The use of optical gas imaging (OGI) cameras has benefited the oil
and gas industry greatly by improving worker safety and plant efficiency while
reducing emissions; however, the technology has yet to gain a similar foothold
in the petrochemical industry, despite offering similar advantages. Comfort
with existing gas-detection methods and a lack of familiarity with the full
capabilities of OGI cameras often act as barriers to implementation. However,
with commercial hydrofluorocarbon (HFC) gas emissions now under increased
scrutiny by governments and regulators around the globe, there is increased impetus
for HFC producers and industrial HFC users to deploy new and emerging
technologies to ensure the mechanical integrity of their processes and
equipment.
Many well-prepared companies already have environmental, social
and governance (ESG) programs driving sustainability, including initiatives
tied to emissions reduction. Still, the continued use of ambient air monitoring
utilizing Fourier transform infrared (FTIR) spectroscopy, supplemented by
handheld leak detectors, is only a partial solution to the need for more
comprehensive industrial monitoring, especially as regulators begin to employ
state-of-the-art instrumentation.
This incumbent system of leak detection has several constraints
that must be understood by industrial practitioners. On-demand point leak
detection generally takes place either during routine maintenance or when a
FTIR ambient monitor alarm is triggered by a possible gas leak. A production
operator with appropriate personal protective equipment (PPE) must then be
positioned close to the leak source to confirm its existence by using a
handheld refrigerant leak detector (referred to as a toxic vapor analyzer,
organic vapor analyzer, or “sniffer”).
A handheld vapor analyzer may be unable to accurately
identify the leaking component—this is key when repairing or understanding the
challenges associated with a leak (FIG. 1). The emissions source may also be in a
difficult-to-access location, making leak confirmation with a handheld detector
difficult or even impossible.
OGI cameras can detect leaks from a safe distance and can identify
leaks in locations or volumes that otherwise would not be discovered. These
cameras supply visible confirmation of emissions—whereas, a vapor analyzer’s readings
can vary from one minute to the next, depending on environmental conditions,
even when sampling in the exact same location. Meeting the industry’s demand
for more precise and safer refrigerant leak detection, the co-author’s company
offers OGI cameras that satisfy a range of use scenarios, from pinpointing
difficult-to-find leaks to identifying different gases with a single device.
The co-author’s company’s proprietary OGI cameraa
is the industry’s only cooled OGI camera filtered specifically to detect
fluorocarbons. In addition to visualizing refrigerant leaks precisely from a
distance, this proprietary OGI cameraa can accurately measure
temperatures, allowing users to note temperature differentials and improve
visual contrast for better gas plume detection (FIG. 2A).
Another proprietary OGI camerab detects hydrocarbon and
volatile organic compound (VOC) emissions from natural gas production and use.
With this OGI camera, inspectors can check thousands of components and see
potential gas leaks in real time. This camera is lightweight, offers both a
viewfinder and LCD monitor, and has direct access to controls. Embedded GPS
data helps in identifying the precise location of faults and leaks for faster
repairs.
A third proprietary OGI camerac is an
uncooled OGI camera with interchangeable lens options capable of detecting
fluorocarbons, methane, sulfur hexafluoride and other gas emissions. While not
as precise as the HFC-focused proprietary OGI cameraa, this
technology offers lower-cost utility to users hunting different types of gas
leaks (FIG. 2B).
Case
study: Petrochemical company adopts OGI technology for detection. Chemours—a
global manufacturer of advanced materials for critical applications—was introduced
to OGI technology by a European third party that provides on-demand site
surveys using the technology. In 2019, Chemours adopted OGI as a component of
its mechanical integrity and reliability programs, and purchased the first set
of camerasa,b.
Building on the success of the European adoption of OGI
technology, Chemours began working with the cameras at its U.S. sites in early
2021. Eager to bolster its leak detection capability, the operator organized a
demonstration of the OGI camera at one of its major manufacturing facilities.
Technical personnel from across the site gathered for an hour-long presentation
before the vendor placed the camera in the hands of the site’s process analyzer
staff engineer.
Over the course of its first day of use, the OGI technology located
opportunities for maintenance and inspection that were previously impossible.
This initial positive trial and the subsequent productive days of monitoring led
to both an acceptance of the technology and a return on the investment in the
camera. OGI technology offers distinct and demonstrated advantages for
operators that include fewer false-positive detections and more precise
location of areas of concern.
The OGI technology’s capabilities were then showcased at other
sites. Several types of leaks were among the training examples used to
introduce OGI to Chemours’ Reliability Network (i.e., an interorganizational
team that evaluates new technologies—also called an innovation division at some
companies):
After the proprietary OGI camerasa,c were introduced
and demonstrated to various Chemour production sites, they were quickly adopted
by local mechanical integrity teams. These teams maintain a steady training
schedule on the technology to utilize its capabilities to optimize leak
detection. This approach and team structure enhance mechanical integrity,
reliability, and leak detection and repair programs, with the capability to be timelier
and more proactive.
Several operators per shift are trained to use the OGI camera, providing
them with a more effective means to find leaks. OGI provides surety to that
investigation—whereas, the use of a handheld analyzer can require more time and
still not yield localized leak sources. In addition, the OGI camerac
offers the utility to find natural gas leaks (e.g., from onsite
furnaces).
Takeaways.
While OGI cameras provide the petrochemical industry with a powerful
addition to the corporate leak-detection toolbox, their effective use requires
proper training. Many different variables can affect measurement, from ambient
air temperature behind the leak and the angle of measurement, to the color
palette applied and the distances from which the leak is measured. Ultimately,
experience is the best teacher. The investment in OGI cameras provides numerous
benefits. Worker safety is improved by providing confidence in predictive
maintenance, proactive inspections and repair validation. Manufacturing
organizations can also have confidence in their ability to meet corporate ESG
goals. HP
NOTES
a Teledyne FLIR GF304
b Teledyne FLIR GF320
c Teledyne FLIR GF77