Internal Ducting Inspection Within a Biomass Facility Using Elios 3 Drone Technology
Air handling and ducting systems within biomass and Energy from Waste facilities play a critical role in maintaining efficient plant operation. Restricted airflow, structural degradation, internal contamination, or mechanical damage within these systems can directly impact the performance of downstream assets such as Air Cooled Condensers (ACC), fans, filtration systems, and heat exchange equipment.
DJM Aerial Solutions recently completed an internal drone inspection of large air supply ducting within a biomass facility using the Flyability Elios 3 confined space inspection drone. The ducting formed part of the air supply system feeding the site’s ACC infrastructure and required internal visual assessment to determine its overall condition.
Using confined space drone technology, we were able to safely navigate the internal ductwork and provide the client with high resolution visual inspection data without the need for intrusive access methods, prolonged downtime, or confined space entry.
The Importance of Ducting Inspection in Biomass Facilities
Industrial ducting systems operating within biomass and power generation environments are exposed to demanding operating conditions.
Over time, internal ductwork may experience:
Corrosion and coating degradation
Dust and particulate build up
Structural fatigue
Mechanical damage or distortion
Joint separation or leakage
Internal contamination restricting airflow
Where ducting forms part of the air supply system feeding an ACC or other critical process equipment, any reduction in airflow efficiency can negatively impact plant performance.
Routine inspection of these systems is therefore essential to support preventative maintenance strategies and maintain operational efficiency.
Inspection Challenges Within Industrial Ducting Systems
Large industrial ducting networks are often extremely difficult to inspect using traditional methods.
Internal access may require:
Confined space entry teams
Isolation of surrounding systems
Temporary access equipment
Scaffold erection
Permit controlled access procedures
Extended shutdown periods
In many cases, the geometry of ducting systems also presents additional challenges. Long horizontal runs, restricted dimensions, sharp transitions, and internal supports can make manual inspection difficult and time consuming.
Within operational biomass facilities, minimising downtime while maintaining safe inspection practices is commercially critical.
Drone Based Internal Ducting Inspection
To overcome these challenges, DJM Aerial Solutions deployed the Elios 3 confined space drone.
The Elios 3 platform is specifically designed for operating within GPS denied industrial environments where conventional drone systems cannot safely function.
The platform offers:
Collision tolerant protective cage
Stable flight within confined spaces
High intensity onboard lighting
High resolution visual inspection cameras
Real time live video feedback
Precise manoeuvrability within restricted environments
These features make the Elios 3 highly effective for internal inspection of ducting, process ventilation systems, flues, stacks, and associated industrial infrastructure.
Inspection Scope
The inspection focused on assessing the internal condition of the biomass facility’s ACC air supply ducting.
Our objectives included:
Visual assessment of internal ducting condition
Identification of corrosion or coating failure
Inspection for mechanical damage or distortion
Review of internal contamination or particulate build up
Assessment of structural support condition where visible
Identification of airflow restrictions or obstructions
Using the Elios 3, the inspection team safely navigated the internal ductwork while transmitting live high resolution footage directly to the client and engineering personnel.
This allowed areas of concern to be reviewed immediately during the inspection process.
Benefits of Using Drone Technology for Internal Ducting Surveys
The use of confined space drone technology provides substantial operational and safety benefits when compared with traditional access methods.
Reduced Confined Space Exposure
The drone performs the inspection remotely, significantly reducing the requirement for personnel to enter hazardous confined environments.
Faster Inspection Delivery
Traditional access methods involving scaffold or confined space teams can require days of preparation. Drone deployment allows inspections to be completed within hours.
Minimal Operational Disruption
Drone inspection minimises downtime and reduces disruption to surrounding plant infrastructure.
High Resolution Visual Data
The Elios 3 captures detailed imagery that supports engineering assessment and maintenance planning.
Access to Difficult Areas
Internal ducting often contains restricted or elevated sections that are impractical to inspect manually. Drone technology allows these areas to be accessed safely and efficiently.
Supporting Asset Integrity and Maintenance Planning
The visual inspection data captured during the survey provides valuable information to engineering and maintenance teams responsible for managing the facility’s asset integrity programme.
Inspection outputs support:
Maintenance planning
Identification of deterioration trends
Repair prioritisation
Condition monitoring between shutdowns
Operational efficiency reviews
Drone inspection does not replace engineering evaluation but instead provides high quality visual intelligence that supports informed maintenance decision making.
Frequently Asked Questions for Industrial Ducting Drone Inspection
An internal ducting drone inspection uses confined space UAV technology to visually assess the condition of industrial ductwork without requiring personnel to enter the asset.
Ducting systems are critical for maintaining airflow efficiency within biomass plants. Corrosion, contamination, or structural damage can reduce system performance and negatively impact associated equipment such as Air Cooled Condensers.
DJM Aerial Solutions used the Flyability Elios 3 confined space inspection drone, specifically designed for operating safely within GPS denied industrial environments.
Drone inspections can identify corrosion, coating failure, structural deformation, mechanical damage, particulate build up, airflow restrictions, and internal contamination.
In most cases, yes. Isolation requirements depend on the operational status of the system and site specific safety procedures.
Drone inspection significantly reduces the need for confined space entry, minimising personnel exposure to hazardous environments and working at height risks.
Many internal ducting inspections can be completed within hours, compared with days required for scaffold installation and traditional access methods.
Clients typically receive high resolution imagery, recorded inspection footage, annotated observations, and condition reporting to support maintenance planning.
Yes. Drone inspections are rapidly deployed and minimise disruption to plant operations, helping operators reduce outage durations and inspection costs.
Industries including biomass, Energy from Waste, petrochemical processing, power generation, manufacturing, and heavy industrial facilities all benefit from confined space drone inspection technology.
Applications Across Biomass and Power Generation Facilities
Confined space drone inspection technology is increasingly being used across the biomass, EfW, and power generation sectors for inspection of:
Air supply ducting
ACC infrastructure
Boiler gas passes
Flue gas systems
Stacks and chimneys
Cyclones and separators
Ventilation systems
Process pipework and containment systems
As facilities continue to prioritise safety, operational efficiency, and cost control, drone inspection is becoming a standard tool within industrial maintenance programmes.
Supporting Long Term Plant Reliability
The successful completion of this internal ducting inspection highlights the growing role of drone technology within modern industrial inspection strategies.
By combining high resolution visual inspection with safe remote access capability, operators gain improved visibility of critical infrastructure while reducing downtime, limiting personnel exposure, and improving maintenance planning efficiency.
For biomass and power generation operators, this approach delivers a practical and commercially effective solution for inspecting difficult to access assets.
Planning Your Next Internal Ducting Inspection
DJM Aerial Solutions provides specialist confined space drone inspections for biomass facilities, Energy from Waste plants, petrochemical infrastructure, and heavy industrial environments across the UK.
We offer:
CAA authorised operations
Confined space trained inspection teams
High resolution inspection reporting
Rapid deployment nationwide
Inspection support for asset integrity programmes
If you are planning shutdown works, investigating airflow performance issues, or reviewing internal infrastructure condition, contact DJM Aerial Solutions to discuss how drone inspection technology can support your inspection strategy.