Introduction

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.

Meet Sergey, an integral part of the IK Trax team and the driving force behind the development of our newly released 4003 Pig Signaller App.

Tell us a bit about yourself?

My name is Sergey and I am an Android App Developer at IK Trax. I was born in Moldova and moved to Italy when I was 14. I came to the UK in 2014, firstly living in London and then moving to Aberdeen where I decided to study Software Development.  I attended college for three years and I am now completing my Honours year at Robert Gordon University.

Outside of work, I have a passion for music – I attended music school and have participated in numerous theatre productions.  I also enjoy martial arts and spending time with my wife and our three-year-old son.

Can you share your journey at IK Trax, from being a summer intern to your current position?

At University, we were encouraged to seek a summer placement to give us further hands-on experience and develop our professionalism.  This is something that has helped me in my studies as well as the workplace.  My primary task during my internship was modifying and improving the EMRx Receiver App.  This was challenging, and  I was pushed to conduct my own research utilising online sources and AI technologies to navigate the process.

I have found my colleagues to be very approachable and constructive during my time here.  This has allowed me to grow both as a developer and a professional.  At the end of my internship, I was lucky enough to be offered a part-time position which I am now balancing alongside the completion of my degree.

What are some of the key highlights and some of the biggest challenges you have faced during your time at IK Trax?

During my time at IK Trax, one of the key highlights (and challenges) has been developing the 4003 App. Prior to this, I  was mainly tweaking and fixing applications which were already in existence. Starting a project from the ground up was a first for me and it allowed me to work on my weaknesses and grow professionally. Building the 4003 App was a significant achievement, and I found great enjoyment in the process.

Another key highlight was presenting the completed Apps to my colleagues, explaining updates made and demonstrating the functionality. I have always enjoyed public speaking and consider it one of my best skills. I would like more opportunities to do this in the future. 

How do the Apps you have worked on and developed contribute to pig tracking and detection and what specific functionality do they offer?

All of our Apps allow the operator to input their required parameters directly into a phone or tablet. This is often a simpler and more user-friendly method compared to using the single push button on the receiver or signaller.

The EMRx App provides a visual display of the received electromagnetic or magnetic signal whilst the 4003 Pig Signaller App provides pig passage information in real-time to the device. Information can also be exported from the Apps for further review.  This all provides the user with more flexibility and control during their operations.

Looking ahead, what are your career goals in the field of App Development?

I don’t want to limit myself to App development. As a software developer I believe I should be expanding my horizons and my goal is to learn about different technologies across various fields. I look forward to broadening my knowledge in all areas of software development.

Pig tracking using Electromagnetic Transmitters is not a new concept, yet we are still uncovering ways to improve detection.  Testing by IK Trax challenged the industry standard frequency of 22Hz, revealing that it is not optimal for pig detection.  By scrutinising the performance of different frequencies, we aim to optimise pig tracking methods for enhanced reliability and efficiency.

Methodology

The testing explored the implications of using various EM Transmitter frequencies, ranging from 15Hz  to 22Hz, on pig detection.  IK Trax’s EM transmitters can be wirelessly configured from 10-30Hz using the EMTx Config App.  By conducting comprehensive testing in controlled environments, we assess the signal strength at different distances from the pipeline surface.  This analysis not only sheds light on the efficacy of lower frequencies but also offers insights into the potential improvements that can be made in pig tracking methodologies.    

Setup

The testing was conducted a 3015X EM transmitter which was placed inside a pig within a 608mm outer diameter, 538mm internal diameter, 35mm wall thickness, 10.5m long pipe.  Readings were taken every metre 5m either side of the centre position. At each of these positions 3 readings were taken. These were on the pipe at 0m, 0.5m from the pipe and 1m from the pipe all in air. The image below shows the EMRx at the centre of the pipe 1 m away.  The EM Tx was set to 4 different frequencies: 15Hz, 17Hz, 19Hz, 22Hz.

Results in Figure 1 show that reducing the frequency from 22Hz to 15Hz consistently increased the received signal on the pipe.  The largest increase was 700 or 58% from 17Hz to 15Hz.  Decreasing from 22Hz to 19Hz resulted in a 55% increase, while going from 19Hz to 17Hz saw a 41% increase. 

Figure 1: EM Tx @ 15Hz, 17Hz, 19HZ & 22Hz with Receiver 0m from pipe

In Figure 2, the results at 0.5m from the pipe again show an increase in the received signal with each frequency reduction.  Comparing percentage increases for each frequency change, reductions resulted in increases of 33%, 50% and 58% respectively.

Figure 2: EM Tx @ 15Hz, 17Hz, 19HZ & 22Hz with Receiver 0.5m from pipe

In Figure 3, results at 1m from the pipe demonstrate consistent signal increases with each frequency reduction, at 38%, 50% and 58% respectively.  Despite lower signal levels due to increased air attenuation, trends remain similar to previous distances.

Figure 3: EM Tx @ 15Hz, 17Hz, 19HZ & 22Hz with Receiver 1m from pipe

Conclusion

The results show that with this configuration of pig and pipe parameters, the lower EM frequencies are easier to detect outside the pipe due to the increased received signal levels over those of the higher frequencies at all 3 distances in air from the pipe surface.  Our findings highlight how significant reevaluating industry standards can be.  These insights can not only lead to improved pig tracking methodologies but also highlight the need for continuous innovation and adaptation.