1. Introduction of the Non-Intrusive Pig Detector

The Non-Intrusive Pig Detector is an advanced tool designed for monitoring the passage of pigs (pipeline inspection gauges) through pipelines, especially crucial in maintaining the efficiency and integrity of pipeline operations. This device is comprised of several key components that work together to provide real-time data and ensure operational safety and precision.

2. Key Components and Functionality

1. Explosion-Proof Remote Display Unit (TZS). The heart of the detector is an explosion-proof remote display unit equipped with an LCD that features heating capabilities for operation in diverse environments. The TZS unit records the time of each pig’s passage and stores this information for up to 99 events. It also transmits data remotely and adheres to safety standards with an ExdIICT6Gb explosion-proof rating and an IP65 protection grade.
2. Sensor Mechanism (YY-FCT). Attached directly to the pipeline, the sensor mechanism detects the magnetic field generated by the pig equipped with magnets as it passes by. This component is vital for the precise detection of the pig’s location within the pipeline.
3. Card Mounting Mechanism. This detachable component allows for easy installation and removal of the detector on the pipeline. Selection of the appropriate card mounting mechanism, or clamp, depends on the pipeline’s specifications.
4. Connection Wires and Extension Rods. These are used to connect the sensor mechanism to the display unit and can be extended with rods for buried pipelines.
5. Insulation Considerations. For pipelines with insulation layers, it is crucial to attach the sensor mechanism directly to the metal pipe wall before insulating it to ensure accurate readings.

3. Working Principle of the Non-Intrusive Pig Detector

Magnetic Detection

The working principle of the Non-Intrusive Pig Detector is centered on magnetic detection. As a pig equipped with magnets moves through the pipeline, it creates a magnetic field. The detector’s sensor mechanism, mounted on the outside of the pipeline, senses this magnetic field as the pig passes.

Signal Generation

When the sensor detects the magnetic field of the pig, it generates an electrical signal. This signal is a direct response to the magnetic disturbance caused by the pig.

Data Transmission

The electrical signal from the sensor is sent to the TZS unit. The TZS unit is the central display and processing device of the system. It receives the signal and logs the exact time when the pig passes the sensor.

Remote Monitoring

After recording the time, the TZS unit transmits a switch signal. This signal is sent remotely to a control center. It allows pipeline operators to monitor the pig’s progress from afar.

Tracking and Confirmation

Operators can use the information from the TZS unit to track the pig’s journey through the pipeline. They can see when and where the pig passes. This helps them confirm the pig’s successful movement through specific sections of the pipeline.

4. Advantages of the Non-Intrusive Pig Detector

Non-Intrusive Monitoring

The Non-Intrusive Pig Detector is engineered to monitor pipeline cleaning, inspection, and maintenance processes without the need for direct intervention in pipeline operations. This non-invasive technology allows for continuous pipeline operation, thereby significantly reducing system downtime and avoiding the operational risks associated with opening the pipeline or manual monitoring methods. It also enables a seamless maintenance workflow that minimizes production losses and operational disruptions, making it an ideal solution for critical and high-throughput pipeline systems.

Enhanced Safety Features

Safety is paramount in pipeline operations, especially when transporting volatile or hazardous substances. The Non-Intrusive Pig Detector is equipped with explosion-proof and waterproof features that meet the highest safety standards, classified under ExdIICT6Gb for explosion-proof and IP65 for ingress protection. These certifications ensure that the detector can operate safely in various environments. Including those prone to explosive gases and wet conditions. By adhering to these stringent standards, the device not only protects the equipment but also ensures the safety of operational personnel, reducing the risk of accidents and enhancing overall workplace safety.

Data Accuracy and Storage

Accurate data collection and storage are crucial for the effective monitoring and management of pipeline integrity. The Non-Intrusive Pig Detector excels in this area by providing precise records of each pig’s passage. Including the time and frequency of each event, with a storage capacity for up to 99 passage records. So this feature allows for comprehensive data analysis and historical tracking, which are essential for detecting trends, planning maintenance schedules, and assessing the condition of the pipeline over time. The ability to store and recall passage information facilitates a deeper understanding of pipeline performance, helping operators make informed decisions based on reliable data. Furthermore, the remote transmission of data ensures that information is readily available for real-time decision-making and long-term strategic planning, enhancing both the immediate response capabilities and the predictive maintenance strategies of pipeline operators.