(33e) Enhancing Ethylene Cracker Radiant Tube Integrity through Innovative Robotic Inspection

The integrity of ethylene cracker radiant tubes is a critical concern, as they are vulnerable to unexpected failures causing from various factors, including carburization, overheating, thermal shock, and more. These failures are often complex and can occur at diverse locations within the tubes. Traditional inspection methods, such as visual inspections, radiographic testing (RT), and portable carburization measurement devices, have demonstrated limited effectiveness. Consequently, tube failures trigger unscheduled shutdowns, causing substantial economic losses for petrochemical companies

In response to this challenge, we have developed a robotic inspection system, integrating cutting-edge technologies. This system makes proactive inspections not just a possibility but a reality. Field demonstrations have confirmed its proficiency in detecting defects along the entire length of radiant tubes, effectively identifying issues like bulging, carburization, and cracks.

A recent inspection of a two-year-serviced cracker unit has yielded unprecedented results. We acquired comprehensive data on circumferential strain in the entire length of the tubes and established a clear correlation between bulging and carburization. Notably, our findings indicate that carburization is not solely influenced by the temperature field generated by burners but also by feedstock turbulence within the tube, in this case, associated with welding joints. The carburization map obtained for each tube serves as a valuable guideline for the recoil process, particularly given the material's reduced ductility when carburization occurs.

This novel inspection system not only enhances equipment management and maintenance efficiency but also bolsters the sustainability and safety of industrial production. Our application marks a pivotal shift toward a more intelligent, precise, and effective approach to ethylene plant management. This includes risk reduction, optimization of process parameters, accurate tube replacement, and significant economic benefits, ultimately boosting overall competitiveness in the industry.