ACC Duct Inspection at an Energy from Waste Facility in Milton Keynes
DJM Aerial Solutions recently completed a specialist confined space drone inspection of Air Cooled Condenser ducting at an Energy from Waste facility in Milton Keynes over the bank holiday weekend outage period.
The project involved the internal inspection of critical ACC duct infrastructure using the Flyability Elios 3 confined space drone, allowing engineering teams to assess the internal condition of the ducting system safely, efficiently, and without the requirement for confined space entry or extensive access equipment.
The inspection formed part of the facility’s planned outage programme and provided valuable visual inspection data to support asset integrity assessment and maintenance planning ahead of recommissioning activities.
The Importance of ACC Ducting Within Energy from Waste Facilities
Air Cooled Condensers play a critical role within Energy from Waste and biomass power generation facilities.
The ACC system is responsible for condensing steam exiting the turbine cycle while maintaining efficient thermal performance across the plant.
Large air supply duct systems feeding the ACC infrastructure are subjected to continuous operational stresses including:
Thermal cycling
Vibration
Pressure fluctuation
Airborne contamination
Moisture exposure
Mechanical loading
Over time, these operational conditions can contribute to deterioration within the ducting system including corrosion, fatigue cracking, joint deterioration, and coating degradation.
Routine inspection of these assets is essential for maintaining operational efficiency and identifying developing issues before they escalate into major maintenance concerns.
Challenges Associated With Traditional Inspection Methods
The ACC duct infrastructure at the Milton Keynes facility presented significant access challenges for conventional inspection methods.
The ducting systems were positioned at substantial height within a congested industrial environment and contained restricted internal access points that would traditionally require:
Confined space entry teams
Working at height access systems
Extensive scaffolding
Rescue team support
Permit controlled entry procedures
Operational restrictions during inspection activities
In many cases, traditional inspection methods introduce increased safety exposure, extended downtime, and significant logistical complexity.
Additionally, accessing the internal sections of industrial ducting manually can be both time consuming and commercially disruptive during tightly controlled outage schedules.
Confined Space Drone Inspection Using the Elios 3
To overcome these access challenges, DJM Aerial Solutions deployed the Flyability Elios 3 confined space inspection drone.
The Elios 3 is specifically designed for navigating complex industrial environments and GPS denied confined spaces where conventional drones cannot safely operate.
Its collision tolerant carbon fibre cage allows safe interaction with surrounding structures while maintaining stable flight performance within restricted environments.
The platform incorporates:
High resolution visual inspection cameras
Powerful integrated LED lighting
Real time live video transmission
Ultra stable flight control systems
Precise manoeuvrability within confined spaces
This capability allowed our inspection team to safely navigate internally within the ACC ducting system while delivering live inspection footage directly to engineers and client representatives.
Inspection Scope
The inspection programme focused on conducting a detailed close visual inspection of the internal ACC ducting infrastructure.
Inspection areas included:
Internal duct walls
Circumferential seams
Longitudinal seams
Expansion joints and bellows
Structural interfaces
Areas showing potential corrosion or coating degradation
General internal condition assessment
The Elios 3 platform enabled detailed inspection coverage throughout the ducting system while maintaining safe remote operation from outside the confined space.
Benefits of Drone Inspection for ACC Infrastructure
The project demonstrated several significant advantages associated with confined space drone inspection technology within Energy from Waste facilities.
Elimination of Confined Space Entry
The most significant benefit was the removal of the requirement for personnel to physically enter the ducting system.
This dramatically reduced risk exposure while simplifying inspection planning and execution.
Reduced Downtime During Planned Outages
Using the Elios 3 allowed inspection activities to be completed rapidly during the bank holiday outage window, minimising disruption to wider maintenance activities across the site.
Improved Inspection Accessibility
The drone platform enabled access to difficult to reach internal areas that would have been extremely challenging using traditional inspection methods.
High Resolution Visual Data
The inspection generated detailed visual imagery and recorded footage that engineering teams can review remotely to support maintenance and asset integrity decisions.
Reduced Working at Height Exposure
Drone deployment eliminated the requirement for extensive manual access solutions and significantly reduced working at height activities around the ACC infrastructure.
Supporting Asset Integrity and Maintenance Planning
The visual inspection data captured during the survey provides valuable intelligence for engineering teams responsible for managing the long term condition of critical Energy from Waste infrastructure.
Inspection outputs support:
Preventative maintenance planning
Condition trending
Repair prioritisation
Outage planning
Operational reliability strategies
Long term asset management programmes
Drone inspection does not replace engineering assessment, however it provides high quality visual evidence that allows engineers to make more informed maintenance decisions.
The Growing Role of Drone Technology Within Energy from Waste Facilities
Energy from Waste facilities continue to adopt advanced remote inspection technologies to improve safety, efficiency, and inspection accessibility across difficult to access assets.
Applications increasingly include:
ACC inspections
Boiler inspections
Gas pass inspections
Ducting inspections
Stack inspections
Cyclone inspections
Pipework inspections
Thermographic surveys
Confined space drone technology is now becoming an invaluable tool within modern asset integrity programmes throughout the UK power generation sector.
Frequently Asked Questions for ACC Duct Drone Inspection
An ACC duct inspection involves assessing the internal condition of Air Cooled Condenser ducting systems used within Energy from Waste and biomass facilities.
ACC ducting is critical for maintaining airflow efficiency and thermal performance across the condenser system. Deterioration or damage can negatively impact plant performance and operational reliability.
DJM Aerial Solutions used the Flyability Elios 3 confined space inspection drone for the internal inspection of the ACC ducting infrastructure.
The ducting systems were difficult to access and positioned at height within a complex industrial environment. Drone technology removed the need for confined space entry, scaffolding, and prolonged working at height exposure.
The inspection covered internal duct walls, circumferential seams, longitudinal seams, expansion joints, bellows, and general structural condition.
Yes. The Elios 3 is specifically designed for confined space inspections and incorporates a collision tolerant protective cage for safe operation within restricted industrial environments.
Key benefits include improved safety, reduced downtime, rapid inspection deployment, reduced access costs, and high resolution visual inspection data.
No. Drone inspection provides visual inspection intelligence that supports engineering evaluation, maintenance planning, and asset integrity programmes.
Energy from Waste facilities, biomass plants, petrochemical infrastructure, power generation sites, and heavy industrial manufacturing facilities all benefit from confined space drone inspection technology
Yes. Drone inspections are commonly carried out during planned outage periods because they can be completed quickly and efficiently with minimal disruption to wider maintenance activities.
Supporting Safer Industrial Inspection Strategies
The successful completion of this ACC duct inspection in Milton Keynes further demonstrates how confined space drone technology is helping industrial operators reduce risk while improving access to critical infrastructure.
By combining high resolution visual inspection capability with safe remote access, facilities can reduce downtime, minimise safety exposure, and improve inspection efficiency during planned outage activities.
For Energy from Waste operators managing complex infrastructure under demanding outage schedules, drone inspection provides a safer, faster, and more commercially efficient inspection solution.
Planning Your Next ACC or Boiler Inspection
DJM Aerial Solutions provides specialist confined space drone inspections across Energy from Waste, biomass, petrochemical, and power generation facilities throughout the UK.
We offer:
CAA authorised drone operations
Confined space trained operators
Rapid nationwide mobilisation
High resolution visual inspection reporting
Inspection support aligned with outage schedules and asset integrity programmes
If you are planning an upcoming outage or require inspection support for difficult access industrial infrastructure, contact DJM Aerial Solutions to discuss how confined space drone technology can support your inspection strategy.