Magnetic flux leakage (MFL) pigs are frequently used for inspecting pipelines for corrosion defects. Experiences with MFL pigs to date indicate that inspection results are sometimes unreliable. Errors in calibration and data analysis can lead to severe under- or over-sizing of defects and subsequent improper conclusions and actions. Experimental and modelling studies have been carried out on the error sources that can influence the reliability of an MFL inspection. It has been found that a number of significant error contributions can be minimised by a proper design of the magnetising system and when the pipe wall is sufficiently magnetised. On the basis of these findings, criteria are being developed for pipe wall magnetisation as a function of pipe wall thickness. This «magnetisation operating window» will depend on the design of the magnetic circuit in the pig, whereby there will be a trade-off between pig flexibility and magnetisation capabilities.
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