Automated Coke Drum Cleaning and Crawler Inspection for Cone-Skirt Cracks
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Solution Overview
Problem
Current methods for inspecting and cleaning coke drums are intrusive, expensive, time-consuming, and ineffective in detecting and characterizing internal and external cracks, particularly in the cone-skirt junction, and lack automated non-intrusive volumetric inspection capabilities.
Innovation Solution
An automated system using an inspection crawler equipped with ultrasonic and visual testing devices, operated remotely, that can detect and characterize cracks in the cylindrical, conical, and cone-skirt sections of coke drums, along with a cleaning mechanism that prepares the surface for inspection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual inspection methods are used, then inspection can be performed, but it requires intrusive methods, scaffolding, and thermal insulation removal which increases time and complexity
Solution Approach 1:
The patent replaces manual mechanical inspection methods with an automated robotic crawler system equipped with ultrasonic testing devices. The robotic system performs non-intrusive volumetric inspection through the coke drum interior without requiring scaffolding or thermal insulation removal, significantly reducing inspection time while maintaining reliability through automated ultrasonic detection capabilities
Solution Approach 2:
The robotic crawler system is self-contained and autonomous, capable of navigating the coke drum interior and performing inspections independently without human presence. The system carries its own power supply, cleaning mechanisms, and testing equipment, enabling self-service operation that eliminates the need for external scaffolding and reduces inspection time
2Productivity
If automated inspection systems are implemented, then inspection efficiency improves, but detection capability for cracks in cone-skirt junction remains insufficient
Solution Approach 1:
The robotic crawler system employs locally adapted inspection strategies with multiple ultrasonic testing configurations tailored to specific zones. The system uses different probe orientations and scanning patterns for the cone-skirt junction area compared to cylindrical sections, enabling enhanced crack detection capability in the challenging cone-skirt region while maintaining overall inspection efficiency
Solution Approach 2:
The patent introduces multi-dimensional ultrasonic testing approaches including phased array ultrasonic testing with adjustable beam angles and multiple probe configurations. This dimensional expansion of inspection capabilities allows comprehensive detection of cracks in the cone-skirt junction from multiple angles, overcoming the limitations of traditional single-angle inspection methods
3Measurement precision
If cleaning is performed to prepare surfaces for inspection, then inspection accuracy improves, but cleaning effectiveness for embedded cracks remains insufficient
Solution Approach 1:
The robotic crawler system performs preliminary cleaning actions automatically during the inspection process. Equipped with integrated cleaning mechanisms, the system cleans the interior surface and areas of interest before ultrasonic testing, ensuring optimal surface conditions for detection. This preliminary cleaning action eliminates the need for separate manual cleaning operations and ensures consistent inspection accuracy
Solution Approach 2:
The patent replaces manual cleaning methods with automated robotic cleaning mechanisms that can access and clean difficult-to-reach areas including the cone-skirt junction. The robotic system uses controlled mechanical cleaning actions to remove coatings, rust, and other contaminants that would interfere with ultrasonic detection of embedded cracks, significantly improving measurement precision
4Ease of operation
If intrusive inspection methods are used, then access to interior surfaces is achieved, but safety risks and operational downtime increase
Solution Approach 1:
The robotic crawler system is designed as a self-contained autonomous unit that enters the coke drum interior through existing access points without requiring scaffolding or thermal insulation removal. The system carries its own power supply, cleaning mechanisms, and testing equipment, enabling self-service operation that eliminates human presence inside the drum while maintaining ease of access to all interior surfaces
Solution Approach 2:
The robotic crawler acts as an intermediary between inspectors and the coke drum interior. Instead of inspectors directly entering the hazardous environment, the autonomous robot serves as a mediator that performs all inspection and cleaning functions remotely, significantly improving safety while maintaining operational ease through automated navigation and control
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient, non-intrusive inspection and cleaning of coke drums, detecting and characterizing cracks regardless of thickness, reducing operational downtime and ensuring reliable fitness for service.
Implementation Method 1
ultrasonic testing (UT) capable of detecting and characterizing internal and external cracks
Implementation Method 2
cleaning by impact or abrasion
Implementation Method 3
cleaning by impact or abrasion
Data Source
AI summary
An integral system for automated and non-intrusive of cleaning and non-destructive inspection (ultrasonic volumetric testing and visual testing) to detect, characterize and monitor with precision the level of internal and external damage (Cracks, deformations, corrosion, erosion, etc.) that may be present in coke drums throughout their life cycle is disclosed. Embodiments are disclosed that enable a condition of a coke drum to be estimated in a reliable manner for their fitness for service from the results obtained from the automated inspection with the non-destructive methods of ultrasound, visual testing and/or liquid Penetrant Testing.