Enio Oliveros
Site Safe Solutions
ACE-EMI Software LLC
1. OBJECTIVES/SCOPE
Modern wellhead inspection systems depend largely on operators interpreting electromagnetic signal graphs displayed on their laptops. Because this task demands both extensive training and unwavering focus, results can vary or be inconsistent due to the subjective nature of human judgment.
This work seeks to present an approach based on intelligent algorithms to reduce such dependency, standardize the results and improve the reliability of the scanning process of production pipes and rods directly at the wellhead.
The current technical and regulatory framework includes the API 5CT standards, with guidelines applicable to EMI (Electromagnetic Inspection). Although these inspections are derived from standards designed for workshops or plants, their adaptation to the field environment presents additional challenges due to the variability of conditions for example the speed of the pipe pulling is not controlled by the EMI inspector, but depends on the capacity of the rig, well conditions and safety concerns on everyday operations of workover rigs.
After completing the testing period in March 2025, the results have been highly satisfactory. To this date ending 2025 approximately 50,000 tubing joints between 2 3/8 and 4 1/2", have been scanned using the algorithm, no errors attributable to the implemented algorithm have been identified. In addition to fulfilling its main objective – to support and improve the interpretation of EMI signals – there has been evidence of significant standardization of results between operators with different levels of technical expertise.
The use of intelligent algorithms has been well received by users, to the point that some operators have begun to require the integration of this type of system in scanning processes. This trend has also aroused the interest of service companies that seek to integrate technologies based on artificial intelligence into their services, as a tool to improve the quality of the results delivered to their clients.
The software significantly reduces the time required to train new operators, allowing them to generate reliable results in less time. The algorithm incorporates a sequence of steps which allow large volumes of data to be evaluated and interpreted in real time.
Programmed logic automates technical decisions based on set parameters and historical defect patterns. Studies show the system's results match or surpass human expert accuracy. This automation is designed to boost operator efficiency and reduce errors, not eliminate human input.
3. RESULTS, OBSERVATIONS AND CONCLUSIONS
The implemented software has proven to be an effective and reliable tool in real field conditions. It can be installed on any Windows operating system and is currently compatible with EMI inspection platforms for tubing and rods.
Among its main functionalities are:
• Elimination of interference and noise typical of the operating environment.
• Real-time processing of electromagnetic signals from MFL (Magnetic Flux Leakage) and MFD (Magnetic Field Detection) systems.
• Generation of automatic classifications based on technical criteria defined by regulations.
The algorithm significantly enhances signal amplitude quality, based on the interplay between tubular velocity, the electromagnetic field within the coil, and the gains applied to digitized signals. This advancement enables more precise classification of tubulars, including in areas that are typically challenging, such as near coupling where signal distortion frequently occurs.
4. NOVEL/ADDITIONAL INFORMATION
This technology represents an evolution in wellhead inspection processes, integrating intelligent analysis tools to reduce human error and standardize results. The algorithm allows for precise filtering and processing of signals, improving the interpretation of defects in production tubulars.
Wellhead scanning is a technically and economically efficient alternative that eliminates the need to transport components to inspection plants, reduces operating time, minimizes environmental impacts from cleaning agents, and lowers costs related to tubular replacement and inventory.
This innovation has significantly enhanced operational efficiency and delivered substantial economic advantages to workover operations.