Aug-2024

Developing automated solutions for maintenance and inspection challenges

In the space exploration industry, renowned American physicist and science writer, Michio Kaku remarked: “It’s very dangerous to put astronauts on a moon base where there’s radiation, solar flares and micro meteorites. It’d be much better to put robots on the moon and have them mentally connected to astronauts on the Earth.”

Derek Sumsion
Integrated Global Services (IGS)

Article Summary

While Kaku’s vision may seem futuristic, it underscores a universal truth: the potential of robotics and automation to revolutionise dangerous and complex tasks is limitless. In fact, according to a recent GlobalData article, sales of industrial robots are predicted to be worth $352 billion by 2030, growing at a compound annual growth rate (CAGR) of 38%. 

The adoption of robotics and automation is being seen across industrial applications, particularly in the energy industry. It has been embraced by Integrated Global Services (IGS) to improve safety standards, reduce fuel consumption/ increase capacity, and significantly reduce scope 1 and scope 3 emissions. Over the past decade, the research and development team at IGS has been dedicated to delivering next-generation technologies to solve long-standing challenges.

One of these technologies is the automated convection section fouling removal rover (ROV) by IGS Tube Tech. This article will discuss the problem of convection section fouling, the development of the technology, a case study, and its diverse application across various assets.

The challenge of convection section fouling
The focus of efforts at IGS Tube Tech has been on finding solutions to safely, precisely, and cost-effectively remove fired heater convection section fouling. It’s a significant issue that costs facilities worldwide millions of dollars in lost revenue each year. Fired heaters, which consume expensive fuel to provide essential heat energy for various processes, can see their efficiency drop by 1-2%. This inefficiency alone can result in an additional $1 million in fuel costs annually.

Traditional cleaning methods have proven inadequate, often reaching only 20-30% of the surface area and sometimes exacerbating the problem, particularly concerning chemical use. To address this challenge, the R&D team at IGS Tube Tech has been continually developing and refining a robotic system that restores heat transfer efficiency by removing 90-95% of fouling from the convection section.

The evolution of the technology
The first version of the convection section fouling removal system was developed in 2010 to meet the needs of a client facing a specific fouling problem. The nature and location of the fouling were unknown, and other methods had failed to remove the deposits. The system Tube Tech developed and deployed was a huge success and went on to complete many more projects around the world.

Since then, there have been six previous versions of the technology:
2010: The original Remotely Operated Vehicle (ROV) was fully air driven, no visual aid or cameras
2011-2013: A flush bar was added
2013-2015: A redesign to include a better track system and lights
2015-2017: Added a camera and a control station screen for the operator
2017-2019: More robust caterpillar tracks, improved gearboxes
2019-2024: Removed air motors, now all-electric with improved lighting, programable lance, and encapsulated motors.
2024: The latest version improves on its predecessor by automatically crawling over intermediate tube support plates and across tubes, requiring fewer access points and enhancing its ability to access hard-to-reach areas. This defining feature enables the system to clean more in less time.

How the system works
The robotic system is designed to be deployed during a plant’s regular turnaround schedule. Utilising ‘as-built’ drawings from the facility, a detailed visual representation of the bundle is created for technicians to use before each project. This preparation ensures the robot is pre-programmed and tailored specifically to each convection bank, saving valuable time on-site.
Once on-site, the robot is placed at the starting position on the tube rows of the convection section. A Tube Tech technician remotely starts the system and it moves up and down and across the tube rows. Its patented lance system penetrates between the tube rows, using high-pressure water (typically 10,000 psi/700 bar) to oscillate and adjust its angle to each bundle. The system features an HD camera that records images and videos for reporting and future maintenance purposes, producing a detailed digital report at the end of each project.

Case study: Tüpraş Izmir Refinery in Turkey
A great example of the results achieved by the system is at the Tüpraş Izmir Refinery in Turkey. The plant faced reduced heat transfer, higher fuel consumption, and increased flue gas temperature due to fouling on the convection bank tubes of its steam methane reformer. This fouling resulted from adsorbents being transported by the tail gas stream and accumulating on the tubes.
Tüpraş contacted IGS Tube Tech to deploy the convection section fouling removal system.

The Results:
· Hydrogen Production Cost: Reduced by $24.6/t, with a payback period of less than 60 days.
· Flue Gas Temperature: Decreased from 278°C to 220°C, translating to a 3% increase in thermal efficiency.
· Steam Production: Increased by approximately 20%, with generated steam temperature rising by 10°C-15°C.

Key advantages and industry impact
The fouling removal system offers several key advantages, driving industry acceptance and transformation:
· Improved Safety: Eliminates the need for manual entry into confined spaces, reducing worker risk.
· Increased Efficiency: Removes up to 90% of fouling deposits, significantly improving heat transfer efficiency and reducing fuel consumption.
· Reduced Emissions: Optimises combustion efficiency, reducing CO₂ emissions by up to 15% and NOx emissions by up to 30%.
· Real-time Inspection and Reporting: Provides valuable data for asset monitoring and proactive maintenance planning.
· Cost Savings: Enhances efficiency, lowering fuel costs and offering payback periods as short as two months.

The future of automated solutions in industry: Metalspray Pipe ID Rover
IGS’s commitment to innovation extends beyond convection section cleaning. The rover has also provided a break-through solution for pipeline corrosion protection. The rover system offers a no-man-entry, field-applied alloy upgrade for pipelines, slug catchers, and flare lines to address the challenges of wet CO₂ corrosion and internal corrosion in pipelines with precision.

The system navigates through pipelines, applying a durable alloy coating to interior surfaces without the need for direct human intervention. This approach ensures comprehensive surface preparation, alloy application, and quality control in environments previously considered challenging or impossible to treat effectively.