Pluto Manufacturing is testing whether acoustic sensors can detect hidden damage in the reinforced plastic pipes used for hydrogen transport and carbon capture. The problem is that these high-pressure, flexible pipes—which can be spooled in kilometre-long coils—are connected using steel fittings that are swaged (compressed) onto the pipe ends. This process can crush the fibre-based reinforcement layers inside the pipe, causing failures that are invisible to standard X-ray inspection. In steel pipelines, X-ray works well; for composite pipes, there is no reliable quality control method. Most pipeline failures occur at or near these connection points. This project will integrate acoustic sensors into existing monitoring hardware to listen for damage during the swaging process itself. If successful, it would provide a real-time, non-destructive way to check connection integrity—something that does not currently exist. That could improve the long-term reliability of pipelines used in emerging energy infrastructure, where failure is not an option. Pluto Manufacturing is collaborating with the UK’s National Physical Laboratory to test the approach.
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Pluto Manufacturing specialises in the design, testing, and manufacture of fittings and connections for composite and RTP (reinforced thermoplastic pipes). These high-pressure, corrosion-resistant, and flexible pipes can be spooled in lengths of up to 1km, making them far easier to transport and install compared to traditional steel pipes, which are limited to 10m sections. To ensure a secure seal, RTP pipes are connected using specialist steel fittings through a swaging process that applies significant force to form the connection between the pipe and fitting. This is considerably more complex than the steel-to-steel welded joints used in traditional pipelines. The increasing global demand for RTP's in challenging applications, such as hydrogen transport and carbon capture, has highlighted a major industry challenge, most pipeline failures occur at or near the connection points. In steel pipelines, X-ray inspection is a well-established method for assessing weld integrity. However, there is no simple and effective quality control (QC) solution for swaged steel fittings on composite and RTP pipes. Many RTP designs incorporate fibre-based reinforcement layers, such as fibreglass or carbon fibre, which are essential for pipe strength but vulnerable to damage during the swaging process. This damage is believed to be a key factor in connection failures. Pluto Manufacturing has developed advanced smart sensor technology for pipeline monitoring. These sensors feature cellular connectivity, ultra-long battery life, and multiple sensing capabilities, including acoustic detection. However, while we have the necessary sensor hardware and the ability to conduct hydrostatic pressure and burst tests, we need to determine whether acoustic signals can reliably detect damage to the reinforcement layers during the swaging process. This project aims to analyse the performance of integrating acoustic sensors into existing technology to monitor RTP connection process in real-time. This approach has not been tested before, and its success could lead to a major breakthrough in pipeline QC and monitoring. With Pluto Manufacturing's expertise in RTP connections and our collaboration with the UK's National Physical Laboratory (NPL), we are uniquely positioned to explore this innovative solution and help improve the long-term reliability of RTP pipelines.
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