Hellcat: Pinpointing Pipeline Threats with Advanced Modular Inspection

Industrial pipeline assets face well-known and costly threats that reduce integrity, safety, and operational reliability. Corrosion under insulation (CUI), internal leaks, weld defects, and wall-thickness loss all represent significant failure modes that can cause unplanned outages, environmental incidents, or safety hazards if undetected. 

Hellcat was engineered to address this critical inspection challenge. Detecting problems earlier, pinpointing problem areas with high precision, and delivering actionable data that enables planned, effective intervention.  

 

Identifying the Key Threats 

Pipeline degradation typically results from multiple interacting failure modes: 

• Corrosion Under Insulation (CUI): Hidden internal corrosion not visible from outside 

• Internal Pipe Leaks: Cracks or defects in pressurised or submerged sections 

• Damaged or Failed Welds: Structural weaknesses at joints and transitions 

• Wall-Thickness Loss: General corrosion or erosion reducing pressure tolerance 

Effective integrity management depends on locating these threats early, quantifying their extent, and planning maintenance before failure occurs. Hellcat was designed as a platform to enable exactly that—high-quality, repeatable detection across challenging environments. 

 

Purpose-Built for Accurate Threat Detection 

Hellcat combines mechanical robustness with advanced imaging and sensing systems to deliver inspection data that supports confident, early decision-making. 

Visual Identification of Corrosion and Weld Defects 

• 4K submersible camera system (Scope 4K) with 10x optical zoom 

• High-intensity LED illumination for clear images in submerged, or unlit environments 

• Ability to closely examine weld seams, elbows, and joints where failures often initiate 

• Enables mapping of thickness variations to detect localised corrosion or erosion 

Capable of Deploying a Range of Advanced NDT Sensors 

• Designed to support various non-destructive testing (NDT) payloads, including ultrasonic (UT), phased-array ultrasonic testing (PAUT), and eddy current array (ECA) systems 

• Actuated probe control and spring-loaded couplings enable stable, reliable surface contact for accurate measurements in submerged or dynamic environments 

Leak Detection in Submerged and Pressurised Assets 

• Hydrophone integration for detecting acoustic signatures of leaks 

• Capable of operating at extreme flow rates while maintaining stable inspection positioning and data capture 

 

Modular Configuration for Targeted Inspection Needs 

Pipeline threats vary by environment—and Hellcat was built to adapt. Its modular chassis and payload architecture allow operators to tailor each deployment to specific inspection goals. From internal corrosion detection to full 3D mapping, payloads can be swapped or combined as needed. 

Nexxis’ BRIX power distribution system supports up to eight independent payload channels, enabling multi-sensor configurations in a single pass. Operators can collect high-resolution visual, UT/PAUT, acoustic, and 3D data concurrently—minimising confined space entries and maximising inspection efficiency. 

This modularity makes Hellcat a future-ready platform, capable of integrating emerging sensor technologies as inspection needs evolve. 

Tested and Validated for Harsh Conditions 

Hellcat’s performance is not theoretical. Its design was validated through targeted laboratory and field testing, including: 

• Pipe Diameter Compatibility: Automated chassis adaptation for internal diameters from 400 mm up 

• Flow-Resistant Operation: Tested to maintain positional control and data acquisition at high flow velocities  

• Depth Rating: 150 m, supporting offshore risers, submerged outfalls, and underwater plant piping 

• Hyperbaric Testing: Conducted to validate electrical functionality and structural integrity of advanced UT arms (CAP and EAP) under simulated subsea conditions 

This rigorous testing ensures that Hellcat can deliver reliable, repeatable data in the kinds of extreme conditions that characterise real-world inspection challenges. 

Industry Applications 

Hellcat’s ability to identify threats early and accurately supports a wide range of industrial sectors: 

Mining 

• Internal corrosion and abrasion in tailings lines and water supply pipelines 

• Weld seam inspection in slurry lines with high solids content 

Oil and Gas (Onshore and Offshore) 

• Submerged flow lines, risers, and onshore pipelines 

• Weld inspection and leak detection under variable pressures and temperatures 

Utilities (Water and Sewer) 

• Sewer and storm drain inspection in high-flow or submerged conditions 

• Wall-thickness monitoring and leak detection in ageing infrastructure 

Petrochemical and Power Generation 

• Confined space plant piping with strict safety requirements 

• Advanced mapping of critical welds and thickness variations 

 

See Hellcat in Action

Hellcat isn’t just built for one inspection method—it’s built for whatever the inspection demands. From ultrasonic and phased-array probes to hydrophones, cameras, LiDAR, and emerging technologies, Hellcat serves as a flexible delivery platform engineered to adapt to a wide range of inspection scenarios. 

Its modular architecture and multi-channel payload support means operators aren’t limited by pre-defined toolsets. Instead, they can configure Hellcat to match the specific threat profile of each asset—combining technologies, swapping payloads, and scaling capability as needed. 

In an industry where no two inspection challenges are the same, Hellcat offers the adaptability to keep pace with evolving requirements—turning a single deployment into a comprehensive, high-resolution inspection operation. 

If you’d like to learn more about Hellcat, get in touch with our expert team, or book a demo for your site.