Professional Documents
Culture Documents
System
Operation and Maintenance
Feng Hongchen
August 2007
黄骅市瑞晨防腐材料有限公司
Cathodic Protection
Level II Training Course
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Company Profile
HuangHua Risen CorrStop Ltd. is a professional corrosion
control company. Besides cathodic protection materials
production , we also produce PVC and FBE powder for
coatings. With technical support from some famous
international companies, we are the first company in
China that used CorrStop Grid for tank bottom cathodic
protection, and completed many cathodic protection
projects.
Our engineering department provides cathodic protection
system design, consultation and training service.
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Corrosion is Disastrous
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Content
Level I Level II
Nature of Corrosion Soil Resistivity
Factors Affecting Corrosion Ground Bed Design
Cathodic Protection Principle Cathodic Protection Design
Pipeline Cathodic Protection
Cathodic Protection Methods
Design
Pipeline Coatings Tank Cathodic Protection Design.
Sacrificial Anode Cathodic Heat Exchanger & Oil Well Casing
Protection Cathodic Protection
Impressed Current Cathodic Stray Current Interference
Protection Cathodic Protection Shielding
Isolating Joints vs Grounding Cell Cathodic Protection System
Cathodic Protection Criteria maintenance
Coating and Cathodic Protection Pipeline Coating Survey
Concrete cathodic protection
Reference Electrodes
In Line Inspection, Corrosion
IR drop and IR Drop Free monitoring
Measurement
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Nature of Corrosion
Corrosion Concept and Conditions
What is Corrosion:
According to the definition of BS7361, corrosion is the chemical
or electrochemical reaction of a metal with its environment,
resulting its progressive degradation ,or destruction.
At atmospheric temperatures the corrosion of metals is an
electro-chemical process.in which, the metal surface is in
contact with an electrolyte. The electrolyte may be a film
of moisture containing dissolved salts or may constitute
the whole or part of the surrounding medium, e.g. when
metal is immersed in fresh water, sea water or buried in
soil. In the last case the electrolyte is the soil water,
containing dissolved salts.
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Nature of Corrosion
Definitions
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Nature of corrosion
Corrosion Concept and Conditions Diagraph
current
cathode anode
e
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Nature of Corrosion
Corrosion Concept and Conditions
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Nature of Corrosion
Corrosion Concept and Conditions
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current
cathode anode
e
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Cathodic Protection
Principle
Cathodic Protection: A technique to control the
corrosion of a metal surface by making that surface the
cathode of an electrochemical cell.
The principle is to make the potential of the whole
surface of the structure sufficiently negative with
respect to surrounding medium to ensure no current
flows from the metal to the medium.
This is done by forcing an electric current to flow
through the electrolyte towards the surface of the metal
protected.thereby, eliminating the anodic area.
Corrosion of steel in normally aerated soils and waters
can be entirely prevented if the steel is maintained at a
potential not more positive than –0.85V CSE. Under
anaerobic conditions when sulphate-reducing bacteria
are present, it is necessary to depress the potential a
further 100mV, to –0.95V CSE.
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Nature of Corrosion
Galvanic Series of Metals Against CSE
1. Carbon,graphite,coke: 0.30v
2. Platinum: 0 to –0.1v
3. Mill scale on steel: -0.20v
4. High silicon cast iron: -0.20v
5. Copper,brass,bronze: -0.20v
6. Mild steel in concrete: -0.20v
7. Lead: -0.50v
8. Cast iron: -0.50v
9. Mild steel (rusted): -0.20v to –0.50v
10. Mild steel (clean and shiny): -0.50v to –0.80v
11. Commercially pure aluminum: -0.80v
12. Aluminum alloy (5% Zn): -1.05v
13. Zinc: -1.10v
14. Magnesium alloy (6%AL,3%Zn,0.15%Mn): -1.60v
15. Commercially pure magnesium: -1.75v
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current e
cathode anode
e
current
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Pipeline Coatings
The function of external coatings
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Pipeline Coatings
Requirement to Coatings
An effective electrical insulator
1. Effective moisture barrier
Applicability.
1. Ability to resist development of holidays with
time.(soil stress and soil contaminant).
2. Good adhesion to pipe surface.
3. Ability to withstand normal handling,storage
and installation.
4. Ability to maintain substantially constant
electrical resistivity with time.
5. Resistance to disbonding. Easy of repair.
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Pipeline Coatings
Coating Selection
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Limitations
1. Strict application control
2. Possible shielding of CP current
3. High initial coast.
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W= U = Using factor
U × Z ×Q Z = Current capacity
Q = Anode efficiency
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Magnesium Anodes
Materials used are magnesium alloy, aluminum alloy
and zinc. Neither magnesium nor aluminum alloys
should be used in situations where sparking may
cause explosion.
The potential difference between magnesium alloy
and steel is greater than that between zinc or
aluminum, enables it to be used economically at a
relatively higher soil resistivity(above 30ohm.m) while
aluminum anode is mainly used for offshore
structure.
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Magnesium Anode
(High potential Mg anode 1.75V CSE)
Chemical Composition
Aluminum 0.01% max
Manganese 0.50 - 1.3%
Copper 0.02% max
Silicon 0.05% max
Iron 0.03% max
Nickel 0.001% max
Others, each 0.05% max
Magnesium Remainder
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Magnesium Anode
(low potential Mg anode 1.55V CSE)
Chemical Composition
Aluminum 5.0-7.0% max
Manganese 0.15% min
Copper 0.10% max
Silicon 0.30% max
Iron 0.03% max
Nickel 0.003% max
Others, each 0.30% max
Magnesium Remainder
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Magnesium Anode
Electrical Property
Q = Current efficiency (0.5)
Z = Theoretical Current Capacity (2200 Ah/kg)
U = Anode usage factor (85%)
Open circuit potential:
high: -1.75V CSE
low: -1.55V CSE
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Magnesium Anode
Electrical Property
The efficiency of magnesium is usually about 50%. It is
also influenced by the environment. In soil or water with a
moderate to low salt content, the efficiency may be low
because the current output is low and consequently the
anode’s own corrosion may be relatively high. The use of
special back fill around the anode gives a higher current
output and a better anode efficiency.
At increased temperature, the self-corrosion of the
anodes is greater and therefore their efficiency
decreases. For this reason, magnesium anodes
should generally not be used when the temperature
is higher than approximately 30oC in brackish or salt
water or higher than approximately 45oC in fresh
water. In sea water their life is too short.
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Magnesium Anode
Configuration ( Cast Magnesium Anode )
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Magnesium Anode
Configuration (Cast Magnesium Anode)
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Magnesium Anode
Extruded Magnesium Anode
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Zinc Anode
Zinc gives a relatively small current output as its
potential difference with protected steel is
approximately 0.25V as compared with 0.7V for
magnesium. It is not economical to use it in
media with resistivity greater than 15ohm.m. It
is mainly used in sea water
Zinc anodes should not be used at temperatures
above 60 °C and better being used below 40 °C.
At temperatures above 70°C, it may change from
negative to positive with respect to iron, thereby
promoting an attack on steel instead of
protecting it.
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Zinc Anode
Chemical Composition
Al 0.1 - 0.5
Cd 0.02 - 0.07
Fe 0.005 max
Pb 0.006 max
Cu 0.005 max
Zinc Remainder
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Zinc Anode
Electrical Property
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Zinc Anode
Application
It is used in soils with its resistivity below
15ohm.m or offshore structure.
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Zinc Anode
Anode Configuration
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Zinc Anode
Bracelet Zinc Anode Configuration
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Aluminum Anode
The main use of aluminum anode is in sea water or brackish
water of less than 200ohm.cm resistivity.
They are not suitable for use in soil.
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Aluminum Anode
Chemical Composition
Zn 2.8-6.5
Si 0.08-0.21 Max.
In 0.01-0.025
Cu 0.006 Max.
Fe. 0.12 Max
Other Each 0.02 Max
Aluminum Remainder
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Aluminum Anode
Electrical property
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Aluminum Anode
Application
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Aluminum Anode
Tank Bottom Application
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Sacrificial anode is
usually placed 1-1.5m
from the pipeline.
Several anodes can be
installed in a group.
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CorrStop
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Anode Materials
Mixed metal oxide anode
The anode is made with
titanium substrate coated
with mixed metal oxide
catalyst . The catalyst is
thermally applied to the
titanium to form an
extremely chemical resistant
bond. It is small, light weight.
Operating current density:
soil and fresh water, 100A/sqm;
sea water,500A/sqm.
Consumption rate: less than
1.0mg/A.yr.
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Anode Materials
Mixed metal oxide anode
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Anode Materials
Silicon anode
Silicon anodes have been
used for decades and it is
proven to be one of the
most reliable anode
materials.
Anode consumption rate:
0.45kg/A.Yr.
Operating current density:
10A/sqm.
Wide application
environment.
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Anode Materials
Silicon anode
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Anode Materials
others
Graphite anode
Scrip iron anode
Platinized
niobium/Titanium anode,
it is used for steel
vessel internal cathodic
protection.
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EXTERNAL COAT.
Epoxy resin
Twopack - 100% RT examination on butt welds [W] ASME VIII UW 51
200 m DFT
solventless
INTERNAL Epoxy Resin - 100% MP examination on welds [F] ASME VIII UW 53 App. 6
LINING 200 m DFT - 100% Hydrostatic test pressure : 1.5 times the DP for 15 minutes
INSULATING Cold cured - 100% Dielectric strength test : >5 KV x 1 min. (50 Hz A.C.) *
FILLER MATERIAL Epoxy resin - 100% Electrical Resistance test >25 Mohm (1000 V D.C.) *
ADHESIVE
Silicone - 100% Visual & Dimensional check
SEALANT
Isolan
SECOND SEALING Test performed before and after the hydrotest
elastomer
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Grounding Cell
Alternating current, lightning strikes may break through
the isolating joints, to protect the isolating joint from
damage, grounding cell is used to discharge the current
from one side to another.
The composition of the Zn inside which forms the grouding
cell is the same with Zn anode.
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Grounding Cell
6mm铁芯
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Zn Rod:35x35x1000mm
Backfill:Gypsum75%、Bentonite20%、Sodium Sulfate5%
Cotton Sack
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Permanent reference
electrode installed for
potential monitoring of
buried pipelines.
It is installed near the
pipeline surface.
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Reference electrode
for under ground
fuel tanks
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I: Anode Current A
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Ra = Grounding resistance
(ohms)
⎛ ρ ⎞ ⎛ ⎛ 4⋅ L ⎞ ⎞
Ra = ⎜ ⎟ ⋅ ⎜⎜ ln⎜ ⎟ − 1⎟⎟ ρ = Soil resistivity (ohm-m)
⎝ 2 ⋅π ⋅ L ⎠ ⎝ ⎝ r ⎠ ⎠ L =Anode length (m)
r = Anode radius (m)
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0.00159 P ⎛ 8 L 2L ⎞
R= ⎜ Ln −1+ Ln 0.656 N ⎟
NL ⎝ D S ⎠
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Calculation:
Protected area:=3.14x112=380 m2
Protected bare area: 190m2,
Currents needed is :1900mA
I × t × 8766
W=
U × Z ×Q
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The anode
grid is formed
by MMO
ribbon
connected by
Titanium
conductor bar.
They are spot
welded at the
intersection
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It can provide a
very uniform
current to the
tank bottom
No interference
current will be
produced with
this kind of
anode bed.
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Groundbed Maintenance
Surface anodes
Periodic checks to ensure that there has been no disturbance of
the earth above the header cable and anode bed.
During routine testing,any significant increase in groundbed
grounding resistance will mean problems happened to the
groundbed.
If pipe-locator is used and found continuous,one or more
anodes may have failed.
If anodes failed, its position can be found out by measuring the
anode potential.
Two reference cell are used and one is placed in remote area
while the other is placed over the anode. The one which is
above the anode is moved along the anodebed0.5m to 1.0m
each time and take the potential reading.
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Groundbed Maintenance
Surface anodes
The potential profile will show positive potential
peaks at each working anode.
Any areas where peaks in the potential are not
found represent anodes that are no longer
working and require repair or replacement.
The number and spacing of the anodes installed
originally should be known.
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Groundbed Maintenance
Deep anodes
If deep anode fails, little can be done.
Increased resistance of a deep well caused by
gas blocking can be remedied in some cases
by air or water injection through the vent pipe.
If injection of a low Resistivity chemical
solution is considered,the possible effect on
anode materials and cable insulation must be
studied as well as the possible contamination
of the underground water.
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Groundbed Maintenance
Galvanic anode
Current out put can be measured during the annual
survey.
Any break of cables should be repaired.
If there is a marked decrease in the out put of a
galvanic anode installation and there is no reason to
believe the anode is approaching its end, a broken
header wire or anode lead may be the cause.
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In Line Inspection
In line inspection is
mainly for pipeline
geometry
measurement and
metal lose
measurement.
There are tow kind of
intelligence pigs which
is mainly in use:
1. Magnetic flux leakage.
2. Ultrasonic tool.
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In Line Inspection
Magnetic flux leakage
The MFI tool is designed to detect small changes in the
induced magnetic flux of the pipeline. The MF.L Tool
measurement sector consists of a magnetizer and
sensors. The sensors are arraigned to cover the entire
circumference of the pipeline. The number of sensors
is dependent on the pipeline size and the type of MFL
tool, conventional or high resolution, analog, or digital.
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In Line Inspection
Magnetic flux leakage
The MFL tool‘s magnetizer section induces a strong
magnetic field, magnetic flux, to the pipeline. The magnetic
flux magnetic field will “parallel” the walls of the pipeline.
The magnetic flux path, which is distorted near a defect, has
a small component normal to the pipeline both before and
after the defect. As the sensors pass over the defect, this
component grows from zero to a maximum and then back
to zero. The changes in magnetic flux in the sensors induce
a voltage in each of the flux leakage sensors passing over
the defect. The voltage produce is proportional to the size of
the defect. The MFL, tool can run in almost any environment,
liquid, or gas. The tools drive section and electronics section
can survey dual diameter pipelines.
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In Line Inspection
Magnetic flux leakage
Any metal lose which occur
in the wall results in the
flux lines being distorted
and this distortion is
sensed by a detector which
then generates an
electrical signal.The signal
will be recorded and stored
for future analysis.
It can be used in liquid,
gas and measure the metal
lose.
Not available to thick wall
thickness
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In Line Inspection
Ultrasonic Inspection Pig
Ultrasonic testing is a nondestructive test that uses a low
amplitude signal that operates well below the yield stress of
the material. Because ultrasonic testing is a mechanical
phenomenon, they are particularly adaptable for determining
the structural integrity of engineering material. Their
principal applications consist of:
(l) thickness measurement,
(2) discontinuity detection, and
(3) crack detection.
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In Line Inspection
Ultrasonic Inspection Pig
The Ultrasonic Tool (UT) operates by emitting
a pulse, in the range of 5 Mhz at pulse rate of
300 times per second (sonic wave) and
measuring the energy of the reflected pulse.
Basic ultrasonic testing equipment requires a
transmitter (sound emitter), a couplant to
transfer the energy to the object under test
(crude oil, refined product or water), the
object being tested, couplant to transfer the
returned energy to the receiver and the
receiver.
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In Line Inspection
Ultrasonic Inspection Pig
Ultrasonic Tools provide precise, direct wall
measurements for sizing of corrosion and mid-wall
defects such as laminations and inclusions. Defects
both internal and external are identified with exact
determination of location, depth, extent, and position
by using all the sensors. The UT Tool measurement
section consists of many transducers. A transducer is
both transmitter and receiver. The transducers are
arraigned to cover the entire circumference of the
pipeline. The number of transducers is dependent on
the pipeline size and the type of UT tool.
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In Line Inspection
Ultrasonic Inspection Pig
The ultrasonic transducer
transmit signals
perpendicular to the surface
of the pipe and receive echo
signals from both internal
and external surface of the
pipe.
The signals are converted
into digital data and detect
any anomalies.
If it is used for gas pipeline,
the tool needs to be in liquid
slug with seal pigs in front
and behind of it.
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In Line Inspection
Ultrasonic Inspection Pig
Ultrasonic Pig
25
74
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In Line Inspection
Gauge Pig
The gauging tool consists of a series of drive cups
and aluminum sizing plates, mounted on a thin
steel body. The diameter and position of the plates
on the pig body are designed to mimic the hard or
“non compressible‘ components of the inspection
tool. Close inspection of the gauging plates upon
receipt of the tool will indicate the type of possible
problems present in the line, determining if an
electronic caliper is or is not required.
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In Line Inspection
Gauge Pig
Foam “Scout” Pig The foam scout pig is a flexible soft-
bodied monolithic pig. This tool is generally the first pig
through the pipeline system. The foam scout pig serves
several functions; first, it is able to confirm if a pig will
pass through the line. It also will indicate basic and
potential diameter discrepancies or protrudences. By close
examination of the material bought out by the pig, it can
be used to determine the type and estimate the volume of
the debris present in the line. The type and amount of
debris dictates the cleaning regime to be employed. The
Foam Scout pig generally contains an electronic location
transmitter to find the pig if it becomes stuck.
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In Line Inspection
Tool propulsion —pumped
The first and most common is the pumped system, the
pumped system use the fluid or gas flow of the pipeline to
push the tool from its starting point to the end point of the
survey. The tool is loaded into a launcher, which is an
assembly made up of piping and valves. The launcher is
designed so that the tool can be loaded without interruption
of the flow. After the tool is loaded into the launcher and
the trap door is sealed, a series of valves are operated so
the pipeline‘s flow is diverted into the launcher. The valve to
the main line of the pipeline is now opened; the tool is
pushed into the main pipeline by the flow behind the tool.
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In Line Inspection
Tool propulsion —pumped
The tool travels through the pipeline collecting
data, until it reaches the receiver. The receiver is
similar to the launcher it consists of piping and
valves configured so that the pig can leave the
main pipeline. As the pig is pushed into the
receiver or trap, the valves are operated so the
flow is divided from the receiver. The pressure
from the line is bled off; the material in the
pipeline is evacuated. The receiver can now be
opened and the tool removed.
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In Line Inspection
Tool propulsion—pumped
The launchers and receivers are generally
located at a station above grade. There are
systems that have permanent launcher and
receivers installed. For systems that do not
have permanent facilities the launchers and
receiver can be rented for the survey program.
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In Line Inspection
Tool propulsion (Tethered)
The Tethered system uses a wire or a tether as the
method providing movement for the tool. The
tethered system is usually used on short lengths of
piping generally less than 3000 feet. The piping is
excavated at the two ends of the section to be
surveyed. The pipeline is then nitrogen purged and
cut for access for the tool, A flange is fitted on to one
end of the line with a packing gland and couplings for
an air compressor.
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In Line Inspection
Tool propulsion (Tethered)
The tool is attached to the tether and pulled
through the line. The system can have a single
line attachment or a double line attachment.
The double attachment is useful if a repeat of
a section of pipeline is required. The double
system also provides a means of pulling the
tool back should it become lodged.
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