DTEK, a leading energy company in Ukraine, recently conducted trials of the Elios 2 drone for inspecting a chimney and a boiler at one of their power plants. The Elios 2 proved to be a game-changer, capturing inspection data far more swiftly than traditional methods while eliminating the risks associated with dangerous climbs for personnel.

Key Benefits at a Glance

Company Overview

DTEK stands as Ukraine's largest private investor in the energy sector, operating numerous power plants across the country. These facilities rely heavily on massive chimneys and boilers to generate electricity and deliver energy services.

Regular inspections of these critical components are essential to prevent unexpected failures and ensure smooth operations. A minor issue like a scratch on one of the boiler’s steel pipes, if unnoticed, could escalate into significant damage over time, affecting productivity and increasing repair expenses.

Client Requirements

Both chimneys and boilers at DTEK’s power plants pose distinct challenges for routine inspections.

The chimneys tower at 180 meters (590 feet) high and are constructed from bricks. Professional industrial climbers are brought in by DTEK to scale the entire structure using specialized, extra-long ladders. As they ascend, they conduct a visual inspection before descending via a rope.

Boilers, standing at 45 meters (147 feet), necessitate scaffolding to access their interiors. Setting up this scaffolding involves eight workers laboring for a full day, transporting 8,000 kilograms (17,636 pounds) of metal components into position.

These inspection techniques are expensive due to the labor-intensive nature, material requirements, and operational downtime. Every moment a chimney or boiler is offline translates into lost revenue from power generation. The downtime is particularly pronounced for boilers, requiring an additional two days for scaffolding assembly and dismantling.

Beyond the financial implications, there are significant safety concerns for personnel involved in these inspections. DTEK has long sought alternative inspection solutions to mitigate risks while maintaining operational efficiency.

Moreover, DTEK’s maintenance records indicate that only about 20% of chimney and boiler inspections result in necessary repairs. In these cases, someone would still need to climb ladders or navigate scaffolding to carry out maintenance tasks. However, the remaining 80% of inspections simply require remote visual data collection. This insight prompted DTEK to explore reliable remote visual data acquisition methods for their chimneys and boilers.

Implementation Strategy

The concept of using drones for remote visual data collection emerged among DTEK staff roughly a year ago. After preliminary research, they learned that most drones cannot operate indoors due to GPS limitations and the risk of collision in confined spaces.

However, they discovered the Elios 2, a drone specifically designed for indoor inspections. Encased in a protective cage, the Elios 2 can bump into obstacles within indoor environments and continue flying uninterrupted. DTEK partnered with DroneUA, a local drone provider, to trial this innovative technology.

The Elios 2 operates without GPS and offers unique features tailored to DTEK’s needs, including distance lock, stabilization, and oblique lighting. This final feature mimics the effect of inspectors moving a flashlight around an object, revealing textures and depths that a direct light source might miss.

Outcomes

The Elios 2 was deployed to inspect one chimney and one boiler at a DTEK power station.

Chimney Inspections with the Elios 2

The Elios 2 ascended from the base to the summit of the chimney, collecting data simultaneously with both visual and thermal cameras. Three flights sufficed to gather comprehensive inspection data.

Inspectors marveled at the high-quality visuals obtained and believed this approach could replace the need for climbers ascending ladders to conduct visual inspections. They also appreciated the speed of data collection—three flights took approximately thirty minutes, compared to the several hours required for a manual inspection.

Boiler Inspections with the Elios 2

Following the chimney inspection, DTEK personnel utilized the Elios 2 for a boiler inspection at the same facility.

Inspectors piloted the Elios 2 into the boiler and systematically gathered visual data from every section. Within an hour, the drone amassed all the visual data needed. A manual inspection of the same scope would have taken an entire day to complete.

[Related reading: Inspecting a Recovery Boiler by Drone]

The boiler inspection proved more challenging than the chimney due to its intricate design, featuring countless small steel pipes requiring meticulous examination. A single scratch on one of these pipes, if left undetected, could eventually render the boiler inoperable. Traditionally, detecting such flaws involves sending low-pressure water through the pipes to identify leaks, but this method is time-consuming and labor-intensive.

With the Elios 2, inspectors rapidly captured visual data that pinpointed potential leaks. Performing the same task manually with a flashlight would have taken considerably longer.

Final Thoughts

The trials of the Elios 2 for chimney and boiler inspections were highly successful, prompting DTEK personnel to investigate integrating drone inspections into their regular maintenance routines.

Thanks to the efficiency of Elios 2 inspections, DTEK anticipates being able to conduct inspections more frequently, thereby identifying potential issues earlier and enhancing both asset safety and longevity.

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