Case Study: JT Wall-Climbing Robots Eliminate Confined Space Risk in Singapore Refinery Tank Maintenance
At a Glance
- Location: Pulau Bukom Refinery, Singapore , Southeast Asia’s largest petroleum complex
- Asset: 8 × crude oil storage tanks, 30m diameter, 18m height, combined 3,200 m² surface area
- Challenge: Severe atmospheric corrosion on tank external walls; manual scaffolding unsafe, slow, and costly in confined refinery spacing
- Solution: Jingtao Energy JT-2 and JT-1-F wall-climbing robots , fully automated surface preparation (SA 2.5) and anti-corrosion coating application
- Result: 3,200 m² completed in 12 days, zero confined space entry incidents, 85% cost reduction vs. scaffolding, coating adhesion 18.3 MPa (ISO 4624)
The Challenge: Tropical Corrosion Meets Confined Space Risk
Singapore’s Pulau Bukom Refinery , a Shell-owned complex processing 500,000 barrels per day , faced a recurring maintenance bottleneck in 2025. Eight crude oil storage tanks, each 30 meters in diameter and 18 meters high, required full external anti-corrosion treatment under the facility’s 5-year integrity management program.
The tanks sit in tight rows with only 4.5 meters between shells , far below OSHA’s minimum clearance for traditional scaffolding. Each tank shell showed grade D rust staining with localised pitting up to 0.8 mm deep, accelerated by Singapore’s 80% average humidity and salt-laden marine air from the Malacca Strait. The refinery’s HSSE team flagged three critical concerns:
- Confined space hazard: Inter-tank spacing created a confined space classification per Singapore WSH Regulations , mandatory gas monitoring, rescue teams, and 45-minute work-rest cycles for manual crews
- Production impact: Full scaffolding erection would require 12-week tank-by-tank shutdown sequencing, disrupting the refinery’s crude throughput schedule
- Quality inconsistency: Previous manual blasting achieved only SA 2.0 on 40% of inspected areas, leading to premature coating failure within 18 months
The Solution: Jingtao Energy JT Wall-Climbing Robot Fleet
Jingtao Energy proposed a robotic anti-corrosion package deploying its flagship JT-2 Large, Four-Wheel-Drive Wall-Climbing Robot for the tank shell bulk areas and the JT-1-F Grinding and Rust Removal Robot for weld seams, nozzles, and edge zones.
The JT-2 robot’s 4-wheel magnetic drive system delivers 2,500 N of adhesion force , enough to carry a 45 kg payload on vertical surfaces while traversing weld seams up to 8 mm high. Its 280 MPa ultra-high-pressure water jet system strips existing coatings and corrosion products to SA 2.5 (near-white metal) standard in a single pass at 300 m² per day. The JT-1-F complements this with a diamond-grinding end-effector for tight-radius nozzle cutouts and weld profiling , areas where water jet alone cannot maintain consistent standoff distance.
Key Technical Specifications
- Robot model: JT-2 (primary) + JT-1-F (precision zones)
- Surface prep standard: SA 2.5 (ISO 8501-1), verified by Testex Press-O-Film replica tape
- Coating system: 3-layer epoxy/zinc/epoxy , 350 μm DFT, applied via airless spray end-effector
- Coverage rate: 280, 320 m² per day per robot, operating 18 hours/day (night shift with LED illumination)
- Safety: Redundant magnetic adhesion, tether cable with auto-brake, ATEX Zone 2 certified electronics
- Remote control: Operator stationed 20m from work zone, outside confined space perimeter
Implementation: 12-Day Blitz Deployment
The 8-tank campaign was executed in Q3 2025 over 12 consecutive days with two JT-2 robots and one JT-1-F operating simultaneously. Each tank required three phases:
- Surface preparation (Day 1, 3): JT-2 robots stripped existing coating and corrosion to SA 2.5. Dust and debris contained by integrated vacuum shrouds , no secondary containment scaffolding required. Profile measured at 65, 85 μm, Rz.
- Coating application (Day 4, 5): Airless spray end-effector applied 3-coat system. Wet film thickness monitored in real time via laser gauge; dry film thickness verified post-cure at 350 μm ± 25 μm.
- QA/QC inspection (Day 6): Holiday detection at 5 kV (ASTM D5162), pull-off adhesion testing at 18.3 MPa average (ISO 4624, minimum spec 5 MPa).
A Singapore MOM-certified safety officer oversaw the entire campaign. Zero confined space entries were required , all robotic operations were controlled from outside the 4.5-meter inter-tank zone. The refinery’s own data showed that a manual crew using scaffolding would have required 390 confined space entries over the equivalent scope.
Results: Verified by Third-Party Inspection
| Metric | Manual Scaffolding (Historical) | JT Robot Fleet (This Campaign) |
|---|---|---|
| Surface Area | 3,200 m² | 3,200 m² |
| Duration | 90 days | 12 days |
| Crew Size | 32 workers | 3 operators |
| Confined Space Entries | ~480 person-entries | 0 |
| Surface Prep Standard | SA 2.0 (inconsistent) | SA 2.5 (verified) |
| Coating Adhesion (ISO 4624) | 10.2 MPa | 18.3 MPa |
| Total Project Cost | ~$670,000 | ~$98,000 |
| Cost per m² | $209 | $31 |
| Safety Incidents | 4 recordable (previous campaign) | 0 |
| Production Impact | 8 tanks offline for 12 weeks | 8 tanks offline for 12 days |
The $98,000 robotic campaign cost included equipment rental, two Jingtao Energy field engineers, local logistics, and third-party inspection by SGS Singapore. At $670,000, the manual alternative would have cost 6.8 times more , and would have stretched the project across three months of disrupted refinery operations.
Why This Matters for Tank Farm Operators
- Abolish confined space risk. The JT robot fleet eliminates the single largest safety hazard in storage tank maintenance , human entry into confined inter-tank zones. Operators remain outside the perimeter at all times. See our deep dive: The “90/10 Rule” vs. 100% Automation.
- SA 2.5 every time. Robotic surface preparation achieves consistent near-white metal standard across 100% of the surface , impossible with manual blasting where operator fatigue causes quality drift. Read: Robotic vs. Manual Anti-Corrosion: Breaking the Scaffolding Deadlock.
- 7× faster, 85% cheaper. 12 days vs. 84 days. $98k vs. $670k. The economics are so one-sided that the refinery’s procurement team accelerated their 2026 robotic maintenance budget by 18 months. See the full analysis: Robots vs. Workers: The Economic Ledger of Wall-Climbing Equipment.
- Multi-surface capability. Beyond storage tanks, the JT platform handles ship hulls, wind turbine towers, bridge pylons, and FPSO modules. The modular end-effector system enables grinding, UHP water jetting, and airless spray coating from the same robot base. Learn more: Modular Robotic End-Effector: The Future of Multi-Task Wall-Climbing Robots.
Explore the JT Robot Family
- JT-2 Large, Four-Wheel-Drive Wall-Climbing Robot , 2,500 N adhesion, 280 MPa water jet, 300 m²/day
- JT-1-F Grinding and Rust Removal Robot , Diamond grinding for weld seams, nozzles, and edge profiling
- JT-1-H Underwater Robot for Marine Biofouling Cleaning , Subsea hull and intake structure maintenance
- JT-1-S Marine Robot for High-Pressure Water Jetting , Ship hull and marine structure rust removal above waterline
- JT-1 Miniature Wall-Climbing Robot (Explosion-Proof) , ATEX/IECEx certified for Zone 1 hazardous areas, 18 kg, 200 m²/day
Related Technical Resources
- Blog: Real Reviews from Frontline Operators on Wall-Climbing Robots , Unfiltered feedback from refinery maintenance crews
- Blog: From “Crawling” to “Working” , Mechanical Compensation for Wall-Climbing Robots
- Blog: Magnetic vs. Vacuum , The “Wall-Clinging Kung Fu” of Wall-Climbing Robots
- Blog: Beyond Paint and Patch , Why Automated Corrosion Protection is a Strategic Investment
- Blog: Confined Space, Zero Risk , Automating Tank and Hull Maintenance
- Blog: Decoding the “Lights-Out Factory” , Power Catwalk and Robotic Integration
- Blog: Deep Sea & High Salinity , The “Dual-Wall” Anti-Corrosion Process for Offshore Equipment
Ready to Eliminate Confined Space Risk from Your Tank Maintenance?
Every tank farm is different , diameter, height, coating specification, inter-tank spacing, and hazardous area classification all shape the robotic solution. Jingtao Energy’s engineering team will review your asset drawings and return a site-specific robotic deployment plan within 72 hours. No scaffolding. No confined space entries. No compromises on surface preparation quality.
📊 Download JT Robot Technical Datasheet , Full specifications, adhesion test data, ATEX certificates, and surface preparation comparison charts.
📞 Talk to a Robotics Engineer , Direct line to our wall-climbing robot specialists in Dongying.
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Technology FAQ
Can wall-climbing robots eliminate the need for confined space entry during tank maintenance?
Yes. Jingtao magnetic wall-climbing robots perform surface preparation, coating removal, and inspection remotely from outside the confined space. This reduces permit-to-work requirements by over 90% and eliminates worker exposure to toxic atmospheres and fall hazards.