An end-to-end redevelopment of an MFL pipeline inspection system, including new electronics, firmware, PC-based configuration software, and a sophisticated defect analyzer engine built to meet modern standards.

A next-generation Magnetic Flux Leakage (MFL) tool was conceptualized and developed to address the growing challenges in pipeline inspection and maintenance. The solution involved a complete hardware and software redesign to replace aging systems and adapt to the latest technological standards, ensuring faster, more accurate defect detection in oil pipelines.

Problem Statement

The legacy MFL tools were increasingly unreliable due to component obsolescence and lacked features to support evolving inspection demands. There was an urgent need to modernize the system architecture, data handling, and user interaction for improved defect analysis and operational efficiency.

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Solution

The modernization project was split into four key components:

1. MFL Tool Electronics Redesign
   Complete revamp of the hardware architecture using modern, reliable components to support accurate magnetic field sensing and data acquisition.
2. MFL Tool Firmware Development
   Embedded firmware development to manage sensor data, storage, communication, and run-time diagnostics efficiently.
3. Communicator Application (Windows GUI)
   • Runs on Windows 10 64-bit systems
   • Configures tool parameters pre-run
   • Views real-time sensor health over high-speed Ethernet
   • Enables high-speed data downloads from the tool after a pipeline run
4. Pipeline Defect Analyzer Application
   • Extracts run data from MFL tool
   • Uses a client-server model for centralized data analysis
   • Identifies pipe defects using analysis engines
   • Enables report generation for pipeline health diagnostics

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