CFM Challenge #1: Crude Storage Tanks
Business Case
Oil and gas tank farms around the globe are experiencing an oversupply of hydrocarbons resulting in decreased ability for offline inspection and maintenance of aboveground storage tanks. Developing solutions capable of providing insight to the quality of the tank floor, floor coating, tank shell, roof, nozzles/appurtenances while cleaning can reduce the amount of rework needed when accomplishing separate tasks (i.e. cleaning + inspection).
Parameters:
• API 620 and 650 Storage tanks diameter: average size 200’ to 300’+
• Manway: Average size of 22”
• Level of sediment or debris: 8-10 feet (20 pounds per gallon estimate)
• Temperatures: Crude stored at 180°F, some may be stored higher
• Encourage Cleaning + Inspection: E.g. remaining wall thickness in tank floor, sediment profiling in service, coating inspection on the floor and walls, etc.
Application: In-Service or Out-of-Service Cleaning of and Fabric Maintenance of large crude tanks
Aim
For in-service applications, the intent is to mitigate or eliminate the buildup of sediment and debris from in-service tanks while also collecting inspection data; alternatively, for out-of-service, the aim is to return to service faster than what is commercially available.
Features that could be included but are not limited to:
• Floor plate inspection, i.e. remaining wall thickness
• Critical area floor plate inspection
• Plate settlement
• Sludge profiling
• Coating inspection and removal
• Surface preparation and coating application
• System for cleanup
• Sludge or sediment and hazardous debris removal
CFM Challenge #2: Pressure Vessels
Business Case
The SPRINT Robotics Action Group Pressure Vessels released the first version of the “Guidelines for the Application of Robotics for the Offline Inspection of Pressure Vessels”. Identified as a barrier for deployment, there is a significant opportunity to further accelerate robotic inspection technologies by first addressing cleaning and fabric maintenance.
Parameters e.g. Horizontal/vertical Separator with internals
• Materials: Carbon steel, stainless steel, aluminum and aluminum alloys, carbon steel alloys, exotic alloys, often nickel or titanium based
• Manway size: 20”
• Substances: Solids, liquids, waxes
• Methods: Water jetting, blasting, steam Out (366°F)
• Considerations: 3-5k PSI cleaning with internal liners (intent is to keep coating intact, without damage, e.g. glass liners, or Fiber Reinforced Plastic (FRP))
• Safety: 4/5 Gas Detection, LEL %
• Inspection: API 510 internal (visual + UT, pit gauge and 3D scanning)
Application: Internal out-of-service Cleaning & Fabric Maintenance
Aim: Routine inspection of pressure vessels is required to ensure safe operations; eliminating personnel entry (CSE) into these environments would significantly improve safety, while decreasing the time associated with the asset outage
Features that could be included but are not limited to:
• Vortex breaker
• Splash plate
• Separator
• Demister
• Diffuser
• Tray
• Ladder
• Washing facilities usually in the base of a vessel to allow water jetting to assist online removal of process residues
CFM Challenge #3: Process Piping
Business Case
Pipelines are routinely inspected by inserting sensors into the pipeline generating an initial survey, prove up is then carried out by performing digs and exposing the buried pipeline for further evaluation (for example). Removal of coatings and insulation is necessary to access bare metal for high resolution inspection which is very challenging when performed with ordinary hand tools. As an example, robotizing this process would enable a better workflow for operators carrying out a significant number of digs per year.
Parameters:
• Piping Diameter: 12”-24” NPS vertical and horizontal sections
• Coating material for buried systems: (the majority of most oil and gas pipelines), the almost-universal standard pipeline coating is fusion bond epoxy (FBE) powder systems
• Coating material for pump & compressor stations: typically an inorganic Zinc primer, an intermediate coat of epoxy, then a top coat of polyurethane for color and gloss retention
• Cladding Material: Aluminium, stainless steel or galvanized steel weather jacket
Features that could be included but are not limited to:
• Straight and vertical segments of pipe
• 90° elbows and tees
• Pipe reducers
• Pipe supports
• Headers
• Welded connections
• Nozzles
• Small bore fittings
• Flange sets
• Trenches/trench boxes
CFM Challenge #4: Floating, Production, Storage, & Offloading (FPSOs)
Business Case
Costs associated with cleaning and fabric maintenance of hazardous material can be a multiple of that same task if performed with non-hazardous materials. Taking these activities into an offshore environment takes these costs significantly higher, leaving more opportunities to create value. In general, complex elevated surfaces with limited access prove to be a continuous challenge for asset management. Addressing cleaning and fabric maintenance from a robotics perspective could significantly impact maintenance operations and costs due to the elimination of scaffolding or rope access, as well as CSE exposure hours while accelerating the maintenance schedule and improving overall efficiency.
Parameters:
• Multi-floor, tight confined spaces, floor obstacles (e.g. I-beam)
• Washing would be path of least resistance for robotic application, versus testing (e.g. dft, soluble salts)
• Remotely operated blasting (priority), main advantage is that the operator is far away from the hazardous operation
• Surface preparation and painting, visual inspection (secondary), next step in the workflow is to remotely paint without having to erect scaffolding and perform a CSE
CFM Challenge #5: Open Call for Cleaning & Fabric Maintenance Robotics
The SPRINT Robotics Collaborative aims to accelerate the utilization and development of robotics for the inspection and maintenance of capital intensive infrastructure.
SPRINT Robotics has released two robotic application guidelines: “Guidelines for the Application of Robotics for In-service Inspection of Aboveground Storage Tanks” and “Guidelines for the Application of Robotics for the Offline Inspection of Pressure Vessels”, which are now both moving towards their second revision.
As of January 1, 2020, SPRINT Robotics has shifted the focus from inspection technologies to cleaning technologies, as there is significant synergy (i.e. one enables the other)
This open call is for any solutions that may not be applicable to any one asset, or could perhaps address them all.
