In the petrochemical industry, the structural integrity of operational equipment is critical for ensuring safety, improving operational efficiency, and meeting regulatory standards. However, traditional methods of carrying out 3D measurements to inspect corrosion and assessing vessel integrity can be cumbersome and time-consuming at best.
This case study examines how a Spanish refinery that was introduced to our scanning technology used the HandySCAN SILVER™|Elite, coupled with VXintegrity software, to help the refinery maintenance department decide to employ contemporary metrology-grade non-destructive testing (NDT) solutions to address inspection challenges.
Challenges: Outdated Measurements Compromise Inspection Accuracy
In order to guarantee that all equipment is operating dependably and safely, the oil and gas sector mostly depends on inspection for quality assurance. The ASME and API rules mandate regular inspections of oil platforms, refineries, and oil and gas pipelines for corrosion, erosion, or any other flaws that could result in hazardous circumstances, crucial failures, or even worse as catastrophic incidents. However, all equipment faces significant challenges in maintaining the integrity of their vessels and pipelines. The primary issues include navigating complex and often harsh environments to perform assessments.
Additionally, a lot of refineries still perform inspections using antiquated techniques like visual inspections, calipers, gauges, and rulers. Regrettably, those instruments lack the precision required to record extremely accurate measurements of corrosion depths and other material degradation brought on by damage mechanisms.
These instruments’ user-dependent outcomes significantly compound the ongoing labor scarcity of qualified inspectors that exists today. When the company compels less experienced workers to take on these responsibilities, there is a greater chance of oversight and possible safety risks, which can result in inconsistent and occasionally erroneous outcomes. This circumstance emphasizes the necessity for refineries to use more advanced and objective NDT systems that can provide accurate and trustworthy data regardless of the operator’s degree of experience. One major refinery in Spain decided it was time to upgrade its inspection equipment. As the team began their search, they knew they wanted to base their decision on the following criteria: portability, accuracy and ease of use.
Solution and Result: Effectiveness of 3D Scanning and Cost-Efficiency
The refinery chose the HandySCAN SILVER™|Elite which is renowned for its portability, performance, and simplicity—regardless of where it is used. The team linked the HandySCAN SILVER™|Elite with VXintegrity software in order to evaluate the data gathered and provide precise corrosion maps and depth measurements.
Moreover, the 3D scanner’s capability to deliver highly accurate and high-resolution data rapidly impressed the refinery team, eliminating the need for complex measurement setups or a senior inspector. The remarkable level of reliability and repeatability of the 3D scanning results were instrumental in evaluating each vessel’s state of health and enabling more thorough reporting.
Furthermore, the detailed corrosion assessments enabled the inspection team to make informed decisions regarding each vessel’s condition. Importantly, the team determined that no immediate repair or replacement was necessary, allowing for the refinery’s continued operation and monitoring. This decision, based on accurate and verifiable 3D measurement data provided significant cost savings by avoiding unnecessary maintenance or downtimes.
A refinery user noted that the usage of this technology has resulted in notable improvements in safety and maintenance scheduling.
“Our maintenance operations have been transformed by our ability to accurately and quickly assess the integrity of our vessels,” they said.
The deployment of 3D scanning technology and integrated software at the refinery has led to benefits in terms of operational efficiency, maintenance effectiveness, and reduced expenses.
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