How to Ensure Your Piping Doesn’t Take Down Your Operation.
Refineries and chemical plants are increasingly complicated operations thanks to cleaner manufacturing process regulations, demand for higher performance products and a greater variety of feedstocks, including lower grade crude, tar sands, etc. These factors, combined with aging infrastructure, can increase plant inspection and maintenance demands to avoid degradation and clogging which impact safety, production and the local environment
What happens when process sewers are not properly purged of debris or deposits, such as wax, sand, or iron sulfide? Obviously, flow capacity could be significantly reduced, with a subsequent increase in pumping costs. But there are several other issues, such as waste and drainage pipes, that can significantly impact operations, increase turnaround time and costs, and create potential safety hazards.
For example, an obstructed oily water or firewater collection system could pose a serious hazard in the event of fire or other incident should firewater back up and pool around tanks, pipe racks, and process equipment instead of flow away to catch basins or other impounding mechanisms. As this water is likely full of flammable material, it poses an ignition threat.
What happens when below ground structural issues go unidentified?
Underground structural problems lead to both ingress of external water and egress of liquids and gases leading to hydrocarbons, other gases and liquids leaking not only into the ground, but also into operating units. Ground ingress is a major cause of sink holes in plants as well. Water ingress also taxes plant water treatment and can cause treatment overflow during rains when the ground water table rises.
Contractors clean pipes during regular turnaround maintenance periods or outages. However, few plant operators independently verify the jobs being performed. Most rely on the knowledge and experience of the cleaner to determine whether pipe flows are back to specifications, but is this sufficient?
How clean is clean?
There is no holy grail cleaning method that can detect and handle every possible pipe fouling mechanism. It can take various methods working in concert to evaluate and address all logical problem spots including elbows, joints, and other points of flow restriction.
Elevated pipe racks can be hard to reach, making visual inspection difficult. Likewise, pipes buried below grade require inspection to ensure no loss of containment, but this is not what cleaning contractors specialize in. Another set of eyes is needed to confirm that not only have pipes been cleaned, but that there are no other issues that could lead to loss of containment
Two factors can contribute to making sure that the time and cleaning dollars you are spending are actually doing what you expect from your investment:
1. Your comprehensive inspection and predictive maintenance plans.
2. Independent verification of maintenance/cleaning performance.
Number one is handled by proper engineering analysis and inspection planning which takes into account design information, historical bad actors, process chemistry, and consequence of pipe failure.
A solution for number two is to deploy high resolution video imagery (RVI) to observe the internal condition of process pipes, oily water sewers, acid sewers, storm drain pipes, etc. after cleaning processes are complete. This imagery allows for the asset owner to understand the probability of failure of each section. Combining that with the above consequence allows for clear, prioritized remediation action that could include additional cleaning, another method of cleaning, or repair using conventional or modern trenchless technologies.
With the ability to access pipe from to 1/5” to 120” and utilize hazardous environment-rated equipment as needed, RVI solutions like ours provide operators with an inside view to provide peace of mind by ensuring pipes are fully functional and lurking problems have been identified, prioritized and mitigated.
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