Development and simulation analysis of a novel flexible deformation inspection units (FDIU) for oil and gas pipelines

Oil and gas pipelines are essential for energy transportation, and their integrity is critical for safety and efficiency. Deformations such as dents can lead to failures, necessitating regular condition monitoring. Traditional methods for detecting dents have limitations in accuracy and reusability. This paper introduces a novel flexible deformation inspection units (FDIU) that addresses these limitations. The design reduces operational requirements for pipeline differential pressure and equipment possibility, offering a simpler structure with repeatability and effective pipeline inspection method. The paper’s structure includes an analysis of the mechanical model of the FDIU, development of the FDIU model using ABAQUS finite element software, and simulations to investigate internal stress, strain distribution, and displacement changes as the FDIU interacts with pipeline dents. The study also examines the impact of the FDIU’s relative position to defects and material hardness on its mechanical performance. The findings indicate that the new design provides a reliable and accurate method for detecting pipeline deformations, with implications for improved pipeline maintenance and safety.