R&D Menu
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PHMSA is proud of the successes seen through its heavy investment in
Research and Development efforts focused on technology! PHMSA
conducts and sponsors research projects focused on providing
near-term solutions that will increase the safety, cleanliness, and
reliability of our Nation's pipeline system. Below are links to just
some of our technology development success stories. We will update
and add to this list from time to time. Please visit our "Program
Performance" navigation link to view our broader successes.
Threat Prevention
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Digital Mapping of Buried Pipelines with a Dual Array System
DTRS56-02-T-0005 (12/31/2004)
Witten's patented technology was at the time, the first commercial
system capable of producing highly accurate, three-dimensional
maps and images efficiently and noninvasively (without digging) in
conditions as much as ten feet underground and based on rapid
computer analysis of radar images.
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Acoustic-based Technology to Detect Buried Pipes
DTPH56-10-T-000020 (7/31/2011)
This project improved the Ultra-Trac® APL acoustic pipe
locator through multiple validation demonstrations at several
urban utility sites. As part of the research an algorithm for
improved locating of pipes without tracer wire (or broken wire)
was developed and tested. The improvements will assist the
pipeline operators in detecting buried metallic and non-metallic
pipes, reduce excavation damages.
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Advanced Development of PipeGuard Proactive Pipeline Damage
Prevention System DTPH56-10-T-000019 (9/30/2012)
This project improved the Senstar FiberLR Pipeline Protection
Sensor System that can provide protection over up to 48 km (30
mi.) via a cable buried beside the pipeline.
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Surface Multi-Utility Asset Location Tool DTPH56-13-T-000001
(08/01/2014)
This project collected additional data in laboratory and in the
field with the Acoustic Pipe Locator (APL) to develop guidelines
to detect multiple pipes. The developed guideline will assist the
industry to detect multiple pipes in the local area and will
ultimately reduce the third party damages before excavations or
construction.
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GPS-Based Excavation Encroachment Notification
DTPH56-08-T-000017 (12/03/2018)
The GPS Excavation Encroachment Notification (EEN) system
developed through the PHMSA project was a crucial component in the
final commercial product which was licensed to HydromaxUSA under
the product name UtilAlert. The benefits of using this product
include minimizing the cost of damages, avoiding delays to
completion schedules, enhancing safety for workers and general
public, and enhancing situational awareness and reducing risks for
stakeholders.
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Improved Tools to Locate Buried Pipelines in a Congested
Underground 693JK31810009 (6/1/2018)
The GPS Excavation Encroachment Notification (EEN) system
developed through the PHMSA project was a crucial component in the
final commercial product which was licensed to HydromaxUSA under
the product name UtilAlert. The benefits of using this product
include minimizing the cost of damages, avoiding delays to
completion schedules, enhancing safety for workers and general
public, and enhancing situational awareness and reducing risks for
stakeholders.
Leak Detection
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Airborne LIDAR Pipeline Inspection System Mapping Tests
DTPH56-01-X-0023 (4/30/2007)
This project resulted in a helicopter based fast, efficient, and
accurate tool for detecting and mapping natural gas and hazardous
liquid pipeline leaks.
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Hazardous Liquids Airborne Lidar Observation Study (HALOS)
DTRS56-04-T-0012 (9/14/2007)
This research enhanced the capability of the former ITT (ANGEL)
technology to detect methane and liquid leaks. This technology has
resulted in DIAL collection and data processing improving from 3-4
weeks to one day. In conclusion, Route Generation can now be
accomplished in the field and requires only 1 hour of effort to
generate 100 miles of pipeline routes. This is a 30X improvement
in speed.
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Free-Swimming Acoustic Tool for Liquid and Natural Gas Pipeline
Leak Detection DTPH56-08-T-000007 (8/31/2010)
This project leverage a free-swimming acoustic leak detection tool
that is currently used in the water pipeline industry and further
develop the device for application in oil product pipelines and
evaluate its potential for natural gas pipelines.
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INO Technologies Assessment of Leak Detection Systems for
Hazardous Liquid Pipelines DTPH56-13-T-000003 (09/08/2015)
The program demonstrated the ability to externally locate,
identify, and assess small liquid and gaseous leaks
(weepers/seepers) from a safe standoff distance. The confidence
gained from the research project enabled the launch of FlyScan,
which detects volatile compounds using a spectroscopic lidar.
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Rapid Aerial Small Methane Leak Survey DTPH56-15-T-00016L
(11/20/2018 )
As a result of the research investment, the technology enables
rapid leak survey of natural gas transmission pipelines from
low-cost, single engine aircraft, with plume imagery to
differentiate blow-over sources from off-system facilities.
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Natural Gas Pipeline Leak Rate Measurement System
DTPH56-15-T-00015L (12/04/2018)
The project supported development of the Heath MobileGuard™
gas leak detection system which consists of a methane/ethane
analyzer, GPS, a sonic anemometer and proprietary leak detection
software that presents real-time geospatial maps of multiple gas
concentrations.
Anomaly Detection & Characterization
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NoPig Metal-Loss Detection System for Non-Piggable Pipelines
DTRS56-03-T-0006 (12/31/2004)
The sponsored research resulted in the NoPig inspection technique.
The NoPig technique realizes a nondestructive testing method for
unpiggable pipelines which uses above ground measurements for
detecting wall thickness anomalies like corrosion. The method uses
an applied current between two points on a pipeline up to 1 km
apart.
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Enhancement of the Long-Range Ultrasonic method for the
Detection of Degradation in Buried, Unpiggable Pipelines
DTRS56-02-T-0007 (6/30/2005)
Improvements were integrated in the TeleTest operating software
that facilitates the new sound beam focusing technique. It
improves the sensitivity and range of inspection and identifies
which quadrant of the pipe circumference contains the defect
measured in cross sectional area. Hardware improvements were also
made to support the multi wave focusing.
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Cathodic Protection Current Mapping In-Line Inspection
Technology DTPH56-05-T-0005 (7/31/2006)
This project developed a commercially viable in-line inspection
tool that measures current traveling in the pipe due to cathodic
protection or stray current from sources other than the pipeline
system's cathodic protection system. The data provides information
used to diagnose problems with the cathodic protection system,
coatings and others.
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Validation and Enhancement of Long Range Guided Wave Ultrasonic
Testing: A Key Technology for Direct Assessment of Buried
Pipelines DTRS56-05-T-0002 (12/7/2006)
This project developed and tested in the field enhanced methods of
using ultrasonic guided waves, employing a physical focus of the
ultrasonic energy to increase sensitivity for detection of
corrosion and other defects in pipelines. Its implemented in both
hardware and software in the Plant Integrity Teletest®
Focus™ system. This allows classification of the severity of
defects detected from guided wave test.
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Enhancing Direct Assessment with Remote Inspection through
Coatings and Buried Regions DTPH56-06-T-000009 (3/31/2007)
This NDT technology can inspect above ground piping coated with
less than 3mm thick. Eliminating the need to strip the thin
corrosion barrier coatings such as Polyken, Fusion Bonded Epoxy,
Tapecoat, Mastic, etc. This technique continues to expand the
miles of pipelines inspected by improving the economy of
inspection. The second facet of project is a new technique capable
of inspecting thick Coatings greater than 20mm.
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Internal Corrosion Direct Assessment Detection of Water
DTPH56-06-T-000010 (12/31/2008)
This effort designed, developed and validated the Sentinel Aqua
wireless sensor system that can detect the presence and location
of water in gas pipelines. The sensor system is in the form of a
1.5" diameter sphere that can roll along the pipe propelled by gas
flow.
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Long Term Monitoring of Cased Pipelines Using Long-Range
Guided-Wave Technique DTPH56-06-T-000006 (3/31/2009)
The research mustered the following improvements on this
technology: (1) Inspect inaccessible areas from a remote
accessible pipeline location with or without product in the
pipeline to detect erosion, corrosion. (2) Evaluate damage
severity based on signal strength and characteristics. (3) Detect
both ID/OD wall loss and circumferential cracks. (4) Detection of
2 to 5% change of cross-sectional area using the survey mode or 1%
using the monitoring mode. (5) Defect Accuracy (2.5" per every 30
FT) (6) Test range - varies depending on piping conditions.
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Application of Remote-Field Eddy Current Testing to Inspection
of Unpiggable Pipelines DTRS56-02-T-0001 (9/30/2009)
The new RFEC sensor configured and tested for application to the
internal inspection of natural gas pipelines. Some of its
capabilities are: (1) Detection and characterization of corrosion.
(2) Operation in natural gas systems up to 750 psig. (3)
Retraction and deployment of the sensor pads during launching
procedures and negotiating obstacles in systems un-piggable by
traditional technology.
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Design Construction and Demonstration of a Robotic Platform
Capable of Inspecting Unpiggable Gas Pipelines DTRS56-05-T-0002
(12/31/2010)
This work lead to the commercial deployment of the first ever
inspection platform (Explorer II) and integrated sensor capable of
internal unpiggable gas pipeline inspection.
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Meandering Winding Magnetometer-Array Detection &
Characterization of Damage through Coatings and Insulation
DTPH56-08-T-000009 (5/27/2011)
The project provided a foundation for the development of the
enhanced characterization of mechanical damage, corrosion, SCC,
and welding defects being developed under related DOT funding
(Project 354, Contract DTPH56-10-T-000009). It has also led to
commercially-funded demonstrations for the characterization of
internal and external corrosion through insulation and weather
protection.
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Broadband Electromagnetic Technology Sensor to Assess Ferrous
Pipes without Removing Coatings in Both Traditional and Keyhole
Excavations DTPH56-08-T-000024 (12/12/2011)
The project developed a Broadband Electromagnetic direct
assessment tool that is enhancing pipeline integrity, operational
reliability and efficiency of the national distribution and
transmission pipelines.
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Adaptation of MWM-Array and MFL Technology for Enhanced
Detection/Characterization of Damage from Inside Pipelines
DTPH56-08-T-000009 (3/31/2012)
This project adapted JENTEK's Meandering Winding Magnetometer
(MWM) Array and Magnetoresistive (MR) MWM Array for inspection and
characterization of pipeline damage from inside the pipe using an
in-line inspection or JENTEK PIG-IT tool. Advancements were made
in the sensor configuration, instrumentation layout, mechanical
integration, and data processing algorithms.
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Completion of Development of Robotics Systems for Inspecting
Unpiggable Transmission Pipelines DTPH56-10-T-000008
(12/31/2012)
This work led to the commercial deployment and deployment of the
first ever robotic inspection platform (Explorer) and integrated
Magnetic Flux Leakage sensor capable of internal unpiggable gas
pipeline inspection through many internal obstructions including
plug valves. Explorer is an untethered, modular, remotely
controllable, self-powered inspection robot for the visual and
nondestructive inspection of 20" and 26" natural gas transmission
and distribution system pipelines.
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A Quantitative Non-destructive Residual Stress Assessment Tool
for Pipelines DTRT57-12-C-10054 (9/28/2014)
This inspection tool quantitatively measures residual stress in
pipeline damage to determine the susceptibility of damaged regions
to failure. The eStress™ system provide much more insight
into the nature and severity of the stresses near dents and damage
regions. This technology coupled with modeling will differentiate
between good and bad amount of stress.
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Improve and Develop ILI Tools to Locate, Size and Quantify
Complex/Interacting Metal Loss Features DTPH56-13-T-000009L
(06/28/2016)
The project enabled a new Mechanical Damage Prioritization Process
distinguishing dents with metal loss from dents with gouges by
creating a process by using multiple magnetic fields and field
angles to distinguish a gouge from metal loss in a dent, as well
as from a plain dent.
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In-Ditch Validation Methodology for Determination of Defect
Sizing DTPH56-13-T-000008L (04/13/2020)
The research development and validation success in this project
supported incorporating IWEX technology onto calibration tools,
seam weld inspections and magnetic crawlers for stress corrosion
cracking inspections.
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Development, Field Testing & Commercialization of a Crack &
Mechanical Damage Sensor for Unpiggable Natural Gas Transmission
Pipelines DTPH56-13-T-000006 (02/08/2021)
The research developed and thoroughly demonstrated a cracking and
mechanical damage sensor in the inspection of unpiggable natural
gas pipelines.
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Electro Magnetic Acoustic Transducer Sensor for Small Diameter
and Unpiggable Pipes; Prototype and Testing DTPH5615T00018L
(6/23/2022)
The project developed and then demonstrated the ability of the
Electro Magnetic Acoustic Transducer (EMAT) crack tool to detect
tight/closed cracks down to 2MM deep for 8” diameter pipes
in traditionally difficult to inspect pipelines. The Intellectual
Property from this research and from the prior research project
under PHMSA contract # DTPH56-13-T-000007 evolved into a
free-swimming tool that operates at 2 m/s, navigates 1.5 diameter
bends, and can be pressurized to 2,200 psi. The EMAT Crack In Line
Inspection tool is now being offered by Baker Hughes/Qi2 Elements.
Welding
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Innovative Welding Processes for Small to Medium Diameter Gas
Transmission Pipelines DTRS56-05-T-0001 (4/30/2006)
The project developed and demonstrated Root Pass Welding
Techniques, Improved Root Pass Techniques, and Process Control
Systems for Pipeline Girth Welding with the CRC-Evans pulsed gas
metal arc welding (GMAW-P) technology (P-450 & P-260).
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Advanced Welding Repair and Remediation Methods for In-service
Pipelines DTRS56-03-T-0009 (6/1/2007)
The new automated system is approximately 2.3 times faster and 62%
cheaper than manual welding. Work continues by Bug-O Systems to
reduce the system mounting time in order to further improve cost
effectiveness when compared to manual welding. Automated system
time is 30-36 min for $176.00 estimated cost compered to around
2.5 hours for $ 280.85 per sleeve.
Alternative Fuels
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Monitoring Conditions Leading to SCC/Corrosion of Carbon Steel
DTPH56-08-T-000013 (3/30/2011)
The project validated a reliable ethanol stress corrosion cracking
monitoring tool that enable timely corrective actions to be made.
In addition to pipeline applications, this monitoring tool can be
also used for other modes of ethanol transportation.
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Technical and Economic Feasibility of Preventing SCC through
Control of Oxygen DTPH56-10-T-000004 (4/14/2012)
As part of the broader scope, the project validated the use of
oxygen probes for measuring oxygen levels in pure ethanol and in
fuel grade/neat ethanol. The project improved Polestar oxygen
probes so that they could directly measure the oxygen
concentrations in ppm rather than in a partial pressure
environment common with legacy systems.
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