Liza Destiny FPSO

Maintaining asset integrity is a top priority in the oil and gas industry, particularly in refineries where equipment operates under extreme heat, pressure, and exposure to corrosive gases. Ultrasonic Thickness (UT) measurements are critical for assessing the condition of furnace stacks and identifying early signs of wear or corrosion. SKYRON, an intelligent flying robot, was developed to provide a safer, faster, and more accurate solution for conducting UT inspections in hazardous environments. Equipped with a rotary arm, an Olympus 38DL PLUS gauge, and a high-definition first-person-view camera, SKYRON allows inspectors to collect real-time data remotely and efficiently while ensuring worker safety.

Overcoming the Risks and Inefficiencies of Rope Access Methods

Traditionally, refinery stack inspections rely on rope access to perform UT measurements at high elevations. While effective, this method comes with significant challenges, including safety risks, high operational costs, and extended inspection times. Rope access also limits coordination with other refinery activities and can result in prolonged downtime. The need for a more efficient and less hazardous inspection process led to the adoption of SKYRON’s advanced robotic technology, which can perform accurate inspections with minimal human exposure to risk.

Delivering Accurate Data and Operational Impact Through Automation

SKYRON was deployed to inspect six furnace stacks at a Canadian refinery, focusing on the measurement of wall thickness in high-elevation areas above the top decks. Each stack required only 14 minutes of flight time, demonstrating substantial improvements in speed and precision compared to conventional methods. During the operation, SKYRON’s robotic arm enabled secure attachment to the stack surface, capturing multiple readings within a 2” x 2” area for precise UT measurements. In total, 189 data points were collected across all stacks. To enhance collaboration and data management, the team used Avesoft, a proprietary software platform designed for real-time data capture, analysis, and reporting. The combined use of SKYRON and Avesoft streamlined the inspection process, enabling faster decision-making and improved maintenance planning.

This innovation not only reduced inspection time and costs but also significantly improved safety standards by minimizing human involvement in high-risk environments. The deployment demonstrated how robotic inspection technology can transform traditional asset maintenance workflows, offering a scalable solution for industrial applications across refineries and other heavy industries.