The application of industrial endoscopes in the petrochemical industry has become a key technical means to ensure equipment safety and improve detection efficiency. The following is an analysis from four dimensions: core technology advantages, typical application scenarios, innovative functions and industry value:
Non-destructive testing (NDT)
Industrial endoscopes penetrate deep into the equipment through flexible probes, and can complete the detection without disassembling pipes, tanks or reactors, avoiding equipment damage that may be caused by traditional detection methods. For example, when detecting high-pressure pipelines, complex flanges can be bypassed to directly observe the corrosion of the inner wall, significantly shortening downtime for maintenance.
High-definition imaging and micro-defect identification
Equipped with a 4K resolution camera and three-dimensional stereo measurement technology, it can clearly capture microcracks on the inner wall of the pipeline (minimum detection accuracy of 0.01mm), scaling layer thickness and thermal stress deformation. In one case, the endoscope found a 0.5mm crystal blockage point in the crude oil pipeline, which is equivalent to accurately locating a sesame seed on the football field.
Adaptability to extreme environments
Special models of endoscopes can withstand extreme working conditions from -40℃ to 1200℃, with a waterproof rating of IP67, and are suitable for high-temperature refining pipelines, deep-sea oil pipelines and other scenes. For example, in the 800℃ high-temperature pipeline inspection in a steel plant, the equipment works stably and transmits clear images back.
Intelligent analysis and automated detection
Integrated AI defect recognition algorithm can automatically mark abnormal areas such as corrosion and cracks, and support real-time image transmission to mobile terminals to achieve remote expert consultation. A certain inspection team completed defect diagnosis of cross-regional pipeline groups within 2 hours through 5G remote collaboration.
Pipeline system inspection
Corrosion and scaling monitoring: Go deep into high-pressure, corrosive medium pipelines to evaluate the thinning of the inner wall in real time. In the inspection of a gas pipeline, the wall thickness reduction of 2.3mm was accurately calculated, and the error was controlled within the range of hairline diameter.
Weld quality assessment: 360° surround lens captures 0.1mm-level pores in the weld, with an accuracy that is 3 times higher than manual visual inspection, ensuring welding compliance.
Blockage location: Accurately identify the location of sediments through an optical imaging system. A petrochemical company found a crystal blockage point with a diameter of 0.5mm through an endoscope to avoid the risk of pipeline bursting.
Storage tank and reactor inspection
Inspection of the inner wall of the storage tank: observe the cracks and corrosion pits on the tank wall and bottom of the tank in all directions to ensure the safe storage of flammable and explosive materials.
Inside exploration of the reactor: detect the distribution of the catalyst bed and the erosion of the inner wall to ensure the stability of the chemical reaction.
Valve and compressor inspection
Valve sealing inspection: observe the wear and cracks of the sealing surface to prevent medium leakage.
Internal flaw detection of the compressor: detect the wear of bearings and cylinders, and intervene in advance to avoid equipment downtime.
Multi-function integration and data analysis
Integrate ultrasonic/eddy current sensors to achieve multi-dimensional detection of pipeline wall thickness and crack depth.
Automatic data recording and cloud sharing support long-term trend analysis and provide a basis for predictive maintenance.
Cost optimization and safety improvement
Reduce disassembly and maintenance costs: A company avoids more than one million yuan in pipeline cutting costs each year through endoscope inspection.
Reduce accident risks: timely detect and deal with tank cracks to prevent environmental pollution caused by leakage of toxic materials.
Intelligent detection trend
AI-assisted diagnosis: Through deep learning models, automatically identify defect types and generate inspection reports.
Robot collaboration: The inspection robot equipped with magnetic adsorption wheels can achieve "gecko-like climbing" in vertical pipe sections, covering areas that are difficult for humans to reach.
With the integration of materials science and AI technology, industrial endoscopes will develop towards smaller probe sizes and higher levels of automation. For example, ultra-fine endoscopes (diameter <3mm) have been used to detect coking in heating furnace tubes in coking workshops, and equipment with integrated chemical analysis functions can monitor the composition of media in pipelines in real time. In the future, endoscopes will become the core tool for "preventive maintenance" in the petrochemical industry, helping to achieve the goal of a zero-accident, zero-leakage smart factory.
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