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Using Robotic Inspection for Flare System to Avoid Plant Shutdown

From day to day, Robots advance from testing in labs to operating in the outside world. The
industrial application of Robotic technologies continually increases, providing unique solutions for
different challenges. Flare System is an important and critical equipment required for continuous
safe operations for any petrochemical plant addressing proper burning of excess hydrocarbon
gases, unusable gases which cannot be recovered or recycled, and gas flaring protects against
the dangers of over-pressure. This paper discusses the different types of robotic inspection,
advantages, and limitations based on actual site demonstrations. As an innovative case, here to
introduce actual business case for close aerial inspection and surveying technique to avoid
polyethylene plant shutdown and providing a reliable inspection technique for on-stream integrity
evaluation for the flare tip. Drones, formally known as unmanned aerial vehicles (UAVs), are a
flying robot that can be remotely controlled, and offer an innovative inspection method launched
between 2006-2008 for Engineering professional aerial inspection and surveying using Remotely
Operated Aerial Vehicles (ROAVs). The visual inspection detection accuracy of (ROAV) offer
higher than the normal visual inspection and easily approach all the flare structure from four
directions. Drone inspection cost is competitive considering the cost of maintenance to dismantle
the flare tip. Drone inspection can be used to assess the elevated flare parts for any seriously
damage in order to define a clear maintenance scope ahead of shutdown.

Product Number: MPWT19-14300
Author: Amro Hassanein
Publication Date: 2019
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Integrity Maintaining and Cost Saving Advanced CUI Detection Technique (PEC)

Product Number: MPWT19-14242
Author: Amro Hassanein, Ahmed Elsharkawi
Publication Date: 2019
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Corrosion under insulation (CUI) is a major problem for petroleum and petrochemical process industries that affects the plant mechanical integrity and attacks assets. CUI can result in sudden and hazardous leaks (safety concern), and plant shutdowns with high losses of production (economical concern).
Traditional detecting methods of CUI to cut a window in thermal insulation used to inspect visually, to measure the thickness, and then return thermal insulation back, giving high chance for water and moisture ingress, accelerating CUI, moreover big amount of scaffolding erection along with thermal insulation removal required.
SHARQ (Eastern Petrochemical Company, one of SABIC companies) is pioneer to study CUI, evaluating many Non–Destructive techniques has proven Pulsed Eddy Current (PEC) as the most effective technique in terms of integrity and cost optimization.
Considering all available techniques, all aspects studied, such as range of applications, features, and limitations, it is concluded and verified to meet our inspection plan strategy needs.
PEC does not require thermal insulation removal; optimize scaffolding erection, has a wide range of applications related to thickness, and temperature. PEC approved by international codes and standards (API) to meet RBI Meridium software requirements.
The validation study results show cost savings of more than 50% compared to traditional thickness measurement methodology, moreover it reduces EHSS (Environment, Health, Safety, and Security) negative impact reduces the probability of safety incidents due to reducing labor, man-hours, and eliminating many associated activities with potential hazard and risk.
PEC has high productivity, easily operated, and provides comprehensive and professional inspection report

Picture for Avoid Potential Repeated Failure (Cracked Gas Compressor line) Through Proper Material Assessment
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Avoid Potential Repeated Failure (Cracked Gas Compressor line) Through Proper Material Assessment

Product Number: MPWT19-14239
Author: Ahmed Elsharkawi, Amro Hassanein
Publication Date: 2019
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The heat treatment condition of industrial materials is a critical parameter for material evaluation and its fitness for intended service. Proper heat treatment will produce desired mechanical and physical properties, while absence or improper heat treatment may lead to major failure with huge production, Environmental, Health, and Safety (EHS) impacts. We hereby explain an actual case for cracked gas compressor (CGC) 5th stage discharge line caustic stress corrosion cracking (SCC) that caused unplanned plant shut down and resulted in noticed financial and production loss.
The proven root cause is absence of normalization. Emergency piping batch is received and supposed to be normalized to avoid failure recurrence. Many discrepancies extracted from submitted material certificates, also many physical signs observed on the material itself raising doubts about received material compatibility. Using advanced Positive Material Identification (PMI) device to verify the chemical composition of the received material, results show that the material is questionable.
As a precise test to verify heat treatment condition, microstructure analysis test (metallography) conducted to confirm normalization condition of the material, the resulted grain structure size and growth confirm that one of the received pipes has improper or absence of normalization.
The material rejected as it is proven and confirmed that it is not normalized as per the requirements to avoid further potential of hydrocarbon leakage due to improper material specification. Rejecting the material eliminate the potential of having repeated failure, in addition to 600,000 Saudi Riyal (SR) cost saving as material cost. A common recommendation shared with concerned parties to consider metallography as a mandatory test to be submitted with heat-treated material test certificate (MTC).
Key words: Heat treatment, microstructure, normalization, grain structure, failure, metallography