Safety Innovation Award 2024
The Safety Innovation Award shall recognise best health and safety practices and is intended to encourage EIGA member companies to look to promote best practice, learn and adopt new ideas that benefit their business, the health and safety of their employees, contractors and customers and the communities they work in.
The theme or focus area selected by the Board of Directors for the 2024 Safety Innovation Award was “Improving safety in/by Hydrogen related projects”, for which 12 submissions were received.
All applications were evaluated against each of the selection criteria, and SAC and BoD unanimously concluded that Air Products deserves the award for its project “Keyper Autonomous Robot” used for hydrogen plant inspection.
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Keyper: advancing plant safety and efficiency
Keyper, an autonomous robot operator for chemical plants, was developed through a collaboration between Air Products and Keybotic. This project stands out for its significant contribution to driving a safer and more efficient industry.
Innovative Features
Keyper is equipped with advanced technologies including video and acoustic recording, gas detection, and thermal imaging. It autonomously carries out plant inspection rounds, raising alarms if any process deviations are detected. This innovative approach leverages artificial intelligence to navigate and operate within industrial environments.
Objectives
The primary goal was to revolutionise plant inspection and deviation detection by deploying an autonomous robot. Keyper, engineered with advanced sensors and AI, serves as the frontline in maintaining operational integrity.
Inspection Capabilities
Keyper performs several critical functions during each inspection round:
- Instrument Reading: Accurately reads and interprets gauge needle positions for precise analysis.
- Video Surveillance: Captures video footage of unexpected movements for further evaluation.
- Thermal Detection: Identifies and records thermal deviations using a thermal camera.
- Audio Detection: Detects and analyzes sounds across various frequencies, alerting to abnormal signals.
- Atmospheric Analysis: Measures up to six different gas components and reports deviations to ensure safe operating conditions.
Reporting
Upon completing each inspection round, Keyper generates and uploads a detailed PDF report documenting its findings. Significant deviations or anomalies are immediately flagged and reported to the plant operator for prompt action.
Implementation
The project commenced in early 2023 as a proof of concept to evaluate Keyper's ability to navigate complex terrains and meet the demanding conditions of a chemical plant environment. Using an advanced 3D mapping system, Keyper created a comprehensive model of the plant, enabling seamless manoeuvring and accurate inspections. Inspection routes are memorized and can be programmed for regular schedules or activated remotely via a user tablet.
Benefits
Keyper, a Labrador-sized robot dog, represents a significant advance in plant integrity and safety, especially for facilities with reduced staffing during nights, weekends, or remote management. By deploying Keyper as the initial responder for process deviations, we eliminate the need to place employees and stakeholders in potentially dangerous situations.
Deployment
Keyper was presented and trained at the HYCO hydrogen production plant and the El Morell ASU (Air Separation Unit) in the Tarragona Chemical Complex, Spain. The positive trend in safety at the Tarragona Chemical Complex is largely due to ongoing investments in advanced technologies and digital innovations. Air Products, collaborating with Keybotic, has introduced Keyper, which plays a vital role in daily inspections, ensuring thorough and accurate inspections while elevating overall safety standards and operational efficiency.