RCS Robotic Camera Systems
Syncrude’s bellows failure. Copyright 2600912 Alberta Inc.
Oil & Gas Journal
While the plant remained online, Syncrude used the first prototype inspection device to troubleshoot a coker vessel. According to the company, the Syncrude vessel is one of the largest in the world, about 100’ in diameter. The vessel contains a pressure of 32 psi and makes about 207,000 bbl/day of synthetic light crude oil. The inspection system discovered a large hole in the transfer bellows.
With the Pressure Cam data pre-knowledge, Syncrude was able to have the bulk of the parts and pieces ready before the shutdown. Having avoided 94 days of downtime at $4 million/day, the Pressure Cam helped the company preserve $376 million in revenue.
When Syncrude personnel realized that a vessel area was running about 150°C (300°F) hotter than normal, they decided to send the RCS Pressure Cam to look at the transfer line. Although Syncrude did not know the problem at the time, a hole in one of the expansion joints on the transfer line was allowing heat to enter the space under the fluidized bed. Although the camera showed a small crack on one side of the bellows, the engineers were able to evaluate the data and recognize that the problem was caused by something larger.
Viewing the other side of the bellows the sensor identified a football-sized hole in the transfer line bellows. An area 2-3 ft below the hole was cherry red, indicating a heat-affected area. By the time the unit was shutdown and cooled, the necessary replacement parts had been manufactured and were ready for installation.
In our effort to build the first proof-of-concept prototype we made assumptions about the environment inside an operating refinery vessel. The concerns were how to protect the Pressure Cam from the 600°C (1112°F) temperature, and oscillating pressure. The first video picture was like being trapped in a blizzard. The engineers determined that the flying particles were pieces of unburned coke. The turbulence caused the sensor pod to act as a sail and allowed it to be dangerous to the operator. In some cases particulate density may be high enough to partially obscure inspected areas, and may interfere with some articulation tech.
Using our new data, the third proof-of-concept prototype was designed for the inspection at the Imperial Oil Sarnia Ontario plant.
.jpg)
Imperial’s skirt hole. Copyright 2600912 Alberta Inc.
O&G cont'd
The RCS Pressure Cam inspected Imperial Oil’s Sarnia Ontario Refinery coker vessel. Once again, the 30’ in diameter vessel remained online. Like Syncrude, Imperials alternative inspection would have required shutting down the unit and sending an inspector inside the vessel which produces 121,000 bbl/day. The upgraded system entered to detect a small hole in the structural skirt that supported the fluidized bed.
Making use of the data accumulated about the operating environment in the Syncrude vessel, the 3rd generation system alleviated the issues that arose. Imperial preserved over $40 million of revenue by reducing the downtime and knowing the extent of the damage before vessel entry.
From the first two inspections, RCS has developed detailed procedures for safety. These procedures address preparation of the site, insertion of the RCS Pressure Cam, internally roaming or focusing within the vessel, and removal steps. The vessel operator can change variables and see a real time picture of how the problem reacts. To ensure that the camera provides good information the operator is given technical tools to provide accurate inspection interpretation.
Once the inspector determined the damage and documented it, it would be explained to others, and together with the team, formulate a repair plan. The system allowed inspection of the vessel and repair formulation to occur simultaneously with the unit operations.
-
Saves shutdown time and protects revenue
-
Fewer shutdowns over the life of a vessel
-
Better over-all planning of shut down
-
Data for evaluation and historical review
-
Informed decisions regarding repairs
-
Procedures and training protect the team
-
Unit requires safety procedure sign-off
-
Reduces shut-down and liability insurance
Using hot tapping as a base line we added data from Syncrude and Imperial Oil which enabled us to modify our designs. The systems use new materials and concepts to enhance the value for vessel owners and protect the team and environment.
CNC machining block. Copyright Glebe
Investment opportunity
The mission is to build inspection systems that enter hazardous, pressurized environments to acquire decision-making data. The priorities are safety, industrial teamwork, training, technical skill and know-how.
Edited public domain image of Syncrude refinery in Fort McMurray Alberta. Copyright 2600912 Alberta Inc.