Pipeline Inspections ILI TECHNOLOGY
Training Program Outline DAY Mon
Module
TITLE Company Introduction & History Scope of Training & Definitions Statistic Study, ILI History, Pigging for Operation & Maintenance
Pipeline, Questionnaire, Tool Autonomy, Tool Specifications,
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Scope of Training This training ….
Class Schedule Weekly Hours • M – F 8:00 a.m. – 4:30 pm • Break 10:00 a.m. – 10:15 a.m. • Lunch – 12:00 – 1:00pm • Break 2:45pm – 3:00pm
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GE Inspection Services
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ILI History In 1961, the first intelligent pig was run by Shell Development. It demonstrated that a self-contained electronic instrument could traverse a pipe line while measuring and recording wall thickness. The instrument used electromagnetic fields to sense wall integrity. In 1964 AMF Tuboscope ran the first commercial instrument. It used MFL technology to inspect the bottom portion of the pipeline. The system used a black box similar to those used on aircraft to record the information, basically a highly customized analog tape recorder. Until recently, tape recording (although digital) was still the preferred recording medium. As the capacity and reliability of solid-state memory improved, most recording media moved away from tape to solid state.
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ILI History In-line inspection is a proven technology used by pipeline operators to monitor the integrity of their pipeline. The information provided by the inspection can be used to identify immediate integrity concerns and can be used in the development of long term integrity plans ‌.
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General Definition Anomaly. Any kind of imperfection, defect, or critical defect that may be present in the wall of the pipe Batching Pig. A utility pig that forms a moving seal in a pipeline to separate liquid from gas media or to separate two different products being transported in the pipeline Bellhole. An excavation in a local area to permit a survey, inspection, maintenance, repair, or replacement of pipe sections Buckle. A partial collapse of the pipe due to excessive bending associated with soil instability, land slides, washouts, frost heaves, earthquakes, etc. Class Location. A criterion for pipeline design set by the Code of Federal Regulations. Class 1 is rural and Class 4 is heavily populated. A class location is based on the number and type of buildings situated in an area that extends 220 yards on either side of the centerline of any continuous 1-mile length of a pipeline Cleaning Pig. A utility pig that uses cups, scrapers, or brushes to remove dirt, rust, mill scale, or other foreign matter from the pipeline. Cleaning pigs are run to increase the operating efficiency of a pipeline or to facilitate inspection of the pipeline. Configuration Pig. An instrumented pig that collects data relating to the inner contour of a pipe wall or of the pipeline. geometry pigs, camera pigs, and mapping pigs are types of configuration pigs. Corrosion. General External - Metal loss due to electrochemical, galvanic, microbiological, or other attack on the pipe due to environmental conditions surrounding the pipe. General Internal - Metal loss due to chemical or other attack on the steel from liquids on the inside of the pipe. Electrochemical attack can also occur in local cells, but this condition is less frequent. Pit - Local concentrated-cell corrosion on the external or internal surfaces that results from the generation of a potential (voltage) difference set up by variations in oxygen concentrations within and outside the pit. The oxygen-starved pit acts as the anode and the pipe surface acts as the cathode. Stress Corrosion Cracking - A progressive intergranular and/or transgranular cracking that results from a combination of applied tensile stress, cathodic protection currents, and a suitable corrosive environment.
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General Definition Cracks. Fatigue - Progressive cracking in the base material, weld, or weld zone that is caused by pressure cycling or oscillatory stresses associated with the operation of the system. Girth Weld - Cracks in the weld or weld zone of the butt welds that connect sections of pipe. Seam Weld - Cracks in the weld or weld zone of the longitudinal seam weld of the pipe. Selective Corrosion - A localized corrosion attack along the bond line of electric resistance welds (ERW) and flash welds (FW), that leads to the development of a wedge shaped groove that is often filled with corrosion products. Critical Defect. As used in this text, a subset of defect, for which an analysis, such as ASME B31G, would indicate that the pipe is approaching failure at pressures equal to maximum operating pressure or the maximum allowable operating pressure for the pipe. Dent. A local depression in the pipe surface caused by mechanical damage that produces a gross disturbance in the curvature of the pipe without reducing the pipe wall thickness. Erosion. Destruction or removal of material by abrasive action of moving fluids (or gases) usually accelerated by the presence of solid particles or matter in suspension. Evaluation. A review, following the identification of an anomaly, to determine whether the anomaly is a False Call. An indication from an inspection that is classified as an anomaly where no imperfection, defect, or critical defect exists. FERC. Federal Energy Regulatory commission. Flux. The (scalar) number of flux lines crossing a unit area at right angles to the unit area. See magnetic flux.
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General Definition Flux Density. (1) A measure of the intensity of magnetization produced by a magnetic field. (2) A vector quantity representing the number of flux lines crossing a unit area at right angles. Flux Leakage. The flow of flux out of a magnetic material, such as the wall of a pipe, into a medium with lower permeability, such as gas or air. Gauging Pig. A utility pig that is permanently deformable by obstructions in the pipeline and thus, upon retrieval from the line, provides evidence of the worst-case obstruction in a given pipeline segment. Gel Pig. A utility pig that is composed of a highly viscous gelled liquid. These pigs are often used for pipeline cleaning and are sometimes called gelly pigs. Geometry Pig. A configuration pig designed to record conditions, such as dents, wrinkles, ovality, bend radius and angle, and occasionally indications of significant internal corrosion, by making measurements of the inside surface of the pipeline. Gouge. Local damage caused by mechanical or forceful removal of metal from a local area on the surface of the pipe that may work harden the pipe and make it more susceptible to cracking. Gouging. The process of creating a zone of mechanical damage that includes cold working, residual stresses, plastic distortion, and (generally) moved or removed metal. Hard Spots. Local changes in hardness of the steel in the pipe resulting from non-uniform quenching procedures during the manufacture or changes in chemistry of the steel. Hard spots, when stressed, are subject to failure from mechanisms, such as hydrogen-stress cracking. Holidays. Discontinuities in a coating, such as pinholes, cracks, gaps, or other flaws, that allow areas of the base metal to be exposed to any corrosive environment that contacts the coating surface. Hydrostatic Retesting. Proof testing of sections of a pipeline by filling the line with water and pressurizing it until the nominal hoop stresses in the pipe reach a specified value.
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Pipeline
What are Pipeline? Where are They? The energy transportation network of the United States consists of over 2.5 million miles of pipelines. That's enough to circle the earth about 100 times. These pipelines are operated by approximately 3,000 companies, large and small. network includes approximately: • 175,000 miles of onshore and offshore Hazardous Liquid pipeline; • 321,000 miles of onshore and offshore Gas Transmission and Gathering pipelines; • 2,066,000 miles of Gas Distribution mains and service pipelines; • 114 active LNG Plants connected to our gas transmission and distribution systems; and Propane Distribution System pipelines. Most hazardous liquid and gas pipelines are buried underground. are located underground in rights-of-way (ROW) . Pipelines play a vital role in our daily lives. Cooking and cleaning, the daily commute, air travel and the heating of homes and businesses are all made possible by the readily available fuels delivered through pipelines.
Pipeline Pigs? Purpose? Pigs are run to maintain line efficiency. Any decrease in pipeline efficiency reduces the throughput of a pipeline. Pipeline pigs are capsule shaped objects/devices that are inserted and travel throughout the length of a pipeline driven by product flow
• cleaning the inner walls of the pipeline by sweeping & pushing action • batching for line filling, dewatering, separation of products and liquid removal
• Gauging & In Line inspection
ILI TOOL TECHNOLOGIES Caliper/Geometry & Inertia Mapping Unit
Dents/ Ovality
Wrinkle Bends & Buckles
Pipeline X-Y-Z Inertial Mapping IMU
MFL & C-MFL & TFI Leakage Axial & Circumferential
Internal/External Metal Loss Gouges, Scratches Selective Seam Corrosion & Weld
Ultrasound and ElectroMagnetic Acoustic Transducers (EMAT)
Stress Corrosion Cracking, Tow Cracking Hydrogen Induced Cracking
Girth Welds
Linear Crack/Long Seam Crack
Seam Weld Defects (C-MFL)
Internal & External Corrosion
Pipeline PIGS Cleaning Batching Gauging ILI Tool
Inspection Pigs “ Smart Pigs” Inspection pigs gather information about the pipeline from within designed electronic systems. Type of information gathered include; • Odometer Survey • Pipe Diameter • Metal Loss; corrosion, pitting, gouges, • Pipeline Features ; valves, fittings, flanges, tees, heavy wall transitions, casing, supports • Cracks • Curvature, Bends • Temperature • Pressure
Specialty Pigs • Plug Pig used to isolate a section of pipe to perform maintenance, Pig plug keeps pressure in the line.
Inspection Pigs “Specialty Pigs” • Plug Pig used to isolate a section of pipe to perform maintenance, Pig plug keeps isolated pressure in the line.
SmartPlug® isolation technology makes it possible to isolate pipelines at high operating pressures. This means that maintenance and repairs can be conducted quickly, without bleeding down the entire system.
Inspection Pigs “Specialty Pigs” Crack detection and coating disbondment EMAT technology, an alternative to ultrasonic and innovative approach to couple the ultrasonic energy into the pipe without the need for the liquid medium. This approach expands inspection capability to include coating condition. • Detects SCC, hook, toe and fatigue cracks even in or near the longseam weld • Assesses condition of external coating disbondment
IN-LINE INSPECTION
• 1 st 90° tool • No Odometer • Survey displayed on BW photographic paper • Only most significant anomalies reported • Metal loss or Gain were difficult to determine 1964 1st
Commercial MFL
Evolving and Improving 1990-2013
1966 – 71 Full Circumference MFL • Odometer binary code • Tape Recorder • Reference Magnets • Survey displayed on BW photographic paper • Anomalies graded in 3 categories (<30%, 30-50% and >50%)
• Odometer binary code & digital • Speed & Orientation • Tape Recorder/DAT • Survey logs displayed on computer • Reference Magnets & Above Ground Marker • Probability of 80% & Sizing 20% WT
1978-86 HR Circumference MFL & Calipers
• Odometer • Multi-Dia.,Caliper, • Advanced Software • Flash Disc • Scanning Run • Odometer • Pits • Welds • Dents, etc. • X-Y-Z • POD of 80% and Sizing 10% WT
Pigging Operations & Maintenance When preparing a pigging program for a specific operation there are minimum parameters that should be known • • • •
Maximum & Minimum pipeline internal diameter Minimum Bend Radius Maximum Bore of branch connections Service & Operational Parameters
(flow rates, medium, pressure, temperature, pipeline cleanness, work area)
• Pig Launching / Receiving facilities
QUESTIONNAIRE - TOOL SPECIFICATIONS Questionnaire
Tool Specification
TRAP DIMENSIONS To ensure inspection tool fits properly in the traps and to avoid costly down time or damages to the tool it is vital that precise measurements of traps are provided.
FLOW RATES
Flow Rate (Barrles per Day)
: :
Product Velocity
:
Pipeline Diameter
8
inches
12,450
1.58
(mph)
PIPELINE PRODUCT VELOCITY M/Seg 0.70 2.54 km/hr Pipeline Length (mts) 1,979.33 82.47 1.37 22.91 522,900.00 363.13
M続/DAY M続/HOUR M続/MIN Liters/MIN GALLONS/DAY GALLONS/MIN
8.65
BARRELS/MIN
518.75
BARRELS/HORA
20,000.00
LINE PACK 648.59 M続 4,079.61 BARRELS
RUN TIME 7.89 Hours
The MFL Inspection Vehicle The primary sensor system High magnetic flux field imposed parallel to the pipe wall. Rare earth neodymium iron boron magnets power the magnetizer of the inspection unit, providing the ultimate strength to meet most pipeline wall thicknesses for the best feature detection and sizing
S
N
Magnetic flux lines will be deflected if there is metal loss on the internal or external surfaces of the pipe The primary sensor detects any leakage of the magnetic flux
The MFL Inspection Vehicle The primary sensor system High magnetic flux field imposed parallel to the pipe wall
S
N
A Hall effect sensor is a transducer that varies its output voltage in response to a magnetic field. Hall effect sensors are used for proximity switching, positioning, speed detection, and current sensing applications.
IDOD Discrimination The instrument pig functions by flux leakage detection coupled with an eddy current system providing means for discriminating between anomalies in the pipeline exterior and interior surfaces. ID-OD discrimination is accomplished employing an eddy current pulser coil and an eddy current detection coil to provide a signal used to indicate whether a detected flux leakage anomaly is in the pipeline interior surface 14. Drive Cups 22A. Floating Magnet Suspension Arm FRT 26. Magnet (south pole) 56. Sensor pkg (Hall Effect & Eddy Current) 28. Magnet (north pole) 12. Floating Magnet Suspension Arm (Rear) 14. Magnet Support Cup 16. Battery Pack w/odometer & transmitter 18. Odometer Magnetic Trigger Pulse Wheels
TOOL AUTONOMY Locator Locatorunit unit
Cup Cupsleeves sleeves Odometer Odometer
Battery Batterypig pig
Data Datapig pig
Ultrasound Ultrasoundpig pig
Universal Universaljoint joint
Sensor Sensorcarrier carrier
UT TOOL
UM Wall Carrier Interchangeable For UCc
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TOOL AUTONOMY MFL TOOL odometers
IDOD sensors
transmitters sensors Drive Cup Seal
Spring loaded support wheels
UT TOOL
Odometer system
UM Wall Carrier Interchangeable For UCc
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GEOMETRIC INSPECTION TOOL Geometric pigs are generally run prior to running inspection pigs to prove that the lines are free from harmful dents or restriction
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Launching Procedure - Liquid The pig trap valve and the bypass valve must be closed. 1. Open the drain line valve and vent valve to allow liquid to drain from the launcher. WARNING Do not attempt to open end closure until launcher is empty and at atmospheric pressure. 2. Open end closure and insert the pig until the rear cup passes the bypass opening. 3. Close end closure and drain line valve. 4. Open bypass valve slightly to purge air from launcher. 5. Close vent valve and slowly bring launcher to line pressure. 6. Close bypass valve. CAUTION Pig damage may occur if the bypass valve is not closed and the pig trap valve is opened. The pig may try to leave the launcher before the pig trap valve is fully opened. 7. Open pig trap valve. 8. Open bypass valve. 9. Slowly close station discharge valve until enough volume will force pig into line
Bypass Line
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Receiving Procedure - Liquid The end closure, drain and vent valves must be closed. 1. Before the pig arrives, open bypass valve, and then open pig trap valve. NOTE If the pig does not enter the trap, slowly close the station suction valve until the pig is forced into the trap. 2. Once the pig is in the trap, open the station suction valve. 3. Close pig trap valve and bypass valve. 4. Open the drain line valve and vent valve to allow liquid to drain from the receiver. WARNING Do not attempt to open end closure until receiver is empty and at atmospheric pressure. 5. Open end closure and remove pig(s). 6. Close end closure. 7. Close drain line valve. 8. Open bypass valve slightly to purge air from receiver. 9. Close vent valve and slowly bring receiver to line pressure. 10. Close bypass valve. The bypass valve and trap valve may be opened at this time to be ready to receive next pig.
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Test Measurements, Digitizing & Processing, Data Evaluation
Database
Questionnaire, Medium Check, Special Conditions, etc.
Software A Visualizing
RunDB
Software C
feconfig.xml itacconfig.xml pigconfig.xml scconfig.xml
Sync Tool
Operating Software
Upload of XML files
Download & Translate Data
Download of XML files
UT TOOL Total Commander
Test Measurements, Digitizing & Processing, Data Evaluation Channel 1 Channel 2
Odometer pulses
Frontend n Channel 32
Channel 1
Frontend 2 CTP
ITAC
Channel 2
Frontend 1
AUXDATA Channel 32 1101 0011 1100 1100 0101 1101 1010 0001 1100
service mode data download
Ethernet switch
USDATA
File server
Test Measurements, Digitizing & Processing, Data Evaluation UT Basics: Wall Thickness Measurement [dB]
Sound Wall
1. Entry Echo 1. Rear Wall Echo 2. RWE 3. RWE
Medium
[µs]
Steel
External Metal Loss
[dB]
[µs]
Internal Metal Loss
[dB]
[µs]
Test Measurements, Digitizing & Processing, Data Evaluation Wall Thickness Measurement
Test Measurements, Digitizing & Processing, Data Evaluation A-Scan
[dB] 1. Entry Echo
2. EE
1. Rear Wall Echo
2. RWE 3. RWE
[Âľs]
Test Measurements, Digitizing & Processing, Data Evaluation Signal Processing
Digitizing and Analysis of Ultrasonic Echoes
dB Analog signal Âľs
Sampling, peak detection
Expectation ranges, threshold check
Echo vectors
Test Measurements, Digitizing & Processing, Data Evaluation Expectation Ranges UM Expectation Ranges Classified sections of the time base where echo signals are expected. dB 80
50
Expected time range for entry echo Expected time range for rear wall echoes
10
Blocked signals
Blocked signals 10
50
80
Âľs
Test Measurements, Digitizing & Processing, Data Evaluation
Wall thickness: 12 mm Medium sound velocity: 1350 m/s Skips: 1.5 dB 80
Surface echo 50
1st external echo 1st internal echo 2nd external echo
10
Blocked signals 10
Suppression of unwanted reflections
Blocked signals 50
80
Âľs
Test Measurements, Digitizing & Processing, Data Evaluation
Purpose: prevention of high data amount Nominal wall thickness value: Most measured value within 100 shot rings Wall thickness, mm
Reduction window
Nominal wall thickness
Distance, m Wall thickness, mm
Nominal wall thickness
Distance, m
Test Measurements, Digitizing & Processing, Data Evaluation Wall thickness, mm
Small reduction window
Nominal wall thickness
Distance, m Wall thickness, mm
Distance, m Wall thickness, mm
Big reduction window
Distance, m Wall thickness, mm
Distance, m
Test Measurements, Digitizing & Processing, Data Evaluation
Pig Offset Distance between center of the transmitter coil and last sensor.
Test Measurements, Digitizing & Processing, Data Evaluation
Test Measurements, Digitizing & Processing, Data Evaluation [dB] 1. Entry Echo
awater
1. Back Wall Echo 2. BWE 3. BWE
[µs] Water
Steel [dB]
1. Entry Echo
amed
Medium
Steel twater tmed
Medium sound velocity:
cmed =
twater ⋅ cwater tmed
Medium attenuation:
[µs]
amed = awater − amed
Test Measurements, Digitizing & Processing, Data Evaluation
Transit time of sound
t = 2tmedium + 2tsteel s s t = 2 med + k steel csteel cmed
Minimum shot length
v pig max =
α 2nd skip; k=2
ssteel =
s WT t s min = 2 med + k csteel cos β cmed
Maximum pig speed
1st skip; k=1
WT cos β
A 32 ⋅ t s min
A: Longitudinal resolution, default: 3mm
β WT
Steel steel sound velocity: 3255 m/s (transverse wave)
Medium
MoCo
Test Measurements, Digitizing & Processing, Data Evaluation
Inspection Data Check Completeness Data Amount Plausibility Data Quality
Storing Data (Cal. & Inspection) Tool Parameters, Tool Built Configurations Sensor Wiring Robot air line & sensor cable routing Maintenance Checklist Mechanical Assy, Odometer System
Storing Data - Tool Parameters – Tool Built
Project Folder Naming Convention RUNS Kinder Morgan 04122013_MFL Galena – West Park Sta. Calibration Test AGM Docs (questionnaire, tracking, job instructions, tool built) Photos Launch Receive
Sensor Positioning UT Skid Sensor Position
Robot Air Line Water in air lines displaces lubricants from critical wearing surfaces in the robots tractor , valves and cylinders,
• Handling & Launching Tool • Radio Communications • GPS Inspection Site • Check Lists • Inspection Document Procedures
Data Verification - Reporting Issues - failures, - troubleshooting techniques
• Inspection Test Data Verification • Reporting Issues • Failures, discrepancy, data degradation • Inspection Data Evaluation (actual data) • Software Reporting & Printing • Troubleshooting techniques
Pig Tracking & AGM Placement Pig Tracking’ is used as a generic term which covers any pipeline inspection requirements to monitor the movement or location of the pig(s) during the pigging operation. PIG SIGNALLING is a method of indicating when the pig has reached a certain point in the pipeline. This is usually achieved by attaching a triggering device, transmitter or ‘signaler’.
Pig Tracking & AGM Placement PIG LOCATING is a method of determining the position of a pig, normally when it is stationery due to it being either held up or stuck (due to damage or obstruction). This normally requires the pig to carry a transmitter device of some kind and a receiver to be carried along the line to locate it. PIG TRACKING is a method of literally following the path of a pig either continuously or, more likely, by locating it at a series of predetermined points. This can be achieved by various methods including transmitter/receiver systems, mass balance via computer calculations, and by acoustics.
Pig Tracking & AGM Placement The AGM reference sites are used to measure to anomalies in the pipeline. Typical ILI odometer accuracy is +/- <0.5%, and chaining with conventional methods is usually accurate to +/- <0.1%. This creates a maximum expected error of +/0.6% on measuring anomalies from the AGM site (although this number is typically around +/-0.2%). Measuring one mile from an AGM can result in a worst case of 31.7’ of error (0.6% x 5,280’). This requires that AGMs sites be created every one to two miles along the pipeline, ensuring that the longest measurements are kept to one mile in length, with a worst case error of <32’.
PIPELINE MARKER MAGNETS Pipeline Marker Magnets was the primary method for ILI reference marks in the 1970â&#x20AC;&#x2122;s. Today they are still used by pipeline inspection pigging operators to provide absolute position, or waypoints, along the pipeline that can be coordinated with the inspection log generated by an intelligent pipeline pig.
PIPELINE MARKER MAGNETS The thickness of the pipe wall as well as the stand-off created by galvanic or corrosion resistant coatings and insulation dictate the required magnetic flux density and pole spacing required to provide sufficient magnetic field for detection of the marker by the intelligent pig inside the pipeline. Whether you are inspecting exposed pipeline, buried pipeline or Subsea Pipeline
ABOVE GROUND MARKER (AGM) A portable or permanently installed device placed on the surface above a pipeline that both detects and records the passage of an in-line inspection tool or transmits a signal that is detected and recorded by the tool.
ABOVE GROUND MARKER (AGM) Reference locations for above-ground markers, when utilized, shall be established and validated to ensure they are sufficient to meet the location accuracy stated in the performance specification. The service provider sets the appropriate tool detection threshold on the above-ground markers to ensure proper detection.
ABOVE GROUND MARKER (AGM) AGMâ&#x20AC;&#x2122;s, when utilized, are placed as close as practical to the planned reference locations defined by the pipeline operator. The actual location of the AGM is measured and documented. If the AGM is not placed at the planned reference points, the actual locations is identified and documented.
TOOL AUTONOMY & SPECIFICATION Example Only, tool component talking points
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Inspector Systems Robot • • • • • • • • • • •
Flexible, self-propelled construction A thorough examination of the pipeline is possible Can travel pipes with bends ( 1.5D ) Vertical pipe sections can be inspected Long sections of pipe ( approx. 300 m ) can be traveled Pipe sections with a small diameter can be examined ( upwards from 4 inches ) A camera for providing an overview is mounted on the ultrasonic module Changes in the pipe's diameter present no problem Pipe sections laid in the earth can be examined The robot can be deployed through an opening in the pipeline The robot can detect both internal and external corrosion
UT Scanner
Tractor 1
Tractor 2
Tractor 3
Software - Power – Cables – Air Pressure - Water
(applicable software as required)
Video Software Power Software UT Scan Software Drive Propulsion Software
Software - Power – Cables – Air Pressure - Water
AC Voltage Field Generator requirements DC Power Supply Unit: Type EA-PSI 8080-60 DC Max. Voltage Current & Power Consumption: approx. 10W (example of wiring block diagram)
Software - Power – Cables – Air Pressure - Water
TMT Technology •
Include block diagram
Power Generator – Cables – Air Pressure - Water
Umbilical Cable Real Operations & Procedure Umbilical Cable break down - Air line - Water line - Power - Control line
Compressor & Air Line Umbilical Cables Air Line & Compressor Operations & Procedure
Requirements
Loading/Driving Tool & Data Evaluation Equipment List • Tray with Lifting Slings • Tool Box • Consumables (towels, hand cleaner, etc.) • PPE • Radios
Radio Communications • • • • •
use standard radio communication procedures to work safely and efficiently during a field operation Listen before transmitting. Be sure you are not on the air with someone else Know what you are going to say before you push the mike button Hold the transmit button down for at least a second before beginning your message Speak slowly, distinctly, clearly, and do not let your voice trail off at the end of words or sentences
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History INSPECTOR SYSTEMS has been involved with the development and manufacture of pipe crawler and customer specific special machines since 1983. Inspector Systems specializes in producing pipe robots for interior inspection and maintenance of pipe networks. Robots have been largely built to suit customer individual needs but are also suitable for inspection and maintenance service worldwide.
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