Magnetically Saturated Pulsed Eddy Current for Inner-Liner Collapse in Bimetal Composite Pipelines: Physics, Identifiability, and Field Validation

Underground gas storage (UGS) is critical to national reserves and seasonal peak-shaving, and its safe operation is integral to energy security. In UGS surface process pipelines, heterogeneous bimetal composite pipes—carbon-steel substrates lined with stainless steel—are widely used but susceptible under coupled thermal–pressure–flow loading to geometry-induced instabilities (local buckling, adhesion, and collapse), which can restrict flow, concentrate stress, and precipitate rupture and unplanned shutdowns. Conventional ultrasonic testing and magnetic flux leakage have limited sensitivity to such instabilities, while standard eddy-current testing is impeded by the ferromagnetic substrate’s high permeability and electromagnetic shielding. This study introduces magnetically saturated pulsed eddy-current testing (MS-PECT). A quasi-static bias field drives the substrate toward magnetic saturation, reducing differential permeability and increasing effective penetration; combined with pulsed excitation and differential reception, the approach improves defect responsiveness and the signal-to-noise ratio. A prototype was developed and evaluated through mechanistic modeling, numerical simulation, laboratory pipe trials, and in-service demonstrations. Field deployment on composite pipelines at the Hutubi UGS (Xinjiang, China) enabled rapid identification and spatial localization of liner collapse under non-shutdown or minimally invasive conditions. MS-PECT provides a practical tool for composite-pipeline integrity management, reducing the risk of unplanned outages, enhancing peak-shaving reliability, and supporting resilient UGS operations.