Client: Stolthaven Tank Farm (on behalf of TUV)
Location: Dagenham, United Kingdom
Service: Confined Space Drone Inspection of Bulk Storage Tank
Project Overview
DJM Aerial Solutions was commissioned to perform an internal inspection of a bulk storage tank at Stolthaven Tank Farm in Dagenham. The tank, containing bitumen, had a diameter of approximately 30 metres and stood at a height of 20 metres. As the tank had never been inspected previously, the client was concerned about potential corrosion above the fluid line and the structural integrity of the roof.
Traditionally, inspecting such a large storage vessel would require erecting internal scaffolding throughout the tank, a costly and time-consuming endeavour estimated at around £200,000. In contrast, DJM Aerial Solutions completed the inspection using the Elios 3 confined space drone for less than £6,000, delivering an annotated 3D model and comprehensive visual data that exceeded the client’s expectations.
This project not only demonstrated the cost-efficiency and safety benefits of drone technology but also established DJM Aerial Solutions as the preferred drone inspection provider for TUV.
Challenges of Traditional Inspection Methods
Bulk storage tank inspections are typically challenging due to the confined space, hazardous atmosphere, and the scale of the internal structure. The client explored traditional inspection methods, both of which presented significant drawbacks:
Option 1: Internal Scaffolding and Manual Inspection:
This approach involves erecting scaffolding throughout the entire interior of the tank, allowing personnel to perform a close visual inspection of the structural elements, including the walls, roof supports, and weld seams. However, this method posed several challenges:
- High Costs: Erecting and dismantling scaffolding for a 30m diameter and 20m high tank was estimated at approximately £200,000.
- Operational Downtime: The tank would need to be emptied, cleaned, ventilated, and remain out of service for several weeks, resulting in significant production downtime and revenue loss.
- Safety Risks: Personnel would need to work at height within a confined space, increasing the risk of accidents and exposure to hazardous gases.
Option 2: Rope Access Inspection:
Alternatively, rope access technicians could be deployed to inspect the internal structure. However, this method also presented issues:
- Safety Risks: Rope access involves working at height within a confined space, posing safety risks such as falls, entrapment, and exposure to hazardous gases.
- Inconsistent Data Capture: Manual inspection by rope access is subject to human error, potentially resulting in inconsistent and subjective data.
- Limited Reach and Accessibility: Rope access technicians are limited by their harness positions and cannot always access all areas, particularly complex structural elements or hard-to-reach corners.
Both traditional methods were costly, time-consuming, and posed considerable safety risks.
DJM Aerial Solutions’ Approach
DJM Aerial Solutions proposed an innovative alternative by deploying the Elios 3 confined space drone. Specifically designed for internal inspections of hazardous environments, the Elios 3 features a rugged caged design to navigate complex structures, advanced collision avoidance sensors, and a high-resolution LiDAR sensor for generating detailed 3D models.
The Elios 3 was utilised to conduct a comprehensive internal inspection of the 30m diameter, 20m high bulk storage tank, delivering:
- High-Resolution Visual Inspection: The drone’s high-definition camera provided detailed imagery of the tank’s internal structure, weld seams, and roof supports.
- 3D LiDAR Mapping: Utilising the onboard LiDAR sensor, DJM Aerial Solutions created an annotated 3D model of the entire storage tank, enabling the client to visualise structural elements and assess the overall condition with precision.
- Non-Destructive Testing: The inspection was conducted without requiring personnel to enter the confined space, ensuring zero risk to human life.
- Real-Time Data Analysis: The drone’s live feed allowed for real-time decision-making and collaboration with the client during the inspection process.
Our approach enabled us to:
- Eliminate the need for internal scaffolding or rope access: This resulted in significant cost savings and minimised safety risks.
- Maintain operational continuity: The inspection was performed without the need to clean, ventilate, or shut down the tank, preventing any loss of production or revenue.
- Capture actionable data: The high-resolution imagery and 3D LiDAR model provided the client with accurate and comprehensive data for informed decision-making.
Drone Inspection Findings
The client was particularly concerned about potential corrosion above the fluid line within the bulk storage vessel. However, the inspection revealed that the tank was in excellent condition:
- No signs of corrosion were identified above the fluid line or on any structural elements.
- Structural Integrity of the Roof: The drone’s high-resolution imagery confirmed that the roof supports and structural elements were in exceptional condition, with no visible defects or wear.
- Comprehensive Documentation: An annotated 3D model was delivered to the client, providing detailed visual and dimensional data for future reference.
These findings gave the client confidence in the asset’s integrity and facilitated informed decision-making for ongoing maintenance and safety compliance.
Cost and Risk Comparison
By opting for drone technology, the client realised substantial cost savings and risk reduction compared to traditional methods:
Traditional Internal Scaffolding Method:
- Cost: £200,000 (including scaffolding, safety personnel, and operational downtime)
- Risk: High risk of accidents during scaffolding erection, confined space entry, and working at height.
- Operational Disruption: Extensive downtime required for cleaning, ventilation, and scaffolding setup.
Rope Access Inspection:
- Cost: Approximately £150,000 (including rope access technicians, safety protocols, and operational downtime)
- Risk: High risk to personnel working at height within a confined space.
- Operational Disruption: The tank would still require cleaning, ventilation, and temporary shutdown.
Drone Inspection by DJM Aerial Solutions:
- Cost: Under £10,000
- Risk: Minimal risk to personnel as no confined space entry, rescue team or manned intervention is required.
- Operational Disruption: Minimised downtime; inspection was conducted during a minor maintenance period.
Client Satisfaction and Ongoing Partnership
TUV was highly satisfied with the retainable data set and the accuracy of the 3D model provided. The inspection results confirmed that the tank was in excellent condition, alleviating concerns about potential corrosion. As a result, DJM Aerial Solutions continues to be the preferred drone inspection provider for TUV, strengthening an ongoing partnership built on trust and reliability.
- Contact Us Today: Contact DJM Aerial Solutions for a consultation or to schedule your next Confined Space Drone Inspection.
- Request a Quote: Learn more about how our innovative drone technology can save costs and enhance safety for your industrial inspections.
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