Process Tube Inspection by Intelligent Pig - Introduction
MERLIN Inspection Technology (MIT) is designed to inspect internal and external tube metallurgic conditions in fired heater tubes. The MERLIN Intelligent Pig is driven by water through the internal passageway of a fired heater/furnace process coil, taking mass quantity diameter and wall thickness measurements during its journey.
For study of corrosion and its effects, this inspection service operates in close scientific consultancy association with the Universities of Manchester & Liverpool (UK) to provide a superior quality of interpretation and recommendation, including residual life analysis (RLA).
MERLIN Inspection Technology has been progressing with scientific Research and Development since the late 1990s, resulting in steadily improving stages of capability, performance and reliability. The most recent achievement stage is the Mark 4 which successfully entered commercial service in September 2011.
Headline Features - Mark IV:
- Untethered, water-driven, 300psi pressure sealed Inspection Pig
- Integral Lithium Ion battery; 8 hour duration, with on-board 64Gb data storage
- Capability to pass through box headers
- Over 7,500 acoustic pulse echoes per second, using patented material analysis
- Multiple array of programmable and demountable ceramic transducers
- Bespoke proprietary controlling software, with automatic quality control
- General Arrangement on-screen display of tube coil or process/steam pass
- Instant tube anomaly identification & location
- Tube cross section imaging, with associated data display
- Full process coil interactive results within 15 minutes of run
- Detailed & Analysed Survey Report (hard copy & CD) before leaving site
- Expert tube corrosion analysis and recommendations, including RLA (if required)
- Interchangeable rings & seals for quick tube diameter change
- Inspection of tube diameters 73mm to 260mm (Imperial 2.9” to 10”)
- Data amalgamation from multiple inspection runs
- Rapid USB data download
World Class Decoking & Inspection in simultaneous service
1 Company 1 Pre-Qualification 1 Quotation 1 Invoice
Mk IV Upgrade Project meets challenge to achieve new levels of excellence:
- Wall thickness measurement at multiple radial points
- Surface condition appraisal
- Faster USB data download
- Miniaturisation advances
- Battery longevity & reliability increase
- Corrosion Advisory capability
- Software rewrite for optimum reliability
- Electronic & pressure-guided location accuracy
- Improved geometric flexibility
- Improved transducer quality & reliability
- Memory capacity improvement
- Bi-directional capability
- Processor power increase
- Box/Plug header passage capability
Explanation of Merlin Tube Inspection Technology
The MERLIN Inspection Pig uses sophisticated ultrasound technology to internally scan fired heater tubes, recording and identifying measurements and internal surface condition. The current development stage is proven in site testing and experience to allow passage through box/plugged headers, without modification, which are often found in older process heaters.
Using a single body of specially prepared composite material, MERLIN Mark IV technology is designed to have narrow passageway capability and has been used in tube circuits which include box headers featuring a central crossover passage with 3” diameter.
Navigating through 180° u-bends is easier! The new Mark 4 Intelligent Pig can pass through 3” schedule 80 tubes which have an internal diameter of 2.9 inches (73.70mm).
Although based in principle on earlier Marks 3 systems which continue in commercial use, internal electronics of the Mark 4 have been significantly miniaturised whilst at the same time increasing data storage capacity, acoustic accuracy and battery longevity. Initial tests and proving trials, followed by wide commercial use, have proven all design and operational aspects of the new Intelligent Pig.
To the Client’s benefit, there are many advantages to the COMBINED SERVICE, including:
- Significant mobilisation savings
- Decoking & Inspection executed in harmony by colleagues in common employment
- Elimination of delays caused by liaison between contractor companies
- Elimination of attendance extra costs typically levied by Decoking Contractor
- Elimination of extra Pumping Machine usage costs for inspection works
- Administration simplicity – only one contractor to qualify and monitor
- Administration simplicity and cost efficiency – only one contractor to pay
- Administration simplicity – only one line of communication and responsibility
- Easier gathering of information – decoking & inspection experiences amalgamated
September 2011 saw the introduction of the Merlin Mark IV Intelligent Pig. This advanced technology is offered in time & cost efficient Combined Service with Cokebusters decoking.
MERLIN Mark 4 Inspection Pig
Single body design
Neutral buoyancy
Fast * Accurate * Reliable
Analysis and Interpretation of Scanned Tube Data
The Cokebusters Technology Centre is situated on the British Aerospace/Airbus Industries site alongside Chester in the United Kingdom.
Cokebusters engages in formal academic and technological collaboration with the Universities of Manchester & Liverpool (UK). Association was formally structured by the British Government and has led to development of in-house corrosion science expertise.
The Universities of Manchester and Liverpool have long standing International reputations as centres for the study and teaching of corrosion science. This close collaboration provides COKEBUSTERS with the highest calibre of academic support for the interpretation of metallurgic data recovered by the new MERLIN process tube inspection procedure.
An additional & associated service for scientific analysis of removed coke shale is available. This Metallurgy Report produces a detailed study of coke, leading to authoritative and valuable data being provided for the Client Refinery. Typical results include evidence of crude feedstock element content and an assessment of furnace performance giving consideration of process tube metal temperatures and degrees of degradation.
Sample copies are available at client request.
Contact at Cokebusters Technology Centre: David THEWSEY Ph.D. B.Eng (hons) GradMIMMM
dthewsey@cokebusters.com
Contact at Cokebusters Technology Centre: John FARRELL FD.Eng
jfarrell@cokebusters.com
Commercial note: Merlin Inspection Technology Ltd. is in common ownership with Cokebusters Ltd. COMBINED SERVICE operations issue a single combined charge. Employing a co-ordinated team of colleagues, site activities naturally benefit in time and cost efficiencies.