This article is intended for professionals who want to know about benefits of using drones in tank inspection. Moreover, how the actual procedure is carried out is also discussed along with case studies.
Introduction
Drone use in the different industries especially for internal tank inspection has become very popular in this era. Considering in oil/gas sector as an example, the petroleum companies are increasingly deploying drones due to their tactical and economical justifications.
This article focuses on the advantages of using drones in tank inspection – a mandatory hectic and costly task in oil and gas industry. But first lets look at the procedure of using drones for Internal tank inspection.
Procedure for Internal Oil/Gas Tank Inspection using Drones
Equipment Required
Drones equipped with high resolution cameras and sensors
For the inspection of the tank, the first and most important tool is a drone. There are many types of drones available in the market with a wide range of their features. The selection of drones is done according to the objective of inspection.
Visual information is one of the most crucial sorts that inspectors must gather for the inspection of tanks in any oil and gas field using drones.
Cameras are the standard inspection tool for gathering visual data, however not all cameras would be helpful for a particular check.
The data need should be the main consideration when selecting an inspection instrument to gather visual data. The camera of the drone you’re mulling about is the main resource of the inspection if it can gather the data you require at a level of quality you can utilize to carry out your inspection.
Proprietary software
How to manage large amounts of data and make it useful information is a rising issue for inspectors.
Because of this, software development has seen many of the most exciting approaches in the inspection sector. Improvements in data-collecting software and advancements in data management stand up as particularly important applications.
Software for Efficient Data Collection
Computer programmers are becoming more aware of how to give a more simplified experience as an inspector to use remote tools, and their demands are becoming more obvious. One such example is the exclusive 3D modeling software included in the Flyability Inspection 3.0 programme. The programme quickly builds a 3D model of the item during the inspection and pinpoints the location of any faults as inspectors fly across the asset.
Software for Data Management
The more excellent information is obtainable using modern software packages than can reasonably be handled manually. AI and Machine learning is being used more often by inspectors to digest data efficiently and render it immediately useful.
Tank inspection software providers are already setting the standard with their products that enable users to submit visual data that is subsequently automatically sorted to identify any flaws.
Every item of software designed to increase the efficiency and effectiveness of inspections leads to safer results for all parties, whether they are innovation or modification.
Pre-Flight Checklist
For a drone inspection to be effective and safe, a pre-flight checklist is a need. A fundamental pre-flight checklist like the one below should be used before every flight:
- Ensure that the internal condition of the tank is suitable for inspection.
- Check that the drone’s batteries are fully charged and securely connected to the drone.
- Examine the drone for any damage, such as cracks or loose parts. Check that all propellers are securely attached and installed
- Confirm that the controller is fully charged and functioning properly. Check that the controls are responsive and that the drone is communicating properly with the controller.
- Ensure that all sensors on the drone are functioning properly. Test the GPS, altitude sensors, and other sensors.
- Make sure that the camera is functioning properly and that the lens is clean and free of any debris.
- Review the inspection plan and ensure that it is suitable for the location and purpose of the flight.
Actual Inspection Process
The inspection system of the tank includes the following stages:
UAV Scanning:
The first stage involves the deployment of Drones/UAVs (Unmanned Aerial Vehicles) equipped with high-resolution cameras to scan the inside of the oil tank. The UAVs capture images of the tank walls, floor, and ceiling.
Image Processing:
In the second stage, the captured images are preprocessed, including image correction and filtering, to remove any noise and enhance image quality. Image segmentation is then performed to extract the features of interest, such as corrosion, cracks, and other defects.
Application of Artificial Intelligence:
The third stage involves the application of Artificial Intelligence (AI) algorithms to the extracted features. The AI algorithms can classify and analyze the features, and detect any anomalies or defects in the tank.
Thresholding Process:
The final stage involves applying a thresholding process to the analyzed features to determine their severity. Based on the severity of the detected defects, the system generates a report that can be used by maintenance personnel to plan and prioritize maintenance tasks.
Case Studies
Rope accessibility and drone technology were used in an innovative way for internal coke tank inspection, saving a quarter million dollars. Using an inventive mix of rope accessibility and drones, “Premium Inspection & Testing” successfully performed an inside coke tank inspection at a refinery while saving $250,000 on manpower and scaffolding. It was the first instance where drones and rope accessibility were used effectively for a coke tank check.
Client Needs
A Texas refinery was looking for independent inspectors who could handle an increased coke tank inspection that was planned.
And though, the refinery used to have a stipulation that made it difficult for them to locate someone: they refused to utilize scaffolding. The refinery had a clear justification. Scaffolding is more expensive than both materials and labor, and the time required for its assembly and disassembly can add significant costs to the downtime of an asset.
The company demanded various contractors whether they’d be able to investigate the interior of the container using rope access rather than scaffolding, but none had prior experience with such an inspection technique. Several agreed to try rope access, but the refinery didn’t want anyone attempting a novel inspection technique as the turnaround timer was running out.
When refinery management learned about” Premium Inspection & Testing”, they were on the point of giving up and resorting to scaffolding. Premium swiftly agreed to complete the task without the use of constructing scaffolding due to the decade’s work expertise executing inspections through rope accessibility, having logged a total of 1.2 million safety hours at ropes without any accidents.
Solution
Premium was capable of completing the tanker inspection of the refinery with no need for scaffolding. The cutting-edge mix of drone technology and rope accessibility was used.
The procedure that Premium followed for the coke tank inspection is as follows
Step 1: With Drone pre-assessment of the tank
Prior to the rope accessibility crew having entered the tanker, Premium developed a drone to ensure the coke container was clean.
The drone also gathered visual data throughout these trips, which was then analysed by automatic crack detection techniques. While inside the coke tank, the rope accessibility crew used that visual information to assist them to concentrate their efforts.
Step 2: Setting up a rope accessibility system.
The ropes team rigged a beam system just above the mouth of the tank and a girder support system within the face of the container to get it ready for inspection when it was established that the container was safe and clean for access.
Inspectors utilised the girder to hang ropes from the outside middle of the coke drum so they could access its walls. The ropes were fastened to the beams and girder.
Step 3: Rope accessibility examination using several sensors.
The rope staff’s initial assessment focused on any flaws found in the drone’s important visual data collection.
Inspectors conducted a variety of tests to examine the interior of the container in all of these places, in the following order:
To start, inspectors utilized creaform scanning technology to assess how much surface rust and pitting there was.
Secondly, a phase array test was employed by inspectors to evaluate the quality of the weld joints.
Finally, inspectors used liquid PT to check the shell and joints for faults.
Premium inspectors sent genuine updates to the maintenance staff of the refinery while they collected data using a drone and subsequently rope accessibility.
Afterward, individuals of the maintenance staff reacted, directing the inspectors where they should concentrate their efforts to find out further about the faults and what steps could be required to repair them.
Results
The refinery finally ended up saving $250,000 because of Premium’s mixed drone/rope accessibility strategy for the tank inspection.
Just by reducing the labor and materials needed for scaffolding, these reductions were achieved.
The time required for the inspections was reduced from thirty days to just seven days, which allowed the refinery to save even more money by reducing the amount of time the tanker was out of commission. This was another advantage of using a drone and rope accessibility for the coke tank inspection.
The hybrid technique was used for the first occasion ever for a coke tank inspection, however given the remarkable outcomes, it won’t be the last.
Exploring the Role of Drones in Tank Inspection
Conventionally the inspection of tanks was a time-consuming and expensive process. Drones have modernized the procedure. Tanks, silos pipes, and other storage devices can be thoroughly inspected both internally and externally in a small period and expense, with the least amount of asset downtime. Engineers use drones to customize inspection so that the results are absolutely what you want.
Remote Surveillance
You can view an inside tank’s digital twin from a safe and secure workplace. So thanks to the drone 3D modeling technology. This exact reproduction may be examined in minute detail, providing you to note any parts that require repair. You may instantly share information with your staff, vendors, and other stakeholders. If there are any problems, such as inadequately performed repairs, overall corrosion, or any other potential weaknesses, they can be fixed accurately.
Trace Irregularities
Drones using thermal imaging cameras can be utilized to spot any issues with a tank’s condition while doing an inside check. The high-temperature fluctuations that might be an indication of problems like hidden heat leakage and moisture damage can be seen in the thermal photos that the cameras have collected. By utilizing this technology, inspectors may find hidden issues that may go undetected during visual inspections alone and take the necessary action to guarantee the tank is dependable and safe for use.
Accurate Measurements
We can properly reflect a geographic region by using ortho mosaic technology and drone photos. Offering you a precise picture of the surface in a bird’s eye that is perfectly clear and has been rectified for geometrical distortions. An ortho-mosaic map is a cutting-edge measurement tool for precise scale and distance readings.
Reach Inaccessible Locations
Drones using impact-resistant technology can offer a safe and effective means to access difficult-to-reach locations during an inside examination of a tank. Constrained spaces or other risky places that would be challenging or dangerous to enter using conventional techniques may be among these locales.
Benefits of Using Drones for Internal Oil/Gas Tank Inspection
There are several benefits of drones in the inspection of tanks. These are given below.
Improved Safety
Elimination of human risks
Security teams may thoroughly examine all areas inside a tank by deploying a drone to do a tank inspection without having to go inside. By doing this, it is no longer necessary to drain, flush, and air this storage tank before people may enter securely.
Drone may be immediately deployed to take pictures and videos, giving asset inspectors access to every interior location safely. This involves pipe fitting, welding, rafters, wall and roof joints, and integration of fabric without requiring people to waste hours in a very dangerous environment.
Proactive Planning
It is possible to conduct inspections much more often because of the drastically cost reduction of drone inspections and the speed at which monitoring can be supplied. This makes it possible to proactively evaluate assets for flaws that could lead to future problems. This not only saves money but also lessens the chance of emergency situations.
Ease of Use
Depending on the kind of drone utilized, the operator does not always need to hold a professional license to fly. UAVs like The Elios are housed in a decoupling cage that enables collision absorption and lets them to bouncing and roll over surfaces. Asset inspectors may readily deploy them and complete all areas of the monitoring with no training because they are simple to operate.
Cost Savings
In comparison to conventional inspection techniques, drones have significant economic benefits. The cost savings associated with Health, Safety, and Environment (HSE) preparedness and measure are one important benefit. As the case study discussed above shows that refinery finally ended up saving $250,000 because of Premium’s mixed drone/rope accessibility strategy to the tank inspection.
Many other companies like Shell believes that just 2% of the overall expenditures connected with tank inspections are due to the actual inspection procedure itself, with the remaining 98% related to HSE and preparation.
Reduction in manpower requirements
Drone inspections may be finished considerably more rapidly than conventional tank inspection techniques, which might take several days to deploy. In fact, depending on the dimensions of the tank and the intensity of the inspection, drone-based tank inspections can be finished in as little as two hours.
Elimination of the need for scaffolding
The ability to conduct tank inspections without the use of scaffolding, cherry-pickers, or ropes is one of the major benefits of adopting drone technology. These procedures frequently cost a lot of money, take a long time to set up, and need a lot of labor to run securely. Drone technology allows inspections to be performed without the need for scaffolding, which can be especially difficult for tanks placed in difficult-to-reach areas or in restricted locations. Drones may soar up to the tank and gather data and photographs in high definition from various perspectives, producing an in-depth and thorough inspection report.
Drone technology often works more quickly and efficiently than conventional techniques, saving businesses both time and money. Drone inspections may be completed swiftly and effectively, eliminating downtime and expenses, as opposed to erecting and removing scaffolding or other equipment.
Challenges and Limitations
The drone sector is expanding more quickly. Unmanned aircraft systems are now often employed by citizens and government organizations for anything from detecting active fires and real-time activities to transmitting messages via light displays. Nonetheless, the growing demand for drones will place enormous stress on companies to fulfill customer needs and drone designs regulations and on governmental bodies to handle the procedures for licenses as well as restrictions that all nations needed for the use of drones. Limitations on flying outside the eye’s reach, flying above 400 feet, insufficient battery life, neighborhood privacy issues, and not flying in restricted areas, particularly close to airports, are obstacles to extending the use of drones for community safety applications.
Conclusion
In conclusion, the use of drones for internal tank inspections provides a technological novelty that improves safety, decreases costs, and boosts efficiency in the maintenance of industrial tanks. Using this technology allows companies to plan and head off problems before they arise, eventually saving time and money while assuring the security of both their employees and the environment. Every firm that deals with the storage of materials in tanks will find the advantages of drone inspections to be a worthwhile investment.
References
- API Standard 620, Design and Construction of Large, Welded, Low-pressure Storage Tanks
- API Standard 650, Welded Tanks for Oil Storage
- https://www.engineerswithdrones.ie/assets-and-industries/tanks-silos-vessels.php
- https://nexxis.com.au/tank-inspections-using-a-drone/#:~:text=Advantage%3A%20Safety,before%20humans%20can%20safely%20enter.
- https://www.conocophillips.com/spiritnow/story/polar-tankers-drone-inspections-reduce-risk-save-time-and-improve-safety/
- https://www.hsmemagazine.com/article/drone-inspection/
- https://www.globaldata.com/store/report/drones-theme-analysis
- https://www.pitinc.com/coke-drum-case-study
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