PROCESS VESSELS & REACTORS

The images and videos on this page are examples of data collected in pressure vessels and reactors using remote video systems. Maverick works with clients to determine the best access points for video inspection systems. Video scopes and pan/tilt/zoom robotics can be inserted through openings such as valve bodies, removed blind flanges, thermo-welds, drain accesses, and opened piping and man-ways. Often Maverick provides custom delivery systems in order to navigate the camera from the access to the inspection area.

Photo Gallery

$This image shows damaged bull-nose refractory at the cross over duct in a cyclone rector. A robotic pan & tilt camera was used for this application. The camera's ability to navigate and freely scan was vital to conducting an inspection of this area of the reactor.$

Reactor Refractory Damages

This image shows damaged bull-nose refractory at the cross over duct in a cyclone rector. A robotic pan & tilt camera was used for this application. The camera's ability to navigate and freely scan was vital to conducting an inspection of this area of the reactor.

Gas Separator Tower

This image was taken after chemical cleaning. It shows the shell-side and internals of a vertical pressure vessel. A CSA Rated Explosion Proof camera with zoom capabilities was used. Video Inspection is an excellent tool for determining the cleanliness and general condition of pressure vessels after cleaning.

Tower Packing Tray

The image was taken from the top man-way access of a vertical tower. Information was required regarding the general condition of the tower for a major turnaround. A PTZ camera was used to view the packing tray to determine whether cleaning was required.

Vane Packing Area

This image shows the vane packing area of the pressure vessel after chemical cleaning removed residual product. There is a slight deflection of the vane packing on the left side of the image.

Compressor Bottle Scaling

A small diameter video scope was used through a narrow opening to gain this view. Access was made available by the client so Maverick could inspect the shell side of this compressor bottle. This image shows light scale and sludge build-up that required consideration for cleaning during the next scheduled outage.

Glycol Dehy Tower Chimney

A video scope was inserted through the bottom glycol return of the tower to view the bottom bubble cap tray and chimney for fouling.

Heating Coils in Dehy Tower

The image shows the tower's bottom heating coils after steam cleaning. The client noted that flash rusting and some oxidization had developed after cleaning without inhibitors.

Gas Separator Shell

This image was taken looking upwards in a gas separator from the bottom 6" flange. The image shows the shell of the pressure vessel after cleaning removed heavy scale and sludge, however the demister pad appears to be still be fouled.

Vortex Breaker Area

The image shows the bottom head area of a vessel and vortex breaker after cleaning. The image also shows the bottom drain path clear without obstruction.

Reactor Catalyst Area

This image shows a perforated sheet with slot screens at the bottom of the reactor. Fouling is apparent, including plugged areas requiring additional cleaning and re-inspection.

Dehy Bubble Cap Tray

The dehy tower bubble cap tray appears to be in good general condition and clean after chemical cleaning.

Dehy Tower Down-comer Tray

This dehydration tower image was taken using a video scope and shows an area underneath a tray with a broken down-comer. It was later revealed that over-pressuring during start up had shifted the internals upwards.

$A large robotic camera was lowered down the reactor's cyclone to observe general conditions of the dip-leg refractory.$

Reactor Cyclone Dip-leg Area

A large robotic camera was lowered down the reactor's cyclone to observe general conditions of the dip-leg refractory.

Weld defect / Reactor Insert

An explosion-proof zoom camera with pan and tilt capabilities was used to capture this area of the gas insert near the plenum of the reactor. The welded section appears to have been torn due to excessive vibration.

Acid Gas Scrubber

This image shows a deflector plate that has given away, exposing the back side of the vessel's shell to impingement from the gas inlet. This has contributed to corrosion of one of the supports and wall.

Dehy Tower Chimney Tray

This is an image of the vertical chimney stack and cap with oxidized build-up. There is also the potential of under-scale corrosion developing. A small video scope captured this area of the tower.

Process Vessel Internal Coating

A explosion-proof camera was used to capture this area of a coated shell and internals. Internal coating defects are apparent, and as well as corresponding corrosion.

Damaged Vane Packing

This image shows a damaged vane packing inside a process vessel. Video inspections are commonly used to quickly verify suspected internal damage in plant equipment.

Horizontal Gas Separator

The image was taken after the vessel was drained of product and cleaned. Maverick frequently inspects internals of vessels using a wide range of RVI tools. Our crews are able to quickly and safely gather visual evidence of the general condition of equipment.

Foreign Object in Vessel

During video inspections, Maverick often retrieves foreign objects. This image shows a universal socket lying in the sludge on the bottom head of a pressure vessel. It is not unusual to note corrosion occurring where two disimilar metals are in contact, such as a foreign object touching the vessel shell.

Reactor Piping Debris Removal

This image shows removal of pieces of the reactor tray media and build-up with a vacuum. Maverick uses robotic crawlers to perform retrievals and guide cleaning companies.

Reactor Piping Tool Placement

In this image, Maverick assisted with the placement of a high-pressure cleaning tool to effectively remove hard build-up.

Fouled Reactor Catalyst Screen

This image shows a fouled reactor screen. It was taken using an explosion-proof crawler with a pan and tilt camera system.

Stripper Tower Column

This image was taken after cleaning. These deposits are in the draw box near a flanged opening. Maverick used a video system to direct a vacuum hose to remove the remaining deposits.

Vessel Nozzle Pluggage

An explosion-proof video camera was used to observe general conditions inside a process vessel. This image shows a nozzle near the bottom head. It appears to be mostly blocked by sludge and hard deposits.

Process Vessel Build-up

Video scopes are excellent for navigation in tight areas in a wide variety of process systems. This inspection showed the client that there was product build-up on the shell side of the vessel. They determined that cleaning was required.

Suction Scrubber / Shell

Video inspection is commonly used to determine the condition of internals such as trays, caps, vanes, etc. Maverick commonly verifies the effectiveness of chemical, mechanical, and other cleaning procedures.

Video Gallery

GLYCOL DEHYDRATION TOWER INSPECTION

This video shows the interior of a vertical vessel after it had been de-pressured and drained of glycol. This is an older bubble-cap tray design. The inspection showed light sand and sludge on the bottom tray, but no fouling was noted in and around the vents of the caps. The underside of the tray above appeared to be clear of fouling after steaming.

CUTTING TORCH STARTS PRESSURE VESSEL FIRE

A video camera was inserted into the vessel so a welder could use a torch to remove the supports and demister material. The torch ignited the vessel internals, so this approach was abandoned.

WELD DEFECTS ON REACTOR OUTLET

In this video, it is evident that the insert ring weld around the gas outlet is failing. It was determined that vibration during the reactor's regular operation likely caused the weld to break away.

PRESSURE VESSEL FOREIGN OBJECT RETRIEVAL

This video shows objects being removed from a 40 foot vertical vessel using a robotic claw. The retrieval tool was inserted from the top head access. Two of the objects removed from the bottom of the pressure vessel were a mini flash-light and a socket.

VACUUM CLEANING REACTOR PIPING

This video was taken of an industrial vacuum removing packing material from a reactor pipe. The live video was provided to direct the suction hose removing the material.

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