Internal coatings play an important role in ensuring the long-term reliability of pipelines. Acting as a protective shield between the steel pipe wall and transported products, these coatings reduce corrosionThe deterioration or degradation of a pipeline caused by chemical or electrochemical reactions with its environment. Corrosion is a significant concern as it ca… riskA measure of loss in terms of both the incident likelihood of occurrence and the magnitude of the consequences., improve flow efficiency, and can even serve as an inline repair measure over areas of pittingLocalized corrosion of a pipeline's metal surface, resulting in small, localized pits or cavities. or surface damage. Despite their importance, internal coatings have traditionally received far less attention in routine integrityThe capability of a pipeline to perform its intended function safely and reliably throughout its life. It includes a range of factors, including the structural … programs.
At NDT Global, we’re advancing pipeline diagnostics: using ultrasonic inline inspectionA method used to assess the the integrity and condition of pipelines. It involves the use of specialized tools that are inserted into the pipeline and propelled… technology not just to measure wall thickness and metal lossRefers to the reduction in material thickness or cross-sectional area of a pipe due to corrosion, erosion, or other forms of degradation. but to diagnose, quantify, and monitor the condition of internal coatings in industrial and in-situ applications.
Why Internal Coatings Are Hard to Monitor
Unlike external coatings, internal coatings are not easily accessible for visual inspectionThe systematic process of visually examining, testing, or monitoring pipeline components to assess their condition, integrity, and compliance with regulatory re…. Once a pipeline is in service, even small signs of deterioration can go undetected until they lead to metal lossRefers to the reduction in material thickness or cross-sectional area of a pipe due to corrosion, erosion, or other forms of degradation. or reduced flow performance.
The difficulty is compounded by the fact that internal coatings can vary dramatically, from thin, factory-applied epoxy linings to uneven, brush-applied in-situ coatings. Over time, these layers can thin, fade, blisterRefers to a localized swelling or blister-like protrusion on the surface of a pipeline. It is typically caused by the accumulation of trapped fluids or gases wi…, disbond, or be completely washed out, each posing a unique riskA measure of loss in terms of both the incident likelihood of occurrence and the magnitude of the consequences. profile to the underlying pipe.
Operators often ask:
Is the internal coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… still intact?
Is it bonded, or is disbondment allowing fluid ingress?
Can we detectTo sense or obtain a measurable indication from a feature.
early signs of coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… failureThe inability of a pipeline system to fulfill its intended function or meet the required performance criteria. Pipeline failures can have significant consequenc… before corrosionThe deterioration or degradation of a pipeline caused by chemical or electrochemical reactions with its environment. Corrosion is a significant concern as it ca… begins?
Until now, the industry has lacked a reliable, non-intrusive method to answer these questions with confidence.
Rethinking UTSystems used in non-destructive testing that utilize sound waves to detect, identify, and measure anomalies within a pipeline integrity test or management progr… ILI Data for CoatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… Analysis
While ultrasonic ILI has long been used to detectTo sense or obtain a measurable indication from a feature.
wall loss and laminations, NDT Global’s latest research demonstrates how this same technology can be repurposed to reveal coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… conditions with surprising accuracy.
Here’s how it works:
UTSystems used in non-destructive testing that utilize sound waves to detect, identify, and measure anomalies within a pipeline integrity test or management progr… compression wave technology emits sound pulses that reflect off material boundaries inside the pipe wall.
Differences in time-of-flight (ToFA technique that measures the time it takes a signal such as sound or light to travel through a material and return to a detector. By knowing the speed of sound…) and signal behavior allow our analysts to distinguish between echoes from the steel wall and those from an internal coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… layer.
By translating these patterns using both steel and epoxy sound velocities, we can reconstruct a detailed picture of coating thickness, consistency, and integrityThe capability of a pipeline to perform its intended function safely and reliably throughout its life. It includes a range of factors, including the structural ….
Resulting in a new level of visibility into internal conditions without the need for excavation, downtime, or pipeline entry.
Real Data, Real CoatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… Defects
Using data from multiple inspectionThe systematic process of visually examining, testing, or monitoring pipeline components to assess their condition, integrity, and compliance with regulatory re… runs across four operational pipelines, we identified a wide range of coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… conditions and failureThe inability of a pipeline system to fulfill its intended function or meet the required performance criteria. Pipeline failures can have significant consequenc… modes, including:
Gradual thinning and fading of internal coatings over 5 to 10 years, particularly in areas subject to high turbulence or abrasive flow.
Peeling and blistering in both industrial and in-situ coatings, often indicating disbondment or chemical degradation.
Bulging and open blisters, visible in stand-offThe distance between a pipeline and external objects or structures. This measure of the separation maintained between the pipeline and other elements ensures sa… data, point to critical failures where the coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… no longer protects the steel.
Undermining where product infiltrates beneath disbonded coatings, potentially creating hidden corrosionThe deterioration or degradation of a pipeline caused by chemical or electrochemical reactions with its environment. Corrosion is a significant concern as it ca… risks.
Metal lossRefers to the reduction in material thickness or cross-sectional area of a pipe due to corrosion, erosion, or other forms of degradation. hidden beneath degraded coatings, which can now be isolated and measured with improved signal processing techniques.
In one example, UTSystems used in non-destructive testing that utilize sound waves to detect, identify, and measure anomalies within a pipeline integrity test or management progr… data revealed a nearly 2-meter-long area where an additional material layer obscured the pipe wall. After processing, a severe corrosionThe deterioration or degradation of a pipeline caused by chemical or electrochemical reactions with its environment. Corrosion is a significant concern as it ca… pocket was identified—something that would have gone unnoticed without our enhanced analysis.
Implications for Pipeline IntegrityThe capability of a pipeline to perform its intended function safely and reliably throughout its life. It includes a range of factors, including the structural … Management
Why does this matter? Because internal coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… degradation can significantly shorten the service life of a pipeline, and these failures often go undetected until it’s too late.
By incorporating internal coating assessment into routine UTSystems used in non-destructive testing that utilize sound waves to detect, identify, and measure anomalies within a pipeline integrity test or management progr… ILI inspections, operators gain:
Early warning of coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… failureThe inability of a pipeline system to fulfill its intended function or meet the required performance criteria. Pipeline failures can have significant consequenc… before corrosionThe deterioration or degradation of a pipeline caused by chemical or electrochemical reactions with its environment. Corrosion is a significant concern as it ca… develops.
Quantitative metrics on coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… thickness, degradation rate, and failureThe inability of a pipeline system to fulfill its intended function or meet the required performance criteria. Pipeline failures can have significant consequenc… modes.
Baseline and trending data for proactive maintenance planning.
Insight into coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… suitability, especially as pipelines are repurposed for hydrogenA natural gas element used in non-destructive testing,
hydrogen is a chemical element with the symbol "H" and atomic number 1. It is the lightest and most abun… or other future fuels.
This diagnostic capability also supports targeted remediationThe appropriate actions taken to address or rectify issues, deficiencies, or anomalies identified in a pipeline system. It involves implementing corrective acti…, such as recoating, sectional repairs, or operational adjustments to extend coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… life.
Looking Ahead
While our internal coatingLiquid, liquefiable, or mastic composition that, after application to a surface, is converted into a protective adherent film. The coating serves as a barrier b… analysis is not yet a standardized commercial service, we’re actively partnering with pipeline operators to refine this approach and develop a scalable offering.
Our next steps include:
Expanding the dataset across more pipeline systems
Improving algorithms for greater sensitivity and classification accuracy
Developing a standardized reporting format that integrates with existing ILI deliverables
