Avoiding operational failure in storage tanks is especially important due to the risk in case of failure being great. If a tank failure occurs, tank contents may leak into the environment, causing severe environmental pollution. In addition to that, since most tanks are used for holding volatile and/or toxic compounds there are high OHS risks in case of a leakage. Lastly, a tank failure means tank will be decommissioned for a significant amount of time, meaning lost profits.

Luckily, inspection and maintenance techniques have come a long way; thus, the possibility of a catastrophic tank failure is minimized. However, maintenance itself continues to incur risks and costs on asset owners. Tanks are huge pieces of equipment with very large interiors. If maintenance is needed in the interior, the massive amount of product inside should be moved elsewhere.

Traditional inspection methods do not provide an opportunity to gauge whether or not tank maintenance is necessary, without taking the tank out-of-service. On the other hand, AIS Field’s current portfolio helps asset owners to know precisely whether or not and where maintenance is necessary. In addition, thanks to the developments in computational methods, we are able to help the customers in performing predictive maintenance. That way, asset owners can plan ahead their maintenance, without wasting their precious time and resources with unnecessary out-of-service inspections and maintenance.

The Importance of Regular Inspections

Inspections have a close relationship with maintenance. For storage tanks, NDT inspections are used to determine if, when and where maintenance is required. Without scanning of the structure via NDT, it would be almost impossible to properly and efficiently carry out inspections in such vast structures.

Regular inspections ensure long-term safe operation for industrial assets. NDT has no detrimental effect on structural integrity, it is rapid, low-cost and reliable. For storage tanks, inspections such as ultrasonic thickness and weld inspections are performed routinely, and are mandatory for asset owners, as per API 653. In-service UT inspections of tank walls are possible in some cases; on the other hand, tank floor inspection with traditional methods is not possible due to the impossibility of human operators to collect data under such conditions.

This means, conventional methods dictate that tank is taken out-of-service if bottom is to be inspected. This creates the problem of impossibility of separating inspection schedules from maintenance schedules and avoiding unnecessary downtimes.

AIS Field’s RUVI Oildiver solves this problem. In addition, AIS Field’s RUVI Wallker can climb interior or exterior tank walls for thorough UT inspection. This not only brings reduction of OHS risks but also brings significant cost reduction since with this method it is now possible to inspect tank walls without scaffolding. 

What is the Ideal Regular Cleaning and Maintenance Schedule?

As is explained thus far, ideal interval for cleaning and maintenance for an asset owner is actually to never do cleaning and maintenance, since these incur great costs. This desire clashes with the difficulty of making sure of asset integrity. For storage tanks, since traditional methods cannot ensure integrity of tank bottom without emptying tanks for inspection, maintenance schedules are the same as inspection schedules, since once the tank is opened, it makes sense to do maintenance as well. As a rule of thumb, Inspection-maintenance interval is around 10 years; however, it can also be altered due to various factors. However, if reliable in-service inspection is possible, the ideal time of maintenance is exactly when a structural defect is detected and no sooner. 

It is not yet possible to perform in-service maintenance on a tank interior. However, if presence or lack of structural defects can be detected in-service, the need for maintenance can be shown to be non-existent. In other words, best case scenario is to do in-service inspections and postpone maintenance if the structure is found in a good condition and only start in-service repairs when it is not.

AIS Field’s solution, RUVI Oildiver, is precisely aimed at doing just that. Since our robotic inspection makes possible in-service scanning of tank bottom floor, asset owners can ensure safety and compliance without putting their tanks out-of-service.

Tips for Optimal Storage Tank Maintenance

Since typically there is limited time allocated for tank maintenance, rendering the maintenance as efficient as possible is paramount. The key concept in efficiency is resource allocation. Thus, the resources necessary for maintenance (manpower, equipment etc.) should be allocated to where they are the most needed. To do that, prior planning is essential.

However, for a successful planning procedure, quality data is a must. Quality data on the other hand can only be obtained via quality inspection. If abundant and accurate inspection data is available, the planner will be able to allocate available maintenance resources to where they are the most needed. Without quality data, maintenance procedure may run into problems, can be more costly or take more time. Examples of the lack of quality data can be given as too few data points, low repeatability, low accuracy, lack of data from critical areas etc.

How AIS Field can Help You?

To reach maintenance best practices, Ais Field can help you with obtaining quality data. Main aim of AIS Field’s robotic solutions are to provide our customers with quality inspection data.

First of all, AIS Field robots reach hard-to-reach or dangerous places without any OHS risks, thus we are able to provide data from everywhere.

Secondly, AIS Field robots are able to carry out full mapping of your asset with tens of thousands of data points, a feat simply impossible for human operators.

Thirdly, robotic inspection has a much higher repeatability compared to human operators.

All things considered, not only does AIS Field robotic solutions help you in reaching regularity in inspections with minimal cost and health hazards, they also provide high quality data to make maintenance planning mush more efficient.

Maintenance Best Practices for Storage Tanks yazısı ilk önce AIS Field üzerinde ortaya çıktı.

In actuality, RUVI Oildiver can be configured to reach to and get signal from even dead corners. However, the main issue for in-service inspections of the critical zone is the heavy sludge that is typically present in such locations. This sludge makes it difficult to conduct healthy thickness readings from the corners. On the other hand, corners are important locations that need to be inspected. In fact, due to the extra stress that occurs in these corners, they are classified by API 653 as “critical zones”. These critical zones in storage tank floors made it necessary for us to develop an additional solution for their inspection.

We believe in a holistic approach in robotic inspection. The ultimate goal is to inspect the whole tank robotically, minimizing human error, inspection time, environmental impact and OHS risks. Since our robots specialize in providing high quality solutions for specific industry pain points, different problems in industry are best challenged by different robots. If one robot has a limitation in its scope, this limitation can be remedied by another supplementary robot.

This is our approach to the critical zone inspection in storage tanks. While RUVI Oildiver inspects the general tank floor, the best quality for critical zone inspection can be obtained by a robot fully dedicated for this task. For the tanks in which critical zones are inaccessible by RUVI Oildiver, we have developed PAars Annular Ring Inspection Robot, designed specifically to inspect critical zones in storage tank floors. In this post, we aim to provide information about critical zone inspections and our robotic solution PAars.

Where is The Critical Zone in a Storage Tank?

Critical zones are defined as the lower corners of the storage tanks, 3 inches (7.6 cm) of inside edge of the shell. Critical zones are not only under the weight of the shell, but they are also prone to sludge build up. This area also contains the weld between tank shell and tank bottom. Due to these issues, critical zones are typically built with a higher thickness. The unique situation of the critical zones of storage tanks makes their inspection more crucial. Higher stress means higher probability of defects occurring and a general higher rate of loss of thickness. 

How to Inspect the Critical Zone?

In conventional tank inspections, since the tank is emptied and the bottom is cleaned prior to inspection, critical zones can be inspected just like the rest of the tank floor. However, in service robotic inspection of the storage tank bottom floors has a weak point for the critical zone inspection in storage tanks.

Our RUVI Oildiver robot has 32 UT probes, collecting comprehensive data from the tank floor. If the critical zone is relatively clean, ie. has low levels of sludge, RUVI Oildiver’s probes can be configured before operation to obtain critical zone data.

However, the critical zone is most of the time not clean and has significant sludge build-up. This makes it difficult for the robot to get near the critical zone for inspection and also makes it difficult to obtain accurate UT measurement data due to sludge interference. Due to this, we have presented our dedicated robot PAars to inspect the critical zone.

Does Inspection Report Quality Matter?

Above all else, inspection aims to collect accurate data. Accurate data can be used to gauge the estimated lifetimes of industrial assets, predict when, where and how failures are going to occur and prepare future maintenance roadmaps. Our robotic inspection solutions provide abundant, accurate, repeatable data very quickly.

However, just as important is a high quality report that is processed by expert personnel that provide valuable insights. In the age of big data that we live in, data processing is nearly as important data gathering. Another aspect of high quality reports is that they provide compliance. AIS Field’s in-service robotic inspection solutions for storage tanks, RUVI Oildiver and PAars Annular Inspection Robot, provide reports for storage tanks are fully compliant with the mandatory API 653 regulation. AIS Field’s NDT Level II and Level III experts prepare comprehensive reports from our robotically obtained data, to provide valuable insight to our customers as well as to ensure their compliance.

How AIS Field can Help You?

Our critical zone inspection robot, PAars Annular Ring Inspection Robot, is specifically designed to solve the issue of critical zone inspection is storage tanks. Unlike RUVI Oildiver, PAars does not need to dive the tank; it can inspect from the outside. It is an automated scanner attached to the tank shell wall.

PAars is equipped with the integration of ultrasonic phased array and 0-degree. Once attached to the tank bottom edge from the outside, PAars is able to detect plate defects from the tank interior, up to 1 meter away from the tank shell. It is able to characterize defects up to 40cm away from the shell. If we remember that the critical zone is defined as 7.62 cm away from the tank shell, it can be asserted that PAars provides a definitive solution for the critical zone inspections for storage tanks.

PAars service can be provided standalone, but it is typically offered as supplementary with our RUVI Oildiver to provide a full picture tank bottom inspection.

Storage Tank Floor Inspection – The Critical Zone in Storage Tanks yazısı ilk önce AIS Field üzerinde ortaya çıktı.

Optimizing maintenance process for storage tanks is crucial due to various reasons. Firstly, most maintenance processed are tightly regulated. If we take storage tanks for example, API-653 inspections are closely tied to tank age and are mandatory. Moreover, there are tight regulations on exactly how the maintenance is to be conducted.

Secondly, routine maintenance is one of the best ways to extend an asset’s maximum lifetime and ensure its operational integrity. Tanks are expensive pieces of equipment which are used for holding valuable commodities. Thus, optimizing their maintenance process will pay off in the long run. 

As competition grows in heavy industry, firms have found it lucrative to invest in cutting edge technologies which give them advantage over their rivals. Asset integrity is one of the most crucial fields for continuous, safe and profitable operation of an industrial facility. However, it cannot be said that it is getting the attention it deserves. Many facilities are reluctant to modernizing their routine inspection protocols.

Why Facilities are Reluctant to Modernizing Their Routine Inspection Protocols?

The main cause of concern is the vast amount of protocols already present in a plant. Heavy industrial facilities are more often than not quite large and complex, thus tinkering with already operational procedures can feel like a bad idea at first. Another concern is that heavy industry is a risky operation, thus operators have a tendency to err on the safer side and stick to older technologies. Lastly, new technologies are not always fully compliant with the regulations, which means that they cannot be implemented such regulation-heavy industries.

However, when it comes to adopting new technologies, a very well known fact is that early adopters get the lion’s share of the benefits and position themselves far ahead of their competitors. The longer companies hesitate, the more they risk being left behind in a rapidly evolving market.

Early adoption accelerates efficiency, boosts safety, and unlocks unprecedented levels of predictive insight. Those who take action first will thrive, while the ones who drag their feet will find themselves desperately playing catch-up, with increased price but decreased return. The market rewards bold moves, not hesitation. In this post, we go through why one should invest in the optimization of maintenance in storage tanks and how we can help you in alleviating your concerns.

The Importance of Modernizing Maintenance in Storage Tanks

When the time of maintenance comes, stressful days commence. Time is tight, costs are high and facility is losing money daily. In the case of storage tanks, there is possibly a very high opportunity cost of maintenance, since production in refineries is tied to available storage space.

Conventional inspection and maintenance all requires taking the tank out of service. This is because bottom is not reachable  while the tank is filled with toxic and explosive liquid. But fortunately, new technology brought in robotic NDT practices, which made it possible to reach the bottom while in-service. Our RUVI Oildiver robot, thanks to its ATEX Zone 0 certification, is able to do fully API-653 compliant tank bottom inspection.

Moreover, our RUVI Wallker robot is able to climb tanks’ outer walls for full thickness mapping. Thus, modernizing storage tank maintenance practices means the customer is able to develop more efficient, safe and low-cost maintenance procedures without any downtime.

Common Maintenance Challenges

Challenges in tank maintenance are well-known for those who are in the sector. One cannot just simply get into tank, the tank should be emptied at first. This alone is a huge problem since if there is no back-up tank, the production will suffer. However, even when this is not a problem, planning for it is also brings in a significant problem.

Afterwards, preparing a tank for this process is long and cumbersome. Degassing, cleaning and sludge reduction are mandatory practices as per regulation. The tank is also to be ventilated via ex-proof fans for several weeks. One thing to underline again is the presence of toxic and explosive solids, liquids and gases/vapors during this whole process. These cause significant environmental risks, OHS concerns and handling costs.

In short, not only is conventional inspection and maintenance impractical, it is also dangerous, dirty and takes a long time. Optimization of conventional maintenance processes is not an easy task, since there are many aspects of it that can go wrong, adding it unpredictability.

Utilizing Technology to Overcome Challenges

In today’s world, robotics and AI are the names of the new revolution and cutting edge innovation is achieved in many sectors via integrating new developments there to that specific sector. Our team, well aware of all the short-comings of current conventional methods thanks to their vast field experience, have done just that. We utilize robotics and AI to decrease human errors, get procedures done faster, build more stream-lined inspection and maintenance operations and most importantly operate in places not possible for human operators thus minimizing the danger to human life.

Robots work with precision simply impossible for human operators, can collect hundreds of thousands time more data than human can, can safely climb to heights, can work in confined spaces, can dive into toxic and explosive fluids. Utilizing AI makes possible to analyze big data for predicting error mechanisms, making possible much more efficient maintenance practices. In the long run, putting together the vast amount of data collected by robots with the analyzing capabilities of the AI models, it will be made possible to build new and unprecedented inspection and maintenance protocols for storage tanks as well as other industrial assets.

Strategies for Optimizing Maintenance Process for Storage Tanks

Making the transformation to robotic extremely straightforward, the robotic inspection of storage tanks is much easier to manage than a conventional inspection. First of all, robotic inspection does not require thorough planning. Since the tank is not to be emptied, no back-up tank is needed. Tank content is left intact, so there is no need for ventilation or sludge management. There are also next to no emissions.

Robotic inspection can be decided only a couple days prior and is quickly finalized. If tank is found in good condition, fully API-653 compliant reports will be received without ever opening the tank. In case a tank requiring maintenance is detected, prior robotic inspection will have given thorough information on so that maintenance can be planned accurately and can be conducted quicker and more efficiently. Thanks to all these reasons, a robotic transformation for tank inspection and maintenance is extremely easy for and works wonders for optimizing maintenance processes for storage tanks.

How AIS Field can Help You?

As mentioned above, there are admittedly difficulties of attempting a robotic transformation for optimizing maintenance processes for storage tanks. To minimize the uncertainty, the company that is offering a robotic solution should be aware of the complexities present in heavy industrial processes.

The AIS Field team, with its vast field experience, is not only a robotic service provider but also is able to act as a consultant regarding the big picture of a plant. Working with such a seasoned team minimizes the risks of a robotic transformation while maximizing its benefits.

Our solutions are not cookie-cutter ones, but are tailor made on the field for real industrial conditions. Our robots are made to solve problems, and are designed to be fully compliant with regulations such as API-653. All our solutions are designed, manufactured and operated by us, thus they are fully optimizable to each customer. With its R&D capabilities, AIS Field is constantly developing new innovative solutions for pressing industrial problems.

Optimizing Maintenance Process for Storage Tanks yazısı ilk önce AIS Field üzerinde ortaya çıktı.

What is a Tank Inspection?

Inspection means careful examination and scrutiny. In an industrial context, inspection procedures are almost always guided by regulations. Industrial assets are not only expensive pieces of equipment, they also provide constant cash-flow; as long as they are in service. This is the main idea of inspection: to prevent future time lost. In that sense, inspection pays for itself. Being important industrial assets, storage tanks are inspected to ensure safe, uninterrupted and long operation.

Why is Tank Inspection Important?

Industrial tanks that store oil, oil derivatives or chemicals are expensive assets. A tank that is small to average in size costs at least several hundreds of dollar to build with most tanks that are currently operated on the field exceeding 1 million dollars in construction cost. To make the most this significant investment, tanks should stay operational at all times. Inspection is the only way to prevent unexpected leakages and ensure uninterrupted operation. Moreover, leakages in fuel and chemical tanks cause significant environmental hazards. This makes tank inspection crucial for green industry and zero emission.

How Often Should a Tank Be Inspected?

As per API-653 regulations guiding tank inspection, storage tanks require full inspection for thickness loss and corrosion every 10 years under normal conditions. Inspections can be carried out more often than that if the asset owner predicts a heightened risk.

How to Inspect a Tank?

Tank inspections are crucial for safety, reliability and longevity of industrial storage units but the method of inspection can make all the difference in efficiency. Traditional Non-Destructive Testing (NDT) methods like Visual Inspection (VT), Ultrasonic Testing (UT) and Magnetic Flux Leakage (MFL) have been the norm for years. But these methods require tanks to be completely emptied and taken out of service for several months which although effective introduces downtime and risks to environmental and safety factors.

Thanks to technology, robotic systems like the RUVI OilDiver offer an alternative. These systems can inspect the tank floor without emptying the tank so companies can stay in operation. In the next section we will look at traditional methods and the RUVI OilDiver, the benefits and the advancements in tank floor inspection.

Traditional Methods

Non-destructive Testing (NDT) is the industry standard since it makes possible to gather a significant amount of data without causing damage to the structure. Tank inspections are generally made via visual inspection (VT), Ultrasonic Testing (UT) and Magnetic Flux Leakage (MFL). These methods detect the damages that are present in the structure so that they can be fixed afterwards. Since it is impossible for these methods to inspect tank floor when the tank is full, traditional methods require the tank to be fully emptied and put out-of-service for several months, but this is considered as a decent trade-off since this procedure helps to prevent future unexpected failures. However, environmental and safety risks that arise from this process cannot be fully mitigated.

Ruvi OilDiver – A Robotic System Designed for Tank Floor Inspection

Recently, technological advancements made it possible to carry out tank floor NDT without emptying the tank. Our advanced system, RUVI OilDiver, is able to dive into a fuel tank that is full with explosive content, thanks to its Zone-0 ATEX certification. This makes possible UT and visual inspection of the tank floor, without taking the tank out-of-service for even one day.

Ultrasonic Thickness Measurement and Corrosion Mapping with RUVI OilDiver

RUVI Oildiver provides API-653 compliant reports. It can fully map the tank floor with both thickness and visual data, detecting exactly where and on which floor plate corrosion had occurred. Thanks to the highly accurate thickness data, asset owners can gauge if and where repairs are required. Data received from RUVI Oildiver inspections makes Risk Based Inspection (RBI) possible. Robotic Inspection can determine “good actor tanks” which do not and are unlikely to require repairs and maintenance. That way, inspection and maintenance budget can be diverted to “bad actor tanks” which need the most attention.  This is also crucial for insurance purposes since the data can be used to reduce uncertainty and decrease the insurance premiums.

API 653 – What is API 653 Standards for Tank Inspections

API 653 is an industry standard set by the American Petroleum Institute (API) for the inspection, repair, alteration and reconstruction of aboveground storage tanks for petroleum and other liquids. While the design and construction of these tanks are covered by API 650, API 653 is for the ongoing integrity of the tanks. It specifies inspection frequency, types of inspections and what to do if any defects are found. API 653 compliant inspections are mandatory for safe tank operation and is often required by national regulations in Turkey. It also emphasizes documentation so API 653 is a must have framework to ensure tanks are safe, reliable and in continuous service.

API 653 says in-service tanks must be inspected every 5 years. More detailed inspections including Non-Destructive Testing (NDT) of the tank floor for thickness and corrosion must be done every 10 years under normal conditions. In the past this would mean taking the tank out of service for a long period of time but with advanced robotic systems like the RUVI OilDiver you can do it without any downtime.

What is API 653?

American Petroleum Institute (API) 653 is a standard that guide inspection, repair, alteration, and reconstruction of aboveground storage tanks of petroleum products and other liquids. Note that initial tank design and construction is guided by API 650. API 653 stipulates the frequency and types of inspections required to ensure the integrity of storage tanks. In addition, if issues are identified, maintenance and repair of tanks are also to be made in accordance with API 653. API 653 also provides guidelines for documentation; thus, an API 653 compliant inspection and reporting is necessary for tank operation. Turkish regulations also cite API 653 and require API 653 compliant inspections.

How often is API 653 inspection?

Every five years, in-service inspections are to be carried out. Under normal conditions, every ten years, bottom-plate thickness NDT is required for above-ground tanks. As mentioned, these traditionally require lenghty out-of-service NDT operations. Not anymore, thanks to the RUVI OilDiver.

Tank Inspection – Everything You Need to Know About Tank Floor Inspection yazısı ilk önce AIS Field üzerinde ortaya çıktı.

NDT, being very widely used and depended on technology, is always quick to incorporate new technological advancements to improve its robustness. Two most exciting fields that have seen significant technological advancements recently are robotics and artificial intelligence (AI). As well as incorporating robotics into NDT with solutions such as RUVI Oildiver and RUVI Wallker, AIS Field also works to incorporate AI for better NDT analysis and reporting performance.

Traditional Methods vs. Robotic Methods

Traditional approaches have several shortcomings which are time-consuming analysis, high potential for human error, limited adaptability to dynamic environments and high dependency on skilled operators. Machine learning can enhance traditional NDT techniques by automating defect detection and minimizing human error, also cutting costs.

The advantages of Machine Learning in NDT are:

• Automation and Efficiency: Machine learning models, especially neural networks, can quickly process large volumes of Non-Destructive Testing data and provide rapid, accurate defect detection.
• Improved Accuracy: In most cases, machine learning makes possible better analysis than humans. In our article titled “Development and Comparison of RNN, LSTM and GRU Neural Network Models for Automated Eddy Current Inspection of Heat Exchanger Tubes Using Real World Industrial Data”, recently published and presented in BINDT 2024, the machine learning models developed (RNN, LSTM, GRU) achieved accuracy levels over 98%, outperforming traditional rule-based software and human inspection (with GRU achieving the highest accuracy of 99.26%).
• Cost Savings: Automating the inspection process reduces the need for manual analysis, thus lowering operational costs by saving time and reducing the need for highly specialized personnel.
• Reduced Human Error: By removing the need for subjective human analysis, machine learning can reduce inconsistencies in reporting and ensure a more standardized evaluation process.

Machine learning in NDT at its current state also faces some challenges and has some limitations which will be mitigated over time with advancing technology:

• Data Quality and Availability: Machine learning models require extensive and well-labeled datasets to perform effectively. Gathering and labeling real-world data (such as the 10 years of data used in the AIS Field study) can be resource-intensive​.
• Computational Demands: Training complex models such as deep learning architectures (RNN, LSTM, GRU) can require significant computational resources, both in terms of time and hardware (e.g., GPUs)​.
• Bias and Overfitting Risks: Without careful curation of training data, machine learning models may develop biases, leading to overfitting on specific types of defects or equipment.

Recent Developments and Case Studies

AIS Field R&D Department contributes to the scientific literature on the use of machine learning in NDT. In our recent study, machine learning models were used for the data analysis and reporting of eddy current testing (ECT) in heat exchanger tubes.

Real-world inspection data from 89 heat exchangers have been gathered. From the data, more than 100.000 potential defect areas have been extracted using advanced signal processing methods. For the machine learning study, three bidirectional neural network architectures have been used: Recurrent Neural Networks (RNNs), Long Short-Term Memory networks (LSTMs), and Gated Recurrent Units (GRUs). It has been determined that GRU is the most accurate model among the three with 0.9842 general accuracy, followed by LSTM (0.9770) and the least accurate was RNN (0.9689). The ranking stayed the same for both ferrous and non-ferrous models.

False positives exceeded false negatives, underlining the prioritization of safety by the machine learning models. It has been shown in the study that with GRU models it is possible to reach 98.55% defect detection for ferrous and 99.89% for non-ferrous tubes. These results show that machine learning models significantly outperform human experts as well as traditional rule-based software systems in both accuracy and speed.

The Future of Machine Learning in Non-Destructive Testing

Increased Integration with Robotics: Machine learning models will likely be integrated into robotic systems for autonomous inspection. One example of such a development is AIS Field’s efforts to make use of machine learning to localize robots and reduce the time needed for NDT data analysis in storage tanks​. This integration can reduce the need for human involvement in hazardous environments.

Predictive Maintenance: Machine learning could enable the transition from reactive to predictive maintenance, predicting when and where defects are likely to occur based on historical data and real-time analysis.

Enhanced Defect Characterization: Moving beyond detection, future advancements in machine learning could allow models to characterize the type, size, and severity of defects with greater precision, enabling more targeted maintenance strategies.

Machine learning offers significant advantages for NDT, from improved accuracy and cost savings to increased safety through automation. While there are challenges, particularly regarding data quality and computational demands, the potential for further advancements makes machine learning an essential tool for the future of NDT.

As industries continue to digitalize and automate, the role of machine learning in NDT is likely to grow, transforming how inspections are conducted and contributing to safer and more reliable industrial operations. Moving maintenance from reactive to predictive will do wonders for better workplace security and lessened environmental impact. In that sense, the future of NDT indubitably lies in the incorporation of robotics and AI.

Machine Learning in Non-Destructive Testing yazısı ilk önce AIS Field üzerinde ortaya çıktı.

Below is an English summary of the article published in Forbes Türkiye, highlighting how AIS Field’s innovation is transforming industrial tank maintenance.

“AIS Field’s RUVI OilDiver robotic system, developed for heavy industry, cuts tank maintenance costs worth millions of dollars while minimizing carbon emissions and environmental waste. A remarkable performance for a start-up…

The World Economic Forum reports that over 30% of global greenhouse gas emissions come from heavy industry. To reach net zero, these industries must undergo a deep transformation, especially in energy efficiency and green technology applications. One Turkish start-up taking this challenge head-on is AIS Field, with its product RUVI OilDiver. A robot that reduces the carbon footprint, chemical waste and safety risks associated with tank cleaning and maintenance.

From an economic standpoint, the scale of the problem is massive. Storage tanks must be emptied every ten years for maintenance, during which they are cleaned, inspected, repainted and repaired before being recommissioned. This process can take up to three months and costs millions in downtime and maintenance expenses. The larger the tank, the higher the loss, sometimes reaching up to 2.5 million dollars per tank.

AIS Field’s RUVI OilDiver offers a game-changing alternative: it can inspect tanks without draining them, significantly reducing both downtime and cost. With over 50.000 storage tanks worldwide, the market potential is immense.

Founded in 2022 by Görkem Bayten, Özgen Bulut, Kayhan Gündoğdu and John Duncan Stephenson, AIS Field is the first company in Turkey to develop such advanced robotic inspection technology. The company was established with TÜBİTAK’s BIGG Entrepreneurship Grant, and its RUVI OilDiver robot was developed under TÜBİTAK’s 1707 Order-Based R&D Program in partnership with TÜPRAŞ. Co-founder Kayıhan Gündoğdu explains:

“Non-destructive robotic inspection is already attracting serious investment in the US and EU. As the only company from our region competing internationally, we believe our technology gives us a strong competitive edge.”

The RUVI OilDiver system uses 32 ultrasonic probes to map corrosion across the tank floor while the robot moves continuously inside the tank. It detects defects in real-time and generates a digital corrosion map, ensuring both precision and safety. The system also employs encoders, IMUs, and 360-degree sonar for navigation. Operators control the robot remotely from a control room using AI-assisted visualization and analysis tools.

AIS Field’s partnership with TÜPRAŞ began with 13 large tank inspections and later expanded to other robotic systems. In 2024, the company launched RUVI WallKer, a magnetic crawler robot designed for boiler and heat exchanger inspections.

Today, AIS Field operates from its R&D lab and workshop in ODTÜ Teknokent’s OSTİM campus in Ankara, employing 15 engineers who continue pushing the boundaries of robotic non-destructive testing.”

AIS Field’s RUVI OilDiver Featured in Forbes Turkiye September Edition yazısı ilk önce AIS Field üzerinde ortaya çıktı.

Our presentation, titled “Development and Comparison of RNN, LSTM and GRU Neural Network Models for Automated Eddy Current Inspection of Heat Exchanger Tubes Using Real-World Industrial Data,” marks a significant milestone in our ongoing efforts to integrate artificial intelligence and machine learning into non-destructive testing (NDT) and robotic inspection systems.

In this study, our team explored the use of advanced deep learning architectures to automate the analysis of eddy current inspection data collected from industrial heat exchangers. Using real-world data from refineries and power plants, we developed and benchmarked multiple neural network models, including RNN, LSTM and GRU, to evaluate their performance in detecting and classifying defects in non-ferrous tube materials. The results demonstrated that AI-driven systems can achieve high accuracy, consistency and speed, offering a promising step toward reducing human error and improving overall inspection efficiency.

We extend our sincere appreciation to Metin Oktay Balaban, our software lead and machine learning engineer, for his exceptional work and leadership throughout this research. We would also like to thank Sait Kökoğlu from Integrity NDT for his valuable technical support, which played a key role in making this study possible.

Participating in BINDT 2024 has been an inspiring experience for our team, and we are excited to continue advancing the frontiers of AI-driven inspection technologies.

Stay tuned for more updates from AIS Field’s R&D initiatives.

AIS Field Presents AI-Based NDT Paper at BINDT 2024 Conference yazısı ilk önce AIS Field üzerinde ortaya çıktı.

Storage tank bottom plates are inspected via Non-Destructive Testing (NDT) methods every 10-years as per API-653 regulations for thickness loss and corrosion. Inspection is generally made via visual inspection (VT), Ultrasonic Testing (UT) and Magnetic Flux Leakage (MFL). These methods detect the damages that occur to the structure during the operation. Thanks to NDT, the remaining wall thickness can be gauged without any further damage to the structural integrity, and repairs may be conducted if necessary.

Traditional Inspection Method for Storage Tanks

For fuel tanks, this inspection is mandatory. Traditionally, the inspection includes several steps:

1. Planning: Since the tank is full of product and constantly in use, it cannot be taken out of service without prior planning. If the tank is incorporated into a production process, that production process may need to be altered or an alternative tank must be found.
   
2. Tank emptying: Once necessary planning is made, tank is emptied. Depending on tank size, this can take substantial time. Moreover, it includes handling of hazardous product.
   
3. Venting and cleaning: The tank that is emptied from liquid product will still contain remnants of flammable and toxic product, in addition to explosive gaseous environment and bottom sludge. Cleaning the tank and making it suitable for man-entry takes several weeks.
   
4. Paint stripping: Prior to inspection, surface paint is stripped via water jetting or sand blasting.
   
5. Inspections.
   
6. Repairs (if needed): If inspection finds flaws, these are repaired.
   
7. Repainting.

Drawbacks of Traditional Method

This lengthy conventional procedure, which had no alternative approaches until recently, has significant drawbacks:

• Tank is taken out-of-service. In refineries with constant production or busy terminals, taking a tank out-of-service means inefficiency, operation difficulties and lost profits.
  
• Manual procedure requires man-entry, which requires significant preparation effort (note that six out of seven steps in the conventional procedure are not directly related to the inspection).
  
• Preparation via planning: Operation planning should be made for an alternative tank that will hold the contents during tank down-time. Production and other operations are to be adapted to the reduced storage capacity during tank is out of service.
  
• Tank itself is to be prepared prior to inspection. Degassing, cleaning and sludge reduction principles are stipulated as per API 653. Special equipment such as ex-proof fans are to be used. Ventilation may required to be carried out for several weeks.
  
• Hazardous tank contents, including toxic fumes and sludges are released. These result in emissions, environmental pollution and additional handling costs.
  
• Confined space man-hours are required, causing OHS risks.

Robotic Inspection of Above-Ground Storage Tank

Thankfully, technological advancements have made elimination of all these problems possible. AIS Field introduces RUVI OilDiver, our zone-0 ATEX certified robot that can safely dive into explosive fuels and do in-service bottom thickness inspections via its UT sensors and cameras.

• Zero planning required. Facility continues its business as usual while our team carries out the tank inspection. All of the additional steps are eliminated.
  
• Zero downtime. Our customers can continue operation with their tank during the inspection (which already takes significantly shorter). In fact, we encourage them to.
  
• Hazardous tank contents, toxic fumes and sludges, are not released, since we leave the tank contents intact.
  
• No confined-space man-hours, RUVI OilDiver takes care of everything.

But, what if the tank bottom is found compliant and not requiring repairs?

This is where our approach really shines. RUVI Oildiver’s robotic tank bottom inspections are fully compliant with API 653. If repairs are found to be not required, bottom inspection data are added to the roof and shell evaluations for a full API 653 report, without ever stopping facility operation or emptying the tank.

Inspection of Above-Ground Storage Tank (AST) – Advantages of In-Service Robotic Inspections yazısı ilk önce AIS Field üzerinde ortaya çıktı.

ASME B31.1 Power Piping; sets requirements for covered piping systems (CPS). The code specifies that any piping system with a nominal size greater than 4 inches, operating at 750F or above, or greater than 1025PSI shall be categorized as CPS

The operation of pressurized piping systems presents significant safety risks with numerous well-documented global events having been recorded. Consequently, International Standards have been developed prescribing guidelines to promote premature failure detection and overall safety.  

Standards detail requirements, recommendations, and guidance for the implementation as the responsibility of the operating company, to exercise control measures to ensure safe facility operations for all Covered Piping Systems (CPS), which include: 

• API 570 Section 5 – Piping Code (In-service inspection (4) 
• API 574 Section 12 – Records 
• ASME B31.1 Covered Piping Systems (CPS) Chapter (VII) Operations & Maintenance 
• Non-Mandatory Section (V) V-2 General 
• The Pressure Safety Systems Regulations (2000) 

Establishing Safe System Management Practices

The standards provide valuable guidance as to the recommended requirements to develop CPS procedures/programs to manage piping systems, and the understanding and application of these recommendations are essential in establishing safe system management practices. 

Therefore, operators are responsible for developing, documenting, implementing, executing, and assessing site-specific CPS procedures and programs, and defining the system(s) and the system components to include. Standards define examples and provide guidance listings from O&M procedures to condition assessment. However, the scope of related inspections and inspection applications are completely plant-dependent and may vary.

When constructing a plant-specific system and plan based on present and/or possible types of failure mechanisms, determining key items for inclusion, and formulating an inspection program is key. The scope and inspection intervals are plant-dependent and the responsibility of a competent person, engineering judgment, and current industry best practice shall be considered.

Standards for Covered Piping Systems (CPS)

The standards cover a wide scope for CPS programs, with a focus on inspection; the key considerations being piping weldments, piping support system (hangers), piping controls (valves), piping bends, piping material condition, and applicable material degradation mechanisms. The inspection methods and the extent of NDE applied shall be evaluated to ensure they can adequately identify the damage mechanisms and the severity of damage.

Standards recommend the development of piping system drawings, and isometric or oblique drawings provide a means of reference, identifying the location and orientation of piping lines. Also, general service conditions, process flow, size, material specification the location of key fittings such as valves and orifices etc, along with piping weldments including butt and nozzle joints and piping supports (hangers). 

Standards govern, all inspection activities and applications, including pre-inspection preparation requirements, which shall be controlled in accordance with written procedures and applied by qualified operatives.

The standards deem that all inspection documentation relevant to system condition is maintained, and plant lifetime records are managed. A typical CPS program will generate large volumes of inspection reports and valuable related data, therefore establishing an electronic record system such as a ‘live’ database, when reviewing forward planning based on findings and CPS program management is recommended.

FIL – Web-Based Inspection Management Solution

Considering the detail and complexities faced in adopting and answering the guidelines of current standards and in support of our clients, AIS Field provides ‘FIL’, a digital-twin-based plant asset management system, built on a wealth of plant inspection and asset integrity management experience.

FIL is a web-based inspection management solution, developed for planning and maintaining records over the pre- and in-service life of a plant asset. The system simplifies the identification of plant items and enables the creation of intelligent graphics, linking critical plant items identified on system isometrics to a database management system. 

Tracking inspection and maintenance records is invariably a challenge to plant engineers. Maintaining system lifetime records and tracking plant item status when forward planning inspection and maintenance schedules, and unit shutdown/outage plans, especially when considering growing historical records, can be time-consuming and inefficient.

Using ‘FIL’, all plant item associated, QA documentation, maintenance and inspection files, and reports can be uploaded, stored, and accessed directly via system drawings and graphical links. In doing so, all activities and plant item STATUS can be tracked and monitored via this digital twin interface. 

Covered Piping Systems – Best Practices yazısı ilk önce AIS Field üzerinde ortaya çıktı.

NDT is used during the entire life cycle of components, systems, products and facilities, starting from design, raw materials control, manufacturing and assembly processes, in-service inspections, condition monitoring management and remaining life assessment of components, systems, products and facilities.

NDT can be performed during or after production and manufacturing and even on equipment in service.

In manufacturing, NDT practices are used to ensure that parts are suitable for a desired function, ie. that they will last for a given time in operation. In-service NDT practices can be used to assess the current state of damage, monitor damage mechanisms and make informed decisions for remaining equipment life assessments [e.g. Risk Based Inspection (RBI), Fitness for Service (FFS).

Why Non-Destructive Testing (NDT)?

There are several reasons leads to Non-Destructive Testing:

• Assures Security: Periodic NDT inspections prevent failure and allow a proactive approach in equipment operation.
  
• Quality Assurance: In production, NDT ensures the product is up to required standards.
  
• Cost Savings: By preventing failure but also unnecessary repairs/replacement, NDT more often than not pays for itself.
  
• Compliance: Many authorities now require or advise NDT in inspections due to its much higher precision.

Some NDT techniques, such as visual inspection, eddy current testing (ECT) and ultrasonic testing (UT), thermal imaging can be automated, and this fact brought forth increased investment in robotic NDT systems for these methods.

Why Robotic NDT?

Replacing human operators who are prone to mistakes and OHS risks with much more reliable robots bring forth many advantages that improve precision, efficiency and safety. In addition, robots allow inspections to be carried out in places not easily accessible to operators and remove people from potentially hazardous environments. Thanks to all these, usage of automation and robotic inspection, especially to deal with difficult to access, remote and hazardous applications are gaining foothold.

• Even More Precise: Unlike human operators, robots can easily collect thousands of data-points, and are fully reproducible. For example, our RUVI Wallker system can collect a data-point every 1 mm from waterwalls, which is impossible for a manual application.
  
• Remote Inspections (No OHS Risks): Working at heights, in confined spaces or dangerous environments are no issue for robots. For example, our ATEX-certified RUVI OilDiver simply dives into oil tanks toxic and explosive hydrocarbons for bottom inspection while our RUVI WallKer climbs waterwalls without needing scaffolds.
  
• Much Faster Inspections: Automated robots can cut inspection times almost ten-fold. Remember, in industry, time is money!
  
• Detailed Reports: Robotics NDT can provide comprehensive reports, providing information on every minute detail. All iterations of inspection reports can also be stored indefinitely and compared with each other thanks to our web-based Inspection Management System, fil.

Robotic Inspection in Non-Destructive Testing yazısı ilk önce AIS Field üzerinde ortaya çıktı.