Mark 6 Smart Pig Enables Inspection of Previously Inaccessible Solar Process Tubing

Cokebusters has recently deployed its Mark 6 Smart Pig to the Middle East to support the inline inspection of a Parabolic Trough Collector (PTC) unit, which presented significant geometric and inspection challenges.

The project demonstrates how ultra compact intelligent inspection technology can unlock critical integrity insights in assets that have traditionally been considered out of bounds to in-line inspection tools.

The Challenge: Inspecting Long, Constrained Solar Collector Loops

Parabolic Trough Collector units rely on long lengths of absorber tubing to transfer heat flux efficiently. In this case each loop exceeded 1.5 km in length, with each cell comprising four individual loops.

While the absorber tubes themselves had a nominal internal diameter of 49 mm (1.93″), the inlet and outlet sections were significantly more restrictive, with a nominal ID of just 42 mm (1.65”). These constrictions prevented the use of conventional inspection tools and had previously ruled out inline inspection by other service providers.

Adding further complexity, the absorber tubes were shrouded in a glass.  This design feature is essential for thermal efficiency, but one that completely prevents external inspection techniques such as handheld ultrasonic testing (UT).

As a result, the operator was left without a practical means of verifying internal cleanliness or assessing tube geometry and wall condition across the full asset.

A Combined Cleaning and Inspection Approach

To enable inspection, Cokebusters developed and deployed bespoke descaling pigs, specifically designed to:

• Navigate the restrictive inlet and outlet sections

• Effectively descale the absorber tubing

• Prepare the internal surface of the tube wall for reliable ultrasonic inspection results

This tailored mechanical cleaning solution ensured the inspection tools could pass freely through the entire system, paving the way for a full inline inspection programme.

Deploying the Mark 6 Smart Pig

Following descaling, Mark 6 Smart Pigs were deployed to perform ultrasonic inline inspection throughout the complete asset.

The ultra-compact design of the Mark 6 Smart Pig enabled it to:

• Navigate the tight inlet and outlet geometry

• Traverse long loop lengths without interruption

• Operate reliably within the constrained diameters of the system

The tool successfully passed through all sections of the asset, whilst gathering:

• Internal Diameter (ID) measurements
• Wall Thickness (WT) readings

This provided the operator with quantitative geometric and integrity data for an asset where inline inspection had previously been deemed not possible.

Delivering Confidence Through Data

The inspection results delivered two critical outcomes for the client:

• Verification of effective descaling, confirming the success of the mechanical cleaning process

• Quantitative insight into tube geometry and condition, enabling informed integrity assessment

By combining bespoke cleaning pigs with compact intelligent inspection technology, Cokebusters was able to replace assumption with evidence.  This gave clarity and confidence in a highly specialised solar process application.

Extending Intelligent Inspection Beyond Traditional Assets

This project highlights the potential of Cokebusters’ intelligent inspection technology beyond conventional refinery and pipeline environments.

As energy infrastructure continues to diversify, operators increasingly require inspection solutions capable of adapting to non-standard geometries, long lengths and restricted access. The Mark 6 Smart Pig has been specifically developed to meet these challenges, extending the reach of inline inspection into areas previously considered “unpiggable”.

Supporting Complex Assets Worldwide

Whether deployed in refineries, pipelines or emerging energy technologies, Cokebusters’ Smart Pig systems are designed to deliver reliable, data-driven insight, even in the most demanding environments.

If you have assets with restrictive geometry, limited access or inspection constraints, our team would be pleased to assess how our intelligent inspection tools can support your integrity objectives.