FLARE INSPECTION BOREALIS

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Inspection Flare PK8851

Would you like to know more about HAVIQ’s flare inspections?

Debby Criel, Inspection & Integrity Manager Borealis Kallo/Antwerp, talks about her experiences with HAVIQ:

The Borealis Kallo plant is protected by a flare for safety and environmental reasons. This is crucial to ensure the safe and responsible production of our plant and to ensure that we can stop our plant in the event of an emergency or for a planned shutdown to carry out inspections, maintenance and repair work.

From 2 flares to 1:

Until recently, Borealis Kallo had two flares (main and back-up flare), making it possible to take the main flare out of service to carry out inspections, maintenance and repair work, while the back-up flare was used to ensure the safety of the part of the plant still in service. This backup flare has recently been degraded, requiring a full site shutdown to carry out inspections, maintenance and repair work on the flare.

As a result of the above, we as Borealis Kallo are now forced to carry out inspections during a site shutdown and at the same time tackle a number of smaller observations such as painting work, insulation work, … using rope techniques. The larger observations must then be secured for execution with a sound plan of action during the next site shutdown.

Inspections with drones:

With this in mind, we then looked for a different way of inspecting in order to be able to guarantee that during the next site shutdown, we can work in a more focused way and set out a clear plan of approach without blind trust. We then decided to inspect our flare using a drone.

In the past we had already been in contact with several companies who had the possibility to inspect using a drone, but at that time we did not see the need for it as we still had our backup flare and the drone inspection was still in its infancy.

For the drone inspection of our flare we contacted HAVIQ (former TRINOVA) as they had already performed an internal drone inspection of our blender silos on-site and we were curious what added value they could offer us in terms of performing a flare inspection.

Prior to the drone inspection of our flare, we developed an inspection scenario specifically for our flare together with HAVIQ. In this way, it was clear to both parties what had to be inspected, what the needs were, the approach, which names had to be used for the different parts of the flare, and so on.

The difference between drone inspections and alternative methods:

The difference between the drone inspection and e.g. rope techniques is this inspection:
-Can be carried out during an operational plant,
-Can be carried out in a safer and faster way thanks to modern techniques,
-Can be quickly adjusted for the availability of a mobile office with live streaming,
-Provides clear visuals to set up an efficient plan of action for the next site shutdown.

During the inspection we found that HAVIQ is open to improvement and optimisation. They not only want to know what the positive experiences were, but also what their points for improvement are, so that they can deliver a personal and tailor-made service in the future. During the start of the inspection, for example, flying was not done in a systematic way, so it would not be obvious afterwards to get a clear picture of the flare. With our advice, the plan of approach was adjusted and data was captured in a much more efficient way.

HAVIQ gives priority to safety; this was reflected in the preparatory activities, such as an exploratory meeting and on-site visit, extensive risk analysis, setting up a detailed inspection scenario, application for RPAS (Remotely Piloted Aircraft System) authorisation.

The final result of the drone inspection of our flare resulted in a well-structured and complete inspection report compiled by HAVIQ in consultation with us. This report enables us to carry out the maintenance and repair work safely and in a structured manner during the next site shutdown as it is now possible to draw up a detailed plan of approach.

 

 

 

 

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