Internally inspecting steam generator tubing presents many of the same challenges encountered in fired heater systems, particularly where assets were not originally designed with inspection in mind.
Steam generators such as Heat Recovery Steam Generators (HRSG), Once-Through Steam Generators (OTSG) and Parabolic Trough Collectors or Solar Steam Plants often feature small internal diameters, tight bend radii, complex geometries and limited access points. These characteristics can prevent the use of conventional inspection tools, leaving large sections of tubing effectively unpiggable.
In addition, internal deposits such as scale and fouling can mask underlying degradation mechanisms. Combined with elevated operating temperatures and pressures, undetected damage can progress rapidly and increase the consequences of failure. Without credible steam generator tube inspection data, owner/operators are left with limited visibility of asset condition and an increased level of unquantifiable residual risk.
Cokebusters’ intelligent pig technology provides a practical and proven solution for internal steam generator inspection, including systems traditionally considered unpiggable.
Based on more than 20 years of continuous development, Cokebusters’ single-module, battery-powered and bi-directional intelligent pig is specifically engineered to navigate complex geometries and restricted access points. The compact, untethered design enables inspection across tight bends, diameter changes and short tube lengths commonly found in steam generation systems.
Using ultrasonic (UT) inspection technology, the intelligent pig gathers high-density wall thickness and internal radius measurements along the full length of the tubing. Water flow is used both to propel the tool and as the ultrasonic coupling medium, enabling efficient, non-invasive inspection with minimal asset intervention.
The current intelligent pig platform is capable of scanning both internal and external tube surfaces across a diameter range of 1.5” to 12” internal diameter, delivering high-quality inspection data in demanding steam generator applications.
Cokebusters’ steam generator inspection services can accurately identify and quantify a range of integrity threats, including:
Inspection data can be presented numerically, graphically and as C-scan visualisations, providing clear insight into tube condition and enabling rapid identification of hotspots or areas requiring further attention.
Steam generator inspection can be delivered as a standalone steam generator integrity inspection or integrated with mechanical descaling operations as part of Cokebusters’ patented combined service approach.
Steam generator inspection can be delivered as a standalone steam generator integrity inspection or integrated with mechanical descaling operations as part of Cokebusters’ patented combined service approach.
Inspection tools are deployed using the same access and connection arrangements as mechanical descaling, allowing inspection after cleaning, pre-cleaning inspection or inspection during descaling activities. This enables inspection data to directly inform descaling strategy, ensuring efforts are focused only where fouling or degradation remains.
For newly constructed assets, inspection can also be used to establish a baseline condition record, supporting long-term integrity management, future comparison and maintenance planning.
Inspection data supports steam generator condition inspection, fitness-for-service evaluations and remaining life assessments, providing operators with confidence in both current operation and future decision-making.
