PipeDiver Ultra XL: An Easier Way to Collect Big Data on Big Pipes

The largest pipelines in a water network are often the most critical. However, they can also be the most difficult to inspect. Until recently, utilities had to shut down and fully dewater their large, metallic pipelines for inspection. These inspections could easily put the main out of service for weeks. Today, many utilities lack actionable condition data on their most critical metallic pipelines due to the difficulty of assessing these buried assets.

More than half of North America’s water pipelines are metallic — ductile iron, cast iron, or steel. These pipes are some of the oldest in the ground, with many nearing the end of their design life. Despite their age, Xylem’s inspection data shows that most corrosion is localized and manageable with planned and targeted repairs.

On a recent webinar, we asked attendees whether they had sufficient budget to fully replace their biggest metallic pipeline at the end of its design life. The vast majority either said no or were unsure. To manage pipelines safely and cost-effectively, it’s more important than ever to collect big data on big pipes.

Introducing PipeDiver Ultra XL

Xylem’s proven PipeDiver platform has been in use for more than 15 years and has inspected over 2,000 miles of pipeline, including 200 miles of smaller diameter metallic pipes. PipeDiver Ultra XL builds on that platform to deliver more efficiency and enhanced detection – with a design honed to manage the unique challenges of large-diameter pipe.

Simplifying Metallic Pipeline Inspections

PipeDiver® Ultra XL is built to inspect metallic pipelines 54 inches in diameter and above. This inline, free-swimming tool minimizes inspection time, operational costs, and service impacts. The tool travels with the flow of water, inspecting the pipeline while it’s in service. The tool’s flexible design enables it to navigate bends, tees, and inline butterfly valves. PipeDiver Ultra XL can inspect an average of 10 miles of pipe per day, making it 10 times more efficient than other inspection options.

Ultrasonic technology can collect big data with less disruption because it allows for a more compact sensor array that is centered in the pipe. Alternative test methods, like magnetic flux leakage (MFL), require a full-diameter tool that places the sensors close to the pipe wall. 

Using PipeDiver Ultra XL, utilities can avoid fully dewatering and physically entering the pipeline, making inspections safer and more water conscious. In most cases, we can insert and extract the tool through existing access points, minimizing the need for complicated civil works to prepare the line.

Maximizing Insights on Big Pipes

PipeDiver Ultra XL uses ultrasonic technology and video to identify threats to metallic pipe integrity, including pipe-by-pipe data on internal and external corrosion, out-of-roundness, as well as debris and lining issues. Together, these data layers help utilities pinpoint risks and gain a robust understanding of pipe condition. Data is presented geospatially to add another layer of insight into the potential causes and consequences of integrity threats.

Verified Performance in Real-World Conditions

To supersize the PipeDiver Ultra, Xylem’s research and development team had to overcome challenges unique to large-diameter metallic pipes. They outfitted the tool with innovative phased-array transducer technology to help ensure full data coverage even when the pipe has high out-of-roundness or buildup on the pipe wall. It also compensates for the tool if it’s not fully centered in the pipe.

However, using phased-array technology led to a new challenge. PipeDiver Ultra XL collects 83 million individual signals per hour. To manage this complex dataset and accelerate analysis, Xylem leverages artificial intelligence trained on years of experience with the original PipeDiver Ultra platform.

Xylem verified the performance of PipeDiver Ultra XL through extensive testing in our flow loop. We also performed over 20 miles of inspection in the northeastern United States and Canada on steel mains ranging from 44- to 98-years-old. The tool demonstrated remarkable performance and reliability in a variety of real-world conditions, measuring a 5% loss in nominal thickness on several pipes. With this level of precision, utilities can take proactive actions to slow or stop corrosion or make repairs where needed.

Managing Metallic Pipes with Confidence

PipeDiver Ultra XL provides utilities with data on the condition of their most vital infrastructure with less disruption to their essential operations. Utilities can use this data to address immediate risks and predict future failures. By relying on big data, utilities can minimize costs, improve pipeline reliability, and bring about big benefits for their communities.   

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