X-RAY PIPE LINE CRAWLER

ABSTRACT
The intensive development of oil and gas industry, as well as transporting the obtained
products to great distances advance high demands to reliability and performance of
nondestructive methods of inspection. A special emphasis should be made on the inspection
sensitivity as emergency situations result in a significant environmental damage.
X-ray Pipe Crawler is the welding seam detection device that is widely used in Oil pipeline
construction of middle and far distance transmission. This comprises a directional x-ray
source which is insert able into a pipeline section and is rotatable within the pipeline. Means
are provided to align the directional x-ray source with an external x-ray detector such that
both may be rotated through 360 degrees substantially coaxially with the pipeline section.
Means for sampling the data detected by the x-ray detector are provided so that it may be
analyzed.
The world leading companies are developing both individual components of the system and
the complete system. The best known companies are Siemens, Institute of Non-Destructive
Testing, National Research Tomsk Polytechnic University (NR TPU); they have developed
several X-ray machines that generate X-rays in the range from 50 kV to 300 kV.
The principle of operation of these systems is based on theoretical calculations to determine
the optimum parameters of the radiation source and detector, namely, a narrow fan beam
passing through a tested weld, getting on the Linear Diode Array, which sends signals to the
system of test results processing where they are converted to grayscale images of the object
internal structure.

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 1

X-RAY PIPE LINE CRAWLER

CONTENTS
CHAPTER

PAGE NO.

1)

Introduction

03

2)

History of radiography

04

3)

A second source of radiation

06

4)

Working principle

08

5)

Working Technique

10

6)

Radiography Technique

11

6.1 Single Wall Technique

6.2 Double Wall Technique
6.3 Different type of defects captured
7)

Types of crawler & specifications

15

7.1 Gamma version model

7.2 X-Ray model
8)

9)

Futures, Advantages & Disadvantages

18

Safety, Benefits & Risks

20

10)

Conclusion
21

11)

References
22

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 2

X-RAY PIPE LINE CRAWLER

Chapter 1:

INTRODUCTION
Pipeline crawler is a kind of instrument for detecting the quality of welding line in longdistance pipeline. This instrument comes up to advanced world standard. It adopts imported
Siemens S7-200 PLC as control center with strong anti-interference resistance, high
integration, high capacity memory and simple programming operation, making the pipeline
crawler getting all-around protection. The instrument is set with various protective measures,
and the faults are clearly displayed through the display screen. High precision tube voltage
adjustment making the setting parameters not changed with the reduction of energy capacity
of battery.
The X-Ray Crawler is similar to conventional radiography however a x-ray source tube on a
crawler device is run inside the pipe to each weld. Film is wrapped around the welds and the
source tube is excited. The film is then developed in a mobile dark-room on location. The
technique is quick and can inspect on average 150 welds per day. The advantages of x-ray
crawlers are their speed and the short exposure time. The film is also crisper and much less
grainy when compared to conventional radiography using Iridium type sources.
The disadvantages are that the tool must be run into the pipe and the testing must be
performed a significant distance from the welding crews. In many situations weld repairs are
not identified until the welding crews are several hundred joints ahead. When repairs are
required a significant cost is incurred as the main line crews must stop and return to the repair
welds delaying the project.

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 3

X-RAY PIPE LINE CRAWLER

Chapter 2:

HISTORY OF RADIOGRAPHY
X-rays were discovered in 1895 by Wilhelm Conrad Roentgen (1845-1923) who was a
Professor at Wurzburg University in Germany. Working with a cathode-ray tube in his
laboratory, Roentgen observed a fluorescent glow of crystals on a table near his tube. The
tube that Roentgen was working with consisted of a glass envelope (bulb) with positive and
negative electrodes encapsulated in it. The air in the tube was evacuated, and when a high
voltage was applied, the tube produced a fluorescent glow. Roentgen shielded the tube with
heavy black paper, and discovered a green colored fluorescent light generated by a material
located a few feet away from the tube. He concluded that a new type of ray was being emitted
from the tube. This ray was capable of passing through the heavy paper covering and exciting
the phosphorescent materials in the room. He found that the new ray could pass through most
substances casting shadows of solid objects. Roentgen also discovered that the ray could pass
through the tissue of humans, but not bones and metal objects. One of Roentgen's first
experiments late in 1895 was a film of the hand of his wife, Bertha. It is interesting that the
first use of X-rays were for an industrial (not medical) application, as Roentgen produced a
radiograph of a set of weights in a box to show his colleagues.
Roentgen's discovery was a scientific bombshell, and was received with extraordinary
interest by both scientist and laymen. Scientists everywhere could duplicate his experiment
because the cathode tube was very well known during this period. Many scientists dropped
other lines of research to pursue the mysterious rays.
Newspapers and magazines of the day provided the public with numerous stories, some true,
others fanciful, about the properties of the newly discovered rays. Public fancy was caught by
this invisible ray with the ability to pass through solid matter, and, in conjunction with a
photographic plate, provide a picture of bones and interior body parts. Scientific fancy was
captured by the demonstration of a wavelength shorter than light. This generated new
possibilities in physics, and for investigating the structure of matter. Much enthusiasm was
generated about potential applications of rays as an aid in medicine and surgery. Within a
month after the announcement of the discovery, several medical radiographs had been made
in Europe and the United States, which were used by surgeons to guide them in their work. In
June 1896, only 6 months after Roentgen announced his discovery, X-rays were being used
DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 4

X-RAY PIPE LINE CRAWLER

by battlefield physicians to locate bullets in wounded soldiers. Prior to 1912, X-rays were
used little outside the realms of medicine and dentistry, though some X-ray pictures of metals
were produced. The reason that X-rays were not used in industrial application before this date
was because the X-ray tubes (the source of the X-rays) broke down under the voltages
required to produce rays of satisfactory penetrating power for industrial purposes. However,
that changed in 1913 when the high vacuum X-ray tubes designed by Coolidge became
available. The high vacuum tubes were an intense and reliable X-ray source, operating at
energies up to 100,000 Volts.
In 1922, industrial radiography took another step forward with the advent of the 200,000-volt
X-ray tube that allowed radiographs of thick steel parts to be produced in a reasonable
amount of time. In 1931, General Electric Company developed 1,000,000 volt X-ray
generators, providing an effective tool for industrial radiography. That same year, the
American Society of Mechanical Engineers (ASME) permitted X-ray approval of fusion
welded pressure vessels that further opened the door to industrial acceptance and use.

Chapter 3:

A SECOND SOURCE OF RADIATION

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 5

X-RAY PIPE LINE CRAWLER

Shortly after the discovery of X-rays, another form of penetrating rays was discovered. In
1896, French scientist Henri Becquerel discovered natural radioactivity. Many scientists of
the period were working with cathode rays, and other scientists were gathering evidence on
the theory that the atom could be subdivided. Some of the new research showed that certain
types of atoms disintegrate by themselves. It was Henri Becquerel who discovered this
phenomenon while investigating the properties of fluorescent minerals. Becquerel was
researching the principles of fluorescence, wherein certain minerals glow (fluoresce) when
exposed to sunlight. He utilized photographic plates to record this fluorescence.
One of the minerals Becquerel worked with was a uranium compound. On a day when it was
too cloudy to expose his samples to direct sunlight, Becquerel stored some of the compound
in a drawer with his photographic plates. Later when he developed these plates, he discovered
that they were fogged (exhibited exposure to light). Becquerel questioned what would have
caused this fogging. He knew he had wrapped the plates tightly before using them, so the
fogging was not due to stray light. In addition, he noticed that only the plates that were in the
drawer with the uranium compound were fogged. Becquerel concluded that the uranium
compound gave off a type of radiation that could penetrate heavy paper and expose
photographic film. Becquerel continued to test samples of uranium compounds and
determined that the source of radiation was the element uranium.
Becquerels discovery was, unlike that of the X-rays, virtually unnoticed by laymen and
scientists alike. Relatively few scientists were interested in Becquerel's findings. It was not
until the discovery of radium by the Curies two years later that interest in radioactivity
became widespread. While working in France at the time of Becquerel's discovery, Polish
scientist Marie Curie became very interested in his work. She suspected that a uranium ore
known as pitchblende contained other radioactive elements. Marie and her husband, French
scientist Pierre Curie, started looking for these other elements. In 1898, the Curies discovered
another radioactive element in pitchblende, and named it 'polonium' in honor of Marie Curie's
native homeland. Later that year, the Curies discovered another radioactive element which
they named radium, or shining element. Both polonium and radium were more radioactive
than uranium. Since these discoveries, many other radioactive elements have been discovered
or produced.

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 6

X-RAY PIPE LINE CRAWLER

Radium became the initial industrial gamma ray source. The material allowed castings up to
10 to 12 inches thick to be radio graphed. During World War II, industrial radiography grew
tremendously as part of the Navy's shipbuilding program. In 1946, man-made gamma ray
sources such as cobalt and iridium became available. These new sources were far stronger
than radium and were much less expensive. The man made sources rapidly replaced radium,
and use of gamma rays grew quickly in industrial radiography.

Chapter 4:

WORKING PRINCIPLE
The Pipe Crawler is fully developed, commercially available, and currently used in a variety
of commercial and nuclear power industry applications. The technology can be transferred to
other sites for similar applications. Aside from verifying the presence or absence of process
DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 7

X-RAY PIPE LINE CRAWLER

materials, the Pipe Crawler can be used to inspect inaccessible pipes (e.g., underground
lines). However, this technology is very well suited to perform the pipe inspection
requirements because of its additional capabilities. The added cost of the radiological
detectors and rate meter make the technology too expensive for the visual-only requirement
at the site. If other facilities require a radiological inspection, then the technology may be
more applicable.
The Pipe Crawler consists of a visual inspection system (a high-resolution micro color
camera with light heads, a monitor, and a video recorder) along with radiological detectors
coupled to a rate meter. Pipe Crawlers are available for 1.5, 2, 3, 4, 6, 8, 10, 12, and
24 pipe sizes. The crawler/detector is capable of visually and radio logically inspecting the
inside of pipes and pinpointing where in the pipe contamination exist.
Individual detectors can be isolated for separate readings if necessary. The system is well
suited for inspecting the interior of most types of piping. The camera and detectors are pulled
through a pipe using fish tape and a fiberglass rod and reel. They can also be mounted on a
push-pull fiberglass rod. As the assembly is pulled through the pipe to be inspected (Figure
4.1), the operator at the console (Figure 4.2) looks for the presence of visual contamination
and monitors the rate meter for radiological contamination. The operator at the console can
give the camera operator directions about the required movements in the pipe in order to
properly inspect the entire interior.

Figure 4.1: The Pipe Crawlers camera and detector assembly entering a pipe.
DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 8

X-RAY PIPE LINE CRAWLER

(Courtesy: Innovative technology summary report U.S department of energy).

A crew of six workers would typically be used for pipe inspection with the Pipe Crawler.
Two workers would move the pieces of pipe into position for the camera and would segregate
the pieces based on the inspection results, one worker would operate the crawler, and one
would operate the video unit. A fork lift operator and a rad tech would also provide support,
either part-time or full-time. Figure 2 shows workers inspecting a pipe with the Pipe Crawler.

Figure 4.2: Workers inspecting a pipe with the Pipe Crawler.

(Courtesy: Innovative technology summary report U.S department of energy).

Chapter 5:

WORKING TECHNIQUE
The x-ray crawler similar to convention radiography however an x-ray source tube on a
crawler device is run inside the pipe to each weld with motorize chassis completed with
microprocessor electronic and command program to move along the pipe line and conduct
radiography testing or shoot. The x-ray crawler is similar to conventional radiography
however an x-ray source tube on a circular device is run inside the pipe to each weld butt
joint.
X-RAY VERSION

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 9

X-RAY PIPE LINE CRAWLER

Figure 5.1: X-ray version

Figure 5.1: x-ray version

(courtesy:U.S. Department of Energy)

Chapter 6:

RADIOGRAPHY TECHNIQUE
The most effective technique is one in which the radiation passes through a single thickness
of the material being radiographed and the film is in contact with the surface opposite the
source side. Other techniques may be used as the referencing code or situation dictates.
Regardless of the technique used, the goal is to achieve the highest possible quality level. The
IQI (penetrameter) placement should be as close to the weld as possible without interfering
with the weld image. A technique should be chosen based upon its ability to produce images
of suspected discontinuities, especially those that may not be oriented in a favorable direction
to the radiation source. Radiography is extremely sensitive to the orientation of tight planar
discontinuities. If a tight planar discontinuity is expected to be at an angle to the source of the
radiation, it will be difficult or impossible to detect. The nature, location, and orientation
should always be a major factor in establishing the technique.

6.1 Single-wall Technique:DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 10

X-RAY PIPE LINE CRAWLER

A single-wall exposure technique should be used for radiography whenever practical. In the
single-wall technique, the radiation passes through only one wall of the material or weld,
which is viewed for acceptance on the radiograph. An adequate number of exposures should
be made to demonstrate that the required coverage has been obtained.

6.2 Double-wall Technique:When it is not practical to use a single wall technique, a double-wall technique should be
used. For materials and for welds in components 3.5 in. (88.9 mm) or less in nominal outside
diameter, a technique may be used in which the radiation passes through two walls and the
weld (material) in both walls is viewed for acceptance on the same radiograph. For doublewall viewing of welds, the radiation beam may be offset from the plane of the weld at an
angle sufficient to separate the image of the source side portions and the film side portions of
the weld so there is no overlap of the areas to be interpreted When complete coverage is
required, a minimum of two exposures taken at 90 to each other should be made of each
weld joint. Alternatively, the weld may be radio graphed with the radiation beam positioned
such that both walls are superimposed. When complete coverage is required a minimum of
three exposures taken at either 60 or 120 to each other should be made for each weld joint.
The radiograph does not interfere with the interpretation. Low power magnification devices
(1.5X 3X) may also be used to aid in film interpretation and evaluation; but too high of a
magnification will also enhance the graininess of the film.

6.3 Different types of defects captured:

Incomplete or lack of penetration:1. The edges of the pieces have not been welded together, usually at the bottom
of single V-groove welds.
2. Radiographic Image: A darker density band, with straight parallel edges, in
the center of the width of the weld image.
3. Welding Process: SMAW.

Inter pass slag inclusion:1. Usually caused by non-metallic impurities that solidify on the weld surface

and are not removed between weld passes.

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 11

X-RAY PIPE LINE CRAWLER

2. Radiographic Image: An irregularly shaped darker density spot, usually

slightly elongated and randomly spaced.
3. Welding Process: SMAW.

Cluster porosity:1. Rounded or slightly elongated voids grouped together.

2. Radiographic Image: Rounded or slightly elongated darker density spots in

clusters randomly spaced.

3. Welding Process: SMAW.

Lack Of Side Wall Fusion:1. Elongated voids between the weld beads and the joint surfaces.
2. Radiographic Image: Elongated parallel, or single, darker density lines

sometimes with darker density spots dispersed along the LOF lines which are very straight in
the lengthwise direction and not winding like elongated slag lines.
3. Welding Process: GMAW

Elongated slag(wagon tracks):1. Impurities that solidify on the surface after welding and were not Removed

between passes.
2. Radiographic Image: Elongated, parallel or single darker density lines, irregular
in width and slightly winding in the lengthwise direction.
3. Welding Process: SMAW.

Burn through:1. A severe depression or a crater-type hole at the bottom of the

weld but usually not elongated.

2. Radiographic Image: A localized darker density with fuzzy edges in the center of
the width of the weld image. It may be wider than the width of the root pass image.
3. Welding Process: SMAW.

Offset or miss match with lack of penetration(lop):1. A misalignment of the pieces to be welded and insufficient filling

of the bottom of the weld or root area.

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 12

X-RAY PIPE LINE CRAWLER

2. Radiographic Image: An abrupt density change across the width of the weld image
with a straight longitudinal darker density line at the center of the width of the weld image
along the edge of the density change.
3. Welding Process: SMAW.

Excessive penetration:1. Extra metal at the bottom (root) of the weld.

2. Radiographic Image: A lighter density in the center of the width of the weld image,

either extended along the weld or in isolated circular drops.

3. Welding Process: SMAW.

Root undercut:1. A gouging out of the parent metal, alongside the edge of the bottom or internal

surface of the weld.

2. Radiographic Image: An irregular darker density near the center of the width of the
weld image along the edge of the root pass image.
3. Welding Process: SMAW.

Transverse crack:1. A fracture in the weld metal running across the weld.
2. Radiographic Image: Feathery, twisted line of darker density running across the

width of the weld image.

Tungsten inclusion:1. Random bits of tungsten fused into but not melted into the weld metal.
2. Radiographic Image: Irregular shaped lower density spots randomly located in

the weld image.

3. Welding Process: GTAW.

Root pass aligned porosity:1. Rounded and elongated voids in the bottom of the weld aligned

along the weld centerline.

2. Radiographic Image: Rounded and elongated darker density spots that may be
connected, in a straight line in the center of the width of the weld image.
3. Welding Process: GMAW.

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 13

X-RAY PIPE LINE CRAWLER

Fig.6.1: Digital radiographic image of defective welded V-pipe

(Courtesy: Vidisco electronic systems)

Chapter 7:

TYPES OF CRAWLERS & SPECIFICATION

Crawlers are available in several different configurations to enable the customer to select the
best suited package for his needs.
The two major types are
7.1 Gamma - using a gamma source and actuator.
7.2 X-ray - using a suitable panoramic X-ray generator.
7.1 GAMMA VERSION (MODELS 6G,8G)
MODEL

SUITABLE
FOR

6G
8G

BATTERY

PIPE CAPACITY

SIZES
6 TO 18
8 TO 18

7 AMP HR.
12 AMP HR.

Table 7.1: Gamma version

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 14

OPERATING

NUMBER OF

VOLTAGE

SECTIONS

24V
24V

1
1

X-RAY PIPE LINE CRAWLER

GAMMA VERSIONS (MODELS 6G, 8G)

Figure.7.1 Gamma versions

Specification of Gamma version model:

Min . Internal Pipe

135 mm

Recommended Max. Pipe Diameter

457 mm (18)

Power Pack

Re-Chargeable sealed lead / Acid Batt.

Traction Motor Rating

24 Volt 200 Watts.

Travel Speed

12 Meters (40 Feet) / Min.

Max. Gradient (Clean Pipe)

45 %(27 Deg. From Horizontal)

Braking

Dynamic

Stopping Positional Accuracy

0.2

Exposure Timer

0-200 Secs. (Pre-settable)

Exposure Safety Delay

0-30 SECS. (Pre-settable)

Ambient Operating Temperature

- 20 Deg. C To + 60 Deg. C

Control and Tracker Isotopes

20 Millicuries

Radiation Source

20 Curies

Length Of Crawler

1050 mm
Table 7.2: specification of Gamma version

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 15

X-RAY PIPE LINE CRAWLER

X-RAY VERSION (MODEL 6XR, 8XR)

Figure 7.2 X-ray version (Model 6XR, 8XR)

6 XR
8 XR
Figure.7.2 X-RAY version
Specification of X-ray version model:
6 XR

8 XR

Min. Internal Pipe Diameter

135 mm

178 mm

Recommended Max. Pipe Diameter

355 mm

457 mm

Weight of Crawler (inc. Battery Pack)

28 Kg

33 Kg

Power Pack

Re-chargeable Sealed Lead / Acid Batteries

Traction Motor Rating

48 Volt

Travel speed

12 meters / min

Max. Gradient

45 % (27 deg. From horizontal)

Braking

Dynamic

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 16

200 Watts

X-RAY PIPE LINE CRAWLER

Stopping Position Accuracy

0.2

Exposure Timer

0-200 Secs. (Pre-settable)

Exposure Safety Delay

0-30 SECS. (Pre-settable)

Ambient Operating Temperature

- 20 Deg. C To + 60 Deg. C

Table 7.4: Specification of X-ray version

Chapter 8:

FEATURES, ADVANTAGES & DISADVANTAGES

Automatically inspects the energy of battery, when the voltage of battery is not
enough, the crawler will turn back in time.

Constant tube current control ensures the consistency of radiography films image.

High precision of tube voltage adjustment also ensures the consistency of radiography
films image.

Having various real time protective measures in case of meeting water, over voltage,
zero voltage, over current, zero current, meeting barrier, antenna falling off, x-ray
generator falling off, over temperature of the x-ray generators, parameters setting
failures, demo setting failure etc.

Disadvantage is negligible against its tremendous performance; the only disadvantage

might be its high cost against other radiography machines.

8.1 Optional accessories for pipeline crawler:

Crawler wheel spacer kitA set of wheel shafts and spacers used to set up the crawler in large pipe sizes.

12/24 volt battery chargerA multi-stage dual channel designed for sealed load/acid battery packs, to ensure

optimum performance and battery life.

Spare battery packs-

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 17

X-RAY PIPE LINE CRAWLER

Extra battery to allow the crawler to remain in continuous operation.

Recovery vehicleA purpose built vehicle complete with a latching harpoon on one end, which can
be sent into a pipe to recover the main crawler if it should become jammed or
disabled.

Remote detector boxFits on the top of the crawler. Enables reliable signaling in large pipe sizes.

Audio / visual warning unit-

A self contained battery operated warning unit which gives clear flashing beacon and
sounder indications outside the pipe when the crawler is emitting radiation.

X-ray film and processing / drying equipmentGood quality film to suit the crawler radiation source and various pieces of
processing and film drying equipment.

Non standard ratios gearboxesGearboxes can be supplied or fitted to the crawler with non standared reduction
ratios. This will allow to change the travel speed.

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 18

X-RAY PIPE LINE CRAWLER

Chapter 9:

SAFETY, RISKS, BENEFITS.

Worker safety issues are of highest importance when performing any work at sites. While the
Pipe Crawler poses no direct threats to safety, there are increased risks due to the additional
handling of process piping. For example, workers will be moving and possibly manually
lifting heavy pieces of pipe and could also be exposed to any process residues inside the pipe
by removing the end seals to insert the camera. However, safety programs in place to
minimize any increased risk. There are no socioeconomic impacts or negative community
perceptions associated with the pipe crawler.

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 19

X-RAY PIPE LINE CRAWLER

CONCLUSION
The Pipe Crawler is an effective technology for radiological inspection of pipe but is not
recommended for castings and pipe having small length. Although required members are a
crew of six workers, a reduced crew size may be possible for future deployments. The camera
operator could also handle pipes, and the fork lift driver and the rad tech could be shared for
other tasks.
The needs for future development include a more rugged and less fragile design of the
crawler, a more flexible cable, and a remote control camera focus. A possible improvement
for operating the system is for the camera operator to also be able to see the video screen as
he moves the camera.

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 20

X-RAY PIPE LINE CRAWLER

REFERENCES:
1) www.jme.co.uk
2) Innovative technology summary report (U.S department of energy).
3) Digital X-ray Solutions for Oil & Gas X-ray Inspection , by VJ technologies.
4) Gamma Ray Radiographic Testing by Global X-Ray & Testing Corp.
5) M. E. Sutulov et al, Crawler Control Procedure, JME Ltd.; Lowestoft: UK.

DEPT. OF MECHANICAL ENGG. MCE HASSAN. Page 21