Visual and 3D Modelling of EfW Boiler Using the Elios 3 Drone

DJM Aerial Solutions’ Approach

Using the Elios 3 drone, we conducted a thorough inspection of the boiler’s 1st, 2nd, and 3rd passes. The drone’s ability to fly in confined spaces allowed us to inspect areas that are difficult to access using traditional methods. Equipped with high-resolution cameras and LiDAR sensors, the drone captured precise data, enabling us to create an annotated 3D model of the boiler.

Key steps included:

• Identifying missing refractory tiles: Our inspection revealed several missing tiles that had been overlooked during the standard inspection process, exposing vulnerable tubes to extreme heat.
• Targeting tube leaks: By pinpointing specific tube leaks, we enabled the client to focus repairs on these areas, avoiding unnecessary scaffolding costs.
• Pre-deslag inspection: A pre-deslag inspection of the 1st pass provided crucial data, allowing the client to build a trend analysis of the boiler’s efficiency over time, which helps ensure balanced heat distribution across the asset.

Findings:

Our inspection uncovered multiple missing refractory tiles and several tube leaks, which, if left unaddressed, would have led to significant efficiency losses and further damage. By using the Elios 3’s advanced imaging capabilities, we were able to deliver precise locations of these issues, allowing the client to target repairs efficiently.
The annotated 3D model we produced allowed the client to pinpoint where scaffold should be built, drastically reducing the scope of scaffolding required for the repairs. Instead of spending £300,000 GBP on scaffolding for the entire boiler, the client was able to erect scaffolding only where needed, saving both time and money.

Results:

The use of drone technology, combined with the Elios 3’s ability to inspect confined and hazardous spaces, resulted in significant cost savings and operational efficiencies:

• Cost Savings: By targeting specific areas for scaffolding, the client saved hundreds of thousands of pounds. The overall cost of the inspection and targeted repairs was a fraction of the £300,000 GBP estimate for full scaffolding.
• Reduced Outage Time: The targeted approach to scaffolding and repairs significantly reduced the outage duration, allowing the client to resume operations sooner than planned.
• Improved Maintenance Strategy: The pre-deslag inspection provided valuable data that enabled the client to track boiler efficiency over time. This trend analysis will help the client optimise boiler operation, ensuring equalised heat distribution and improved overall performance.
• Preventative Maintenance: The discovery of exposed tubes due to missing refractory tiles helped prevent further damage that could have resulted in additional tube leaks, saving the client from costly future repairs.

Cost and Risk Comparison:

• Traditional Full Scaffolding Method:
  • Cost: £300,000 GBP for scaffolding, not including additional costs for loss of production during extended outage times.
  • Risk: Increased risk of undetected damage leading to inefficiencies and further unplanned maintenance in the future.
  • Outage Duration: 2-3 shifts just for scaffolding erection and dismantling, prolonging the outage.
• Drone Inspection with Targeted Repairs:
  • Cost: A fraction of the £300,000 GBP cost of full scaffolding.
  • Risk: Minimal risk, with early detection of critical issues allowing for preventative repairs.
  • Outage Duration: Significantly reduced, as scaffolding was only erected where needed, and repairs were targeted.

Pros and Cons of Drone Inspections for Boiler Maintenance

Pros:

• Cost Efficiency: Drone inspections eliminate the need for full scaffolding, reducing costs by hundreds of thousands of pounds.
• Early Detection of Critical Issues: The Elios 3 drone identified multiple missing refractory tiles and tube leaks that could have gone unnoticed, preventing future damage and loss of efficiency.
• Reduced Outage Time: Targeting specific areas for repair reduced the overall outage duration, allowing the client to resume operations more quickly.
• Comprehensive Data Collection: The pre-deslag inspection and 3D modelling provided valuable data for building a trend analysis of boiler efficiency, helping the client optimise future operations.
• Increased Safety: Drone inspections eliminate the need for personnel to enter hazardous areas, reducing the risk of accidents.

Cons:

• Weather Limitations: Although this inspection took place during a planned outage, external weather conditions could affect drone operations in other scenarios.
• Initial Setup for 3D Modelling: While the creation of 3D models is highly valuable, it requires expert analysis and can take time to process depending on the complexity of the asset.

Conclusion:

This case study demonstrates how DJM Aerial Solutions’ use of the Elios 3 drone allowed for a comprehensive inspection of an EfW boiler during a planned outage, uncovering critical issues such as missing refractory tiles and tube leaks. By providing detailed data and a targeted 3D model, we enabled the client to perform repairs with minimal scaffolding, saving hundreds of thousands of pounds and significantly reducing the outage duration. Additionally, the pre-deslag inspection provided the client with valuable insights for optimising boiler performance over time, ensuring a more efficient and cost-effective operatio