Aerial Thermography Survey of Air Cooled Condensers in Energy from Waste Plants
Detecting Leaks and Thermal Inefficiencies Without Shutdowns or Risk
Air Cooled Condensers (ACCs) are a critical component of the energy generation process, particularly in the Energy from Waste (EfW) sector, where heat transfer efficiency has a direct impact on plant performance and profitability. However, the large footprint, elevated position, and complex piping structure of ACCs can make routine condition monitoring both time-consuming and high-risk using traditional methods.
At DJM Aerial Solutions, we’ve developed a proven, efficient approach: aerial thermography surveys using drone-mounted thermal sensors. This technique allows us to quickly and accurately detect thermal anomalies—including leaks, blockages, or cooling inefficiencies, across the full surface area of the ACC, without physical access or downtime.
Why ACCs Need Thermal Inspection
ACCs are exposed to extreme operating conditions and consist of thousands of finned tubes, manifolds, and structural joints. Over time, they are prone to:
Tube leaks
Blocked or inefficient fans
Uneven cooling distribution
Weld or joint fatigue
Degraded thermal performance
Leaks or thermal inefficiencies in just one section can compromise the efficiency of the entire system, increase back pressure, reduce power output, and introduce risks of contamination.
How Aerial Thermography Works
Using our Matrice 300 RTK platform paired with a radiometric thermal sensor, we conduct a high-resolution aerial scan of the ACC during live operation. This process includes:
Hovering directly above and alongside the ACC deck
Capturing radiometric thermal imagery to detect heat signatures
Mapping temperature variations across the system
Identifying abnormal hot or cold spots indicative of fluid leaks or blockages
Overlaying thermal data with RGB imagery for precise defect location
Because we collect this data in real-time, engineers can quickly prioritise maintenance efforts based on accurate, visualised thermal output.
Benefits of Thermal Drone Survey for ACCs
Non-Intrusive
No shutdowns, scaffolding, or rope access required. All surveys are performed while the system remains operational.
Faster Identification of Leaks
Thermal anomalies are immediately visible, allowing fast diagnosis of tube leaks, failed manifolds, or disconnected components.
Safer Inspections
No need for personnel to climb structures, work at height, or enter restricted zones.
High-Resolution Radiometric Data
Every image contains precise temperature readings, aiding in root-cause analysis and maintenance planning.
Accurate and Repeatable
Surveys can be repeated over time to monitor thermal performance trends and validate completed repairs.
Who Benefits from Aerial Thermography?
While we’ve delivered this method successfully across Energy from Waste sites, the technique is equally effective for:
Power generation plants (gas, biomass, CHP)
Industrial cooling towers
Data centres and HVAC systems
Refineries and process plants
District heating networks
Any site with elevated cooling assets stands to gain from faster, safer, more cost-effective condition monitoring.
Deliverables We Provide
After each thermal survey, clients receive:
Annotated radiometric thermal imagery
RGB overlay and visual references
Defect mapping and asset-level reporting
Optional thermographic video or 3D model
Comparison reports for follow-up surveys
All data is compiled in an engineer-friendly report, with key findings clearly identified for rapid decision-making.
Frequently Asked Questions About Drone Surveys
Aerial thermography uses drone-mounted thermal cameras to detect temperature differences across infrastructure, revealing defects like leaks, blockages, or inefficiencies.
ACC inspections via drone are faster, safer, and can be done during live operation. They detect anomalies without the need for shutdowns or scaffolding.
Yes. Leaks and underperforming cells show up as abnormal hot or cold spots in the thermal profile, allowing for precise defect detection.
No. Our thermal inspections are conducted during live operation, making it completely non-intrusive
We use the Matrice 300 RTK platform paired with a high-resolution radiometric thermal sensor to capture accurate and detailed data.
Our thermal sensors provide radiometric readings with temperature accuracy within ±2°C or ±2%, depending on conditions and configuration.
Energy from Waste, biomass, gas power, district heating, and any facility with elevated cooling infrastructure.
Annotated thermal images, RGB overlays, defect maps, visual reports, and optional thermographic video or 3D model outputs.
Reports are typically delivered within 48–72 hours of survey completion, depending on project complexity.
We operate nationwide across the UK, with rapid deployment available for urgent inspections or planned maintenance support.
Why Choose DJM Aerial Solutions?
Extensive experience surveying ACCs and energy infrastructure
CAA-approved, fully insured, and trained in thermographic analysis
Ability to deploy nationwide with fast mobilisation
Trusted by major EfW operators and facility managers
Proven process with measurable operational benefits
Book Your Thermal Drone Survey
If you operate Air Cooled Condensers or other high-level thermal infrastructure, our aerial thermography surveys offer a powerful tool for leak detection, efficiency monitoring, and risk mitigation.
We help you save time, reduce risk, and protect your bottom line with accurate, non-intrusive drone data.
Contact us today to book your survey or request a quote.