing the endcaps, removing that extra layer of complexity. Different endcap options are now available to achieve delayed switch-on, allowing the pigs to be loaded before launch without depleting the transmitter battery.
To address the challenges of extra-large diameter transport pipelines spanning long distances across countries and continents, the transmitter performance and power had to be enhanced while ensuring compliance with pressure and temperature requirements and remaining commercially viable.
Design Challenges and Solutions
Designing a housing for such a large EM transmitter presented mechanical challenges. It needed to withstand high operating pressures while adhering to size, cost and manufacturing constraints. Considering that this is the largest EM transmitter we have developed, the unit will experience the highest loads and forces during the operation that we have seen and would have to be designed accordingly. Size restrictions were also a critical consideration; a larger housing would limit the number of pigs that could house the transmitter, reducing its commercial potential. To address this, we conducted an in-depth investigation to determine the optimal size that would maximise marketability without compromising functionality.
To meet the demands of extra-large diameter transport pipelines, we significantly improved the transmitter’s power output, increasing from 1000mV in the 3007 model to 2300mV in the new EMTx50, and, ensuring reliable performance over long distances. Considering the extensive length of these pipelines, battery life was a major focus. The electronics were designed to be low-power, the coil was optimised for efficiency, and the battery pack was maximised for energy capacity. These improvements extended the operational life of the transmitter, reducing the need for frequent maintenance and replacements.
Rigorous Testing and Validation
During the testing phase, we conducted comprehensive assessments to ensure the reliability and durability of the transmitter. We utilised Finite Element Analysis (FEA) and meticulous design calculations to ensure the enclosure could withstand external pressure tests. Once manufactured, the units underwent a successful 24-hour pressure test at 1.25 times the operating pressure. During this test, we closely monitored creep behaviour in the composite enclosure, which proved to be negligible. An internal pressure test also confirmed that the EM Transmitter had a 130 bar internal pressure rating. The EMTx50 was also subjected to comprehensive testing for high and low-temperature extremes, as well as shock and vibration testing. This ensured the transmitter could withstand the harsh conditions it would encounter in the field.
Extensive battery testing was performed at various power levels and pulse rates. This testing provided valuable data on battery performance and longevity, ensuring reliable operation over extended periods. We also conducted thorough yard testing using our test pipes, which have wall thicknesses over 35mm. This allowed us to determine the different detection envelopes achievable with the EMTx50 compared to our existing transmitters, confirming its superior performance.
Ensuring Performance: Collaborative Design and Efficient Manufacturing
We had to employ several strategies to ensure that the EMTx50 not only met but also exceeded the required specifications, and collaboration was key to achieving this.
Our design team worked closely with the IK Trax sales team, which was crucial in determining the optimal size of the EM transmitter. This ensured the transmitter could meet a wide range of job requirements and maximise its commercial potential. Maintaining strong relationships with various suppliers and machine shops allowed the engineers to optimise the design for both cost and manufacturability. These partnerships ensured that the components could be produced efficiently and economically.
For the mechanical build of the EMTx50, the design team collaborated with our technicians, who have years of experience building for the oil and gas industry. Their extensive expertise was invaluable towards developing detailed build instructions and the necessary assembly tooling. This significantly reduced build times, ensuring efficiency and precision in the assembly process.
Conclusion
The EMTx50 demonstrates that with greater size comes increased power. Through collaborative efforts, meticulous design and efficient manufacturing processes, we have achieved a product that meets the demands of modern pipeline tracking and sets new benchmarks for reliability, performance and user experience in the field.
The EMTx50 is suitable for larger-diameter pipelines where signal strength and reliability are key to precise and quick detection. This groundbreaking development represents a significant leap forward in pig tracking technology with unmatched signal strength and robust design.
The EMTx50 is compatible with the EMTx Config Android and Windows Apps. The Apps enable customers to modify transmitter parameters and gain insights into expected battery life, offering customisation options and an improved user interface. This can be done in the field without removing the endcaps, eliminating an extra layer of complexity.
“Bringing the EMTx50 to market was a true team effort,” said Gavin Duncan, R&D Manager at IK Trax. “By working closely with our colleagues in Production and Sales, we were able to create a product that not only meets the highest technical standards but is also practical to produce and aligned with our customers’ needs.”
Designed to meet the demands of modern pipeline monitoring, the EMTx50’s advanced features and robust design ensure it can handle even the most challenging tracking scenarios.
“With the EMTx50, we’ve set a new standard in efficiency and precision for pig tracking technology,” said Charlotte Hope, Vice President at IK Trax. “This transmitter is tailor-made for environments where real-time tracking is non-negotiable, providing our clients with the power and reliability they need.”
For further information or to schedule a demonstration, please get in touch with us at sales@iktrax.com
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