Even today, undetected volumetric defects in pipelines remain a significant hazard. Issues such as corrosion and weld flaws can go unnoticed if proper inspection methods aren’t used, leading to leaks, ruptures, or explosions. While conventional inspection methods like magnetic particle inspection (MPI) or radiographic testing (RT) and manual ultrasonic testing (UT) still dominate some regions and certain sectors, they are often inadequate for detecting complex or subsurface flaws, particularly in aging pipelines.
The risk of relying on these outdated methods is compounded by the fact that pipelines in use today are decades old. With infrastructure aging and demand for safe, reliable energy transportation rising, ensuring the structural integrity of these pipelines has never been more crucial.
Though incidents like those in San Bruno and Marshall are often seen as historical, they underscore risks that persist today. The conventional NDT techniques still in use in many regions, such as radiographic testing and manual UT, have several limitations:
Despite increased awareness, recent data shows that the risks of undetected pipeline defects remain a present-day issue. In 2023, the U.S. Pipeline Hazardous Materials Safety Administration (PHMSA) reported 614 pipeline incidents, resulting in $334 million in property damage. Many of these incidents were caused by corrosion (28.2%) and mechanical/material failures (42.5%)5—failures that could be significantly reduced with more advanced inspection methods like phased array ultrasonic testing.
Globally, aging pipelines are still prone to failures. For example, in 2021, a fire broke out on an underwater gas pipeline in the Gulf of Mexico after a leak6, drawing attention to ongoing integrity risks in pipeline infrastructure.
The precision and efficiency offered by PAUT make it the go-to solution for modern pipeline inspections. Compared to traditional methods, PAUT offers several key benefits:
A study comparing phased array ultrasonic testing to radiographic testing7 found that PAUT "outperforms RT in terms of the Probability of Detection (POD), particularly for critical planar flaws," demonstrating its effectiveness in identifying defects in pipeline welds. This increased sensitivity and accuracy not only enhances the reliability of inspections but also leads to improved risk management and significantly reduced chances of catastrophic pipeline failures. By adopting PAUT, operators can ensure a more proactive approach to pipeline integrity, safeguarding both infrastructure and public safety.
Despite its advantages, the adoption of PAUT is not yet universal:
The importance of adopting advanced NDT solutions, like PAUT, cannot be overstated. Recent incidents, combined with the proven track record of past disasters, show that many pipeline failures could have been avoided with proper inspection methods. By investing in PAUT technology, operators can ensure safer operations, reduce the risk of undetected defects, and ultimately prevent the next disaster.
Eddyfi Technologies is leading the way with innovative PAUT solutions designed specifically for pipeline inspections. With high-sensitivity detection capabilities and faster, more accurate results, PAUT is the clear choice for operators looking to safeguard their infrastructure. Check out our free resource to learn how to turn pipe (inspection) dreams to reality here.
As pipelines continue to age and global energy demands grow, the need for advanced inspection technologies has never been more urgent. The risks of missed defects—whether due to outdated inspection methods or incomplete data—are simply too high. By adopting advanced phased array ultrasonic testing, operators can ensure the safety and integrity of their pipelines, protecting both the public and the environment from future catastrophes.
1 San Bruno Pipeline Explosion – NTSB Accident Report
2 Enbridge Marshall Oil Spill – NTSB Accident Report
3 EPA Report on the Enbridge Marshall Oil Spill Cleanup
4 USDOT Failure Investigation Report for Plains All-American Pipeline Spill
5 PHMSA Pipeline Incident 20 Year Trends Report