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Positive Infrared Results In the Refining Industry

Robert G. Bonin, Motiva Enterprises LLC.


Inspection Dept., Port Arthur Refinery

ABSTRACT
The key to positive infrared results, whether in the refining industry or in any other predictive maintenance
endeavor, is to keep the infrared thermal imaging camera running and to build interest in the benefits of
thermography with the right people. As long as the infrared thermal imaging camera is running, it can give us
useful information. Finding the right people to receive the infrared information is the key to the actual use of
the information, and to achieving cost savings and improved reliability.
As thermographers, our job includes finding influential individuals in our organizations who can benefit from
the use of infrared. Using infrared thermal imaging cameras to locate temperature differentials is new to a lot
of our operational personnel, and some of our fellow workers need to understand how the infrared tool can be
applied to help them. A positive and aggressive communications program continues to be the best way to get
our fellow workers involved in helping us justify existing infrared applications and to develop additional infrared
applications.
Some people are very skeptical about the reliability of infrared thermography and others that think it is smoke
and mirrors. Changing this attitude is a challengebut success will go a long way in boosting your infrared
program. When youre asked to take an infrared (IR) scan, take the time to ask what the expectations of the IR
scan are. After the scan is complete, explain what was done and the limitations of the infrared thermal imaging
camera, if any are found. Be very careful and present its usefulness in real terms. Do not promise helpful results
for every application unless you can deliver on every promise. For example, shooting thermal images on running
units can be difficult at best, due to all the reflective energy sources in a small area. Most reflectors can be
shielded and an accurate temperature produced if the area is critical and the costs are effective.
This paper describes typical uses for IR inspections and some new applications found through requests from
people on the job who wanted to try IR thermography to solve an ongoing problem.

Key words: applications, positive, cost savings, process stream, tanks, electrical, refinery, predictive
maintenance
CHECKLIST FOR POSITIVE ACTION
Take these basic steps to insure that the IR information that is captured can be reproduced and used in the
future and can help identify similar areas throughout the refinery where a similar IR process will apply.
1. Identify and list equipment and areas to be inspected. Alter the list as the program leads to areas that
need to be included or dropped.
2. Use appropriate IR procedures where and when they apply.
3. Collect base-line data.
4. Use base-line information you have collected and keep it updated for future trending needs.
5. Establish a frequency and routing schedule for each type of equipment to be scanned. Set intervals
by how critical the equipment is and the effectiveness of IR scanning. Change intervals as the faults
are evaluated.
6. Perform follow-up inspections and track cost savings.

InfraMation 2004 Proceedings

ITC 104 A 2004-07-27

INTRODUCTION
Sometimes thermal imaging information will solve problems for process personnel; at other times it helps your
reliability group. In some cases we are looking for temperatures that will prove our process is working. There
are also times when we can use thermography to prove something is not happening.

TANKS
A good example of this would be measuring tank sludge levels while a vendor is cleaning a tank. Figures 1, 2,
and 3 show the progress of the cleaning of a tank. Although the contractor initially reported that he had
removed about 95% of the sludge, we found that the IR images could more accurately measure his progress
and reveal how much sludge was actually removed. In this case, only about 60% of the sludge was removed.
116.4F

130.9F

146.9F
140

120

120

100

100
100

80

80

80

60

60

60.2F

Figure 1. Thermal image of tank


before sludge removal

47.6F

49.7F

Figure 2. During sludge removal

Figure 3. After sludge removal

Infrared (thermal) imaging is just one of the diagnostic tools we have available to help prevent or find the
cause of process problems. For example, what if you are using one product in a tank in your process and find,
through thermal imaging, that there is more than one product in the tank? How might your process be
affected?
The image of the storage tank in Figure 4 clearly shows three different temperatures, suggesting that more
than one productincluding an unknown materialis in the tank. What if the product in this tank is used to
neutralize the process stream? What could happen when the unknown product is introduced to the process?
A very real possibility is that the product stream will go off test! Now the real problem beginsfinding out
what caused the problem.
122.2F

162.8F

169.6F

160
140
120
100

80
60
40
38.1F

Figure 4. Thermal image of storage tank showing


two liquid levels

InfraMation 2004 Proceedings

27.9F

Figure 5. Thermal image of


process vessel showing two
product levels

90.2F

Figure 6. Thermal image of


process vessel showing one
product level

ITC 104 A 2004-07-27

Figures 5 and 6 are images of the same vessel showing different levels of product. Which level is correct? If
we are clever enough to understand what the infrared thermal imaging camera is telling us, we can preempt
problems and costs. We have found on the job that positive results lead people to start thinking of new ways
we thermographers can help make their jobs easier and more productive.

PROCESS STREAMS
An operator requested a scan of a 30-inch vapor line that was approximately 30 feet off the ground The lines
had back pressure, indicating a restriction or internal fouling. A scaffold was erected, and insulation was
removed to permit access for taking IR images of a section of each of the vapor lines. The effort was well
worth the cost. The IR images (Fig. 7) clearly showed that the lines were not as hot as they should have
been. This gave us additional information with which to pursue the solution to the problem. On the basis of the
thermal data, we expanded our work plan for the upcoming planned outage to include the cleaning of these
lines, which proved to be a very good decision. After opening the lines (Fig. 8) and finding that the IR images
were accurate, we proceeded with the plan to clean out the restrictions.
Having the ability to plan this work in a predictive or proactive manner, instead of having to do reactive work,
allowed us to do the work without adding to the duration of the outage. This equates to full unit throughput
and lower maintenance cost.
876.2F
800
SP01: 226.1F
SP04: 755.0F

600
400

SP02: 131.9F
SP03: 744.5F

200
0

-200

-325.6F

Figure 7. Thermal image of 30 vapor line

Figure 8. Internal visual photo of the 30 vapor line


showing serious blockage

An IR image can be worth a thousand words. It can also tell you that what you see with your eyes may not be
what you actually have. The thermal image in Figure 9 is of a process valve that was believed to be open.
Actually, the disk had fallen off the stem and closed the valve. As a result, the valve wheel can be turned in
either direction without having any effect on the temperature across the valve. Figure 10 shows a process
valve believed to be leaking, but actually closed. Without the use of thermography, finding this problem would
be very time-consuming and costly at best. In the petrochemical refinery there are thousands of valves that
have the potential to fail. IR is a critical tool that is used to solve problems and that allows for speedy repairs
to be made to the process system.

InfraMation 2004 Proceedings

ITC 104 A 2004-07-27

102.5F

118.2F

100

80

60

40
36.0F

66.8F

Figure 9. Process valve with dropped seat

Figure 10. Closed process valve (foreground)

MORE PROCESS
What could be faster than using these images to find flow restrictions? Seeing these types of thermal patterns
should alert the thermographer that there is a flow restriction of some kind. IR makes finding the problem easy
in most cases. The information in these images would take several days to confirm using older methods. Our
program welcomes operations to request IR scans to solve problems of this kind. However, keep in mind that
not all temperature differentials are this clear. These exchangers are on the edge of units and have minimal
added reflective energy sources to mask the image.
194.5F

150

100

138.6F

100

50

50

0.9F

Figure 11. Tube side fouling indicated by higher heat


differential in outlets at top (far left and 4th from left)

-24.3F

Figure 12. Shell side fouling. The most fouled is on


far right (hottest).

ELECTRICAL
The images below are good examples of what the infrared thermal imaging camera can detect during a typical
daily survey. Figures 13 and 14 are thermal images of a power distribution pole taken from about 200 yards away.
Several warm spots were seen that alerted us to investigate further. The visual photo in Figure 15 shows that
the pole is actually on fire. This fault was on a major distribution line, and the failure of the pole could have
caused major electrical problems and possible unit upsets and outages. Finding this fault was indeed lucky,
but without an IR program, it is a sure thing that we would have had a serious problem involving costly repairs
and unit outages. Getting the information to the right person in a timely manner prevented potential unit upsets.
The highline was promptly switched out of service, and the fault was corrected. The only cost was replacing
the pole.

InfraMation 2004 Proceedings

ITC 104 A 2004-07-27

89.6F

97.1F

90

80

70

69.5F

Figure 13. Thermal image of a


wood power distribution pole
taken from the south

62.8F

Figure 14. Thermal image of the


same pole taken from the north

Figure 15. Visual image taken


from the North showing flame on
burning pole

SUMMARY
Our IR program has had positive results getting off the ground due to the efforts of many people. Our
management saw the potential and allowed it to expand as new applications were found. Our company is
very proactive in finding innovative, safe, and cost-effective ways of solving old problems with new methods
and equipment. Thermography has proven to be an extremely effective tool in the never-ending search for
better predictive planning.
Our investment in infrared equipment and in training has been very cost beneficial. Our infrared inspection
program is now part of the day-to-day procedure in our refinery. Meanwhile, we continue to investigate new
ideas. Our experience so far strongly suggests that it may be harder to find areas where you cant use IR than
it is to develop new applications. Indeed, new IR applications keep coming in. As long as we can generate
useful information with the infrared thermal imaging camera and communicate that information promptly to the
proper personnel, our infrared inspection program will continue to be an asset.

ACKNOWLEDGEMENTS
We wish to acknowledge A. J. LeClercq of Emerson-Electric Reliability Services, John Coleman of Infrared
Scanning Services, Inc, and Al Ohliger of Chevron Texaco Inc. for the directions and guidance to help make
our program a positive one.

InfraMation 2004 Proceedings

ITC 104 A 2004-07-27

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