Industrial Robot: An International Journal

Development of an inspection robot for long-distance transmission pipeline on-site overhaul

Jianming Yuan, Xinjun Wu, Yihua Kang, Chen Huang,
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Jianming Yuan, Xinjun Wu, Yihua Kang, Chen Huang, (2009) "Development of an inspection robot for long‐distance
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doi.org/10.1108/01439910910994614
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 Research article

Development of an inspection robot for

long-distance transmission pipeline
on-site overhaul
Jianming Yuan, Xinjun Wu, Yihua Kang and Chen Huang
School of Mechanical Science and Engineering, Huazhong University of Science and Technology, Wuhan, China

Abstract
Purpose – Damage of oil and gas long-distance transmission pipelines caused by corrosion, stresses, geological change, and other factors can result in
catastrophic failures. The purpose of this paper is to describe a mobile out-pipe inspection robot for the pipeline inspection.
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Design/methodology/approach – This paper adapts to the requirements of long-distance transmission pipelines on-site overhaul, the robot
developed in this paper utilizes a local magnetic flux leakage testing method for the pipeline inspection. Detection, walking, attachment, steering, and
control units are designed for the robot.
Findings – The detection apparatus of the robot plays dual roles as detection and attachment unit. So, the structure of the robot is relatively simple and
it is relatively small in size and relatively light.
Practical implications – A prototype of the robot has been manufactured according to the design. Results of the test in lab show the robot can be
used to inspect pipe.
Originality/value – The robot is able to scan and inspect the pipeline along the planned route automatically.

Keywords Robotics, Non-destructive testing, Flux, Pipelines, Oil industry, Gas industry

Paper type Research paper

1. Introduction inspection method is relatively simple because the inspection

equipment is in pipe so there is no need for excavation and
As one of the five major transportation systems including backfilling work. Equipment called “intelligent pig” was
railroads, highways, waterways, air transportation, and widely used for testing pipeline in service (Bright et al., 1997).
pipeline transportation has been employed as major utilities The pig which is launched at one end of a line section and
in oil and gas transportation. The sum of large-scale oil retrieved at the other end travels in the pipeline and records
pipelines’ lengths is more than two million km in the world the testing results. However, in order to adopt this method,
and it is increasing at a rate of 40,000-50,000 km annually. the pipe needs to be cut or other special inlet should be
Long-distance pipeline consists of many steel pipes welded established and the pipeline’s operation has to be stopped.
together and it is usually buried underground. Damage of oil Another drawback is that the robot may be contaminated by
and gas pipelines caused by corrosion, stresses, geological the material remainders inside the pipe. In addition, many
change, and other factors can result in catastrophic failures, so robots for in-pipe inspection have been developed. However,
routine inspection is strongly demanded to ensure the while using such an in-pipe robot (Zhu, 2007; Lu et al.,
pipelines to operate under safe conditions. Manual 2007), it is necessary to stop the operation and take the
inspection is difficult to be taken due to the enormous product out of the pipeline. Besides the in-pipe inspection
amount of inspection needed and especially in some apparatus mentioned above, lots of out-pipe inspection robots
inaccessible places. Therefore, an automatic inspection have been developed which have already been performed on
robot is desirable to enhance the efficiency and accuracy of complex pipe surface inspection such as vertical pipe, curved
the inspection procedures.
pipe, T-tube, joints, and flanges (Choi and Jung, 2006;
There are two types of inspection method for buried
Chatzakos et al., 2006; Sakamoto et al., 2005; Fukuda et al.,
pipeline in service. One is the in-pipe inspection method and
1987; Suzuki et al., 2006). There is one condition which
the other one is the out-pipe inspection method. The in-pipe
should be considered in out-pipe inspection, that is, robot
must be adhered to the pipe surface to avoid falling down
The current issue and full text archive of this journal is available at from the pipe when it advances along the pipe. Some robots
www.emeraldinsight.com/0143-991X.htm use gripper or arm mechanisms to enclasp the pipe and creep
in warm (Choi and Jung, 2006; Chatzakos et al., 2006). For
avoiding too great shape, these robots cannot be applied
Industrial Robot: An International Journal commonly to large-diameter pipes because their grippers or
36/6 (2009) 546– 550
q Emerald Group Publishing Limited [ISSN 0143-991X]
arms’ diameter must be larger than the pipes’. Another
[DOI 10.1108/01439910910994614] research result shows a kind of robot is developed which has a

546
 Long-distance transmission pipeline on-site overhaul Industrial Robot: An International Journal
Jianming Yuan, Xinjun Wu, Yihua Kang and Chen Huang Volume 36 · Number 6 · 2009 · 546 –550

magnetic wheel-type mechanism (Suzuki et al., 2006). shown in Figure 1 can be used. By this means, the testing
The robot is composed of three units and it is able to apparatus just scans and inspects a small area of the pipe
automatically inspect a pipe’s surface, traverse flanges, and along the axial direction. When one scan is completely
even crawl on a vertical pipe. In order to pass the flanges, the performed, the whole testing apparatus is moved to another
robot’s mechanical structure and control system are very area adjacent to the previous scanned area along the
complicated. circumference, and then the next scan begins. The testing is
Usually, pipeline need to be overhauled on-site after years. completed when the whole surface of the pipeline is scanned.
The purpose of pipeline overhaul is not only to repair and MFL method has many advantages such as high-testing
replace anti-corrosion coating on the pipeline but also to speed, simple operation, and high-testing sensitivity (Ivanov
repair the damages of the pipeline. If the pipeline is buried et al., 1998). So, it is relatively more suitable to be applied to
underground, it is inevitable to excavate the ground above the test ferromagnetic pipeline automatically. In MFL method,
pipeline in order to expose all sides of underground pipes. strong permanent magnets are used to saturate the pipe wall.
While the pipes exposed cannot be pulled out of the trench in A magnetic flux loop exists between the permanent magnet
order to maintain the normal operation of the pipeline. and the pipe. When the magnetic loop which traverses the
Maintenance work for the pipes such as inspecting and pipe wall encounters an anomaly, a portion of the magnetic
coating operation has to be carried in the pipe trenches. To flux will leak out from the loop. Magnetic flux sensitive
adapt to the requirements of working in the pipe trenches, the component such as Hall-effect sensor is applied to detect the
robot should meet the following characteristics: flux leakage signal. To increase the scanning efficiency, a
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.
The robot should be able to walk along the pipeline number of hall sensors are usually installed around the
without additional supporting equipment, and should not circumferential direction of the pipe between the two poles of
fall down from the pipeline. the magnetizer to build a sensor array to measure the leakage
.
The size of the robot should be as small as possible. flux. The signal picked up by the sensor array can be
Smaller excavated space around the pipeline in the interpreted as a “magnetic image” of the condition of pipe
trenches means lighter excavation workload and lower cost. wall. The shape and amplitude of the signal indicate the
. Robot’s weight should be as light as possible so that one characteristics of the anomaly.
person could lift it without additional assistance because
the narrow excavated space would not allow assistance 2.2 The requirements to the robot’s structure
from lifting equipment in field work environment. Besides, As mentioned above, the size of the inspection robot should
the pipeline hung in the air may be damaged by the weight be as small as possible to fit the limited space around the pipe
of the robot. in trenches. Robot should be able to reach every surface area
.
The robot should be able to adapt to the large-diameter of the pipe to scan the entire pipe surface. When the robot
pipe and the variety of the pipe’s diameter. stands on the top of the pipe, it will not fall off because the
.
The robot should be capable to smoothly cross the spiral pipe supports it. But when it moves to the edge of the pipe,
welds and circular welds on the surface of pipe without the robot will fall down from the pipe due to gravitation. So, it
considering other obstacles. Long-distance pipeline is necessary to set an attachment unit with which the robot
consists of many steel pipes welded together and welds will not fall down. To achieve the goal, the first method is to
height is less than 5 mm commonly. use gripper or arm mechanisms to enclasp the pipe. The
.
The robot should have intelligent control systems to second method is to utilize a vacuum suction cup to catch the
automatically inspect the pipelines and it should be able to pipe wall. The third method is to use permanent magnet or
accept manual operation under exceptional condition. electromagnet to generate magnetic force to adhere the robot
.
The robot should be easily installed/uninstalled on the to the pipe surface. As discussed above, the first method is
pipeline. unsuitable to be used in strait pipeline trenches. The second
.
The robot should work reliably under the severe method is ineffective to the rough surface of the underground
environment of the field. pipe. Therefore, the method which uses magnetic force is
suitable to make inspection robot attach to the pipe. The
Based on the above requirements, the robots mentioned in the
magnetizing magnetic of the MFL method plays dual role in
references are unsuitable to inspect long-distance pipeline
the testing robot. One is to saturate the pipe wall to generate a
buried underground. This paper describes a mobile out-pipe
magnetic flux needed by testing purpose. The other one is to
inspection robot with magnetic flux leakage (MFL) testing
generate the magnetic force needed by the robot to catch the
sensor for pipe inspection.
pipe wall. Because of no need for extra attachment part, the
size and weight of robot can be reduced. The configuration of
2. Technical analysis the magnet and sensor are shown in Figure 2.
Robot is able to move along the pipe in many ways such as
2.1 Detection method
wheel-, creep-, and track-types. Wheel-type should be the
As discussed above, due to limited space around the pipe in
best choice for pipe robot due to its simple structure and
pipeline trenches, the method that the whole circumference of
control logic, high-move speed, and good turning ability.
pipe is surrounded by the detection sensor is unsuitable. To
When the robot completes one scan along the axial
reduce the size of testing apparatus, a local testing method
direction, it must be moved to another area adjacent to the
Figure 1 Local testing method for pipe inspection previous scanned area along the pipe circumference before
next scan. It is difficult to lift the robot and then put it to
Pipe Planned route another place because the magnetic force between the robot
and pipe will prevent them from being separated. Another
Robot
method is to let the robot change its moving direction

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 Long-distance transmission pipeline on-site overhaul Industrial Robot: An International Journal
Jianming Yuan, Xinjun Wu, Yihua Kang and Chen Huang Volume 36 · Number 6 · 2009 · 546 –550

Figure 2 MFL method and magnetic attachment between detection Figure 3 Structure of the robot
unit and the pipe
Hall Steering Detection & attachment Walking
Magnetic Hall Magnetic Backing Permanent Pipe sensors device device device
attachment Defect sensors flux loop iron magnet

Φm Pipe

F F

F Φw F
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when needed. The steering unit of the robot is designed for

this purpose. The steering unit of the robot can make the (a) Main view of the robot
robot change its movement direction with a turning angle up
to 908 so the robot is able to move straightly to the area Car Driven Driving Steering
adjacent to the previous scanned area along the circumference frame procket procket motor Chain
without being lifted.
The robot should scan and inspect the pipe along the
Wheel
planned route or some defect will be missed. However, the
frame Bolts
robot may deviate from the planned route due to gravitation,
welds and obstacles. The control unit of the robot can find the Walking
deviation and make the robot back to the planned route. motor Permanent
magnet
Wheel
3. Robot design
According to the above analysis, detailed design for the robot
is given in the following.
Figure 3 shows the structure of the robot. The robot
consists of detection, walking, attachment, steering, and
control units.

3.1 Detection unit

MFL method is used. Backing iron, two permanent magnet (b) Side view of the robot
poles, pipe wall, air clearance between the magnetic poles,
and the pipe wall form a magnetic flux loop. Detector
includes an array of Hall sensors, a magnet collector which only drives the respective wheel. This configuration makes the
leads magnetic flux to Hall sensors and a trace spring which robot overcome movement resistance without skidding. Four
presses the Hall sensors close to the pipe wall surface. wheels which are all made from rubber make the robot move
smoothly and the vibration which will influence the detection
3.2 Walking unit signal can be reduced.
The robot’s walking unit is able to take detection unit to move
on the surface of the pipe. It consists of a car frame, four 3.3 Attachment unit
wheels and wheel frames, and four driving devices. Every It is unnecessary to employ an additional attachment unit for
wheel is installed in a wheel frame, respectively. Four wheel the robot. The permanent magnet of detection unit will
frames are installed in the car frame symmetrically. Four supply magnetic force to make the robot firmly attach to the
wheels and wheel frames have the same structure and size, so pipe. So, the detection unit is also employed as an attachment
four wheels can stand on a plane like a car. When the robot is unit. The attachment unit is installed under the walking
placed on the surface of cylindrical pipeline, the central line of unit by four bolts. There is a clearance of five millimeter
the robot’s body must be parallel to the axial line of the which is slightly larger than the height of welds between the
pipeline, otherwise one or more of the four wheels will depart permanent magnet and the pipe. Although the clearance will
from the surface of the pipe and the permanent magnet of reduce the magnetic force, it is necessary to avoid the
detection unit may cling to the surface of the pipe. Every permanent magnets clinging to the surface of the pipe. For
wheel frame can be turned 908 by the steering unit. The pipes with different diameters, the dimension of clearance can
driving device which consists of a DC motor and a retarder be adjusted by twisting the four bolts.

548
 Long-distance transmission pipeline on-site overhaul Industrial Robot: An International Journal
Jianming Yuan, Xinjun Wu, Yihua Kang and Chen Huang Volume 36 · Number 6 · 2009 · 546 –550

3.4 Steering unit according to the instruction from SCM or manual control
When it is needed to change the robot’s movement direction on unit. Manual control unit offers some control functions such
the pipe, all of the four wheels of the walking unit must be turned as moving forward, moving backward, turnning left, turnning
synchronously. The steering unit of the robot is to drive the four right, system starting, and system stopping to manually
wheel frames of the robot to turn with same angle around their control the movement of the robot while needed. Figure 5
respective centers when needed. The driving device of the shows the schematic diagram of the control unit.
steering unit which consists of a stepper motor and a motor
controller is relatively simple. If a driving device drives a wheel
4. Robot tests
frame solely, it is difficult to ensure four wheel frames to turn
synchronously and the structure and the control of the steering A prototype of the robot has been manufactured according to
unit are complicated. A way to solve this problem is to utilize above design. The technical parameters of the prototype are
only one driving device to drive four wheel frames. The shown as followed:
synchronization of the turning of the wheels are completed by .
Diameter of pipe: f530 , 1,220 mm.
mechanical transmission. As the distance between two wheels is .
Annular space’s size outside of pipe: 450 mm.
large, a chain-driven will be a better choice for power .
Height of obstacles on pipe: less than 5 mm.
transmission than gear-driven or belt-driven. A sprocket is .
Weight of the prototype: 40 kg.
fixed on each output shaft of step motor as the driving sprocket. . Size of the prototype: 550 £ 450 £ 270 mm3.
Four sprockets are fixed on the turning shaft of four wheel .
Velocity of the prototype: 1 , 6 m/min.
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frames, respectively, as sprockets to be driven. A chain links the

Two tests had been conducted in the laboratory. First, the
driving sprocket and four driven sprockets together. When the
authors did an experiment which tested the movement
driving sprocket is rotated by stepper motor, four driven
performance of the prototype and the control performance of
sprockets will follow synchronously. Figure 4 shows the process
the control unit. The diameter of the pipe is 720 mm and the
of robot changing its move route.
thickness of the pipe wall is 8 mm. The experiment result showed
the prototype could move to any place of the pipe without falling
3.5 Control unit
down from the pipe and the control unit could control accurately
When the walking unit of the robot moves on the pipe along the
the prototype to move along the planned route. Figure 6 shows
axial direction, it may deviate from the planned movement route
the prototype stands on the different places of the pipe.
by inches due to gravitation, welds, and obstacles. Deviation
should be corrected duly, or the walking unit will lose planned
Figure 5 Schematic diagram of the control unit
movement route completely. Control unit should measure
accurately the real-time deviation, and then controls the walking Display Power
unit to turn an angle so that the robot can return to the correct unit supply
route. This is the automatic control function of anti-deviation. Walking
Controller can also be operated as needed by the personnel to driving
manually control movement route of the walking unit.
Control unit consists of angle display unit, single chip SCM PLC Relay
micyoco (SCM), programmable logic controller (PLC),
Steering
relays, angle sensor, and manual control unit. Angle sensor driving
is installed in the central line of the robot’s body, and it
Angle Manual
measures the real-time angle of the robot to horizontal line. sensor control unit
The result of angle measurement will be transmitted to SCM.
Before the robot begins one scan to the surface of the pipe, a
Figure 6 Robot movement testing on pipe
maxim allowable deviation angle will be set and stored in
SCM. During the process of scan, SCM compares real-time
angle and the setting angle, and then decides whether or not
to send steering instruction to PLC. SCM also sends angle
measurement result to display unit. PLC controls walking
driving device and steering driving device by the relays

Figure 4 Four wheels turning synchronously and robot changing its

move route

Pipe (a) Robot on the top of pipe (b) Robot on the side of pipe

Driven Driving Angle

sprocket sprocket Chain sensor
(c) Robot on the bottom of pipe (d) Robot on the side of pipe

549
 Long-distance transmission pipeline on-site overhaul Industrial Robot: An International Journal
Jianming Yuan, Xinjun Wu, Yihua Kang and Chen Huang Volume 36 · Number 6 · 2009 · 546 –550

Figure 7 Testing signals of the pipe the robot will be multifunctional equipment for pipe
maintenance.
c2:
c1: 1 × 3.6 × 32
4.0 1 × 4.8 × 32 h1: h1:
Amplitude (V)

c3: ø3 ø3 References
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2.0 inspection robot”, Industrial Robot, Vol. 24 No. 4, pp. 285-9.
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Khalid, A. (2006), “On the development of a modular
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Industrial Robot, Vol. 33 No. 4, pp. 291-7.
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along the circumferential direction of the pipe. The diameters of Ivanov, A., Zhang, Z., Yeoh, C.H., Udpa, L., Sun, Y.,
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5. Conclusion Lu, C.-P., Huang, H.-P., Yan, J.-L. and Cheng, T.-H. (2007),
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mentioned in introduction for inspection the pipe in trenches. Annual Conference of the IEEE Industrial Electronics Society
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characteristic which makes the robot differ from other Abe, Y. (2005), “Parallel-link robot for pipe inspection”,
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planned route, the deviation can be rectified automatically by
control unit. So, the robot can scan and inspect the pipe along
Corresponding author
the planned route automatically. If the robot is equipped with
other devices, such as cleaning, spraying, and welding device, Xinjun Wu can be contacted at: [email protected]

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 This article has been cited by:

1. Kyujun Choi, Shujiro Dohta, Tetsuya Akagi, Shota Ninomiya. 2016. Development of Pipe Holding Mechanism for Pipe
Inspection Robot Using Flexible Pneumatic Cylinder. MATEC Web of Conferences 51, 02006. [CrossRef]
2. Wei Zhao, Xinjing Huang, Shili Chen, Zhoumo Zeng, Shijiu Jin. 2014. A detection system for pipeline direction based on
shielded geomagnetic field. International Journal of Pressure Vessels and Piping 113, 10-14. [CrossRef]
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