Client: Confidential
Location: North East England
Service: Confined Space Drone Inspection of Anaerobic Digester
Project Overview
DJM Aerial Solutions was engaged to perform a confined space drone inspection of an anaerobic digester within a leading waste management facility in North East England. Anaerobic digesters play a critical role in processing organic waste and generating biogas, but due to their enclosed and hazardous environment, routine inspections are challenging and carry significant safety risks.
Traditionally, these inspections involve confined space entry by personnel equipped with breathing apparatus and safety harnesses, necessitating comprehensive safety protocols and substantial operational downtime. The client sought an alternative that would not only minimise safety risks but also reduce inspection time and costs.
Challenges of Traditional Inspection Methods
Conducting an internal inspection of an anaerobic digester presents several challenges due to its confined space and hazardous atmosphere. The client previously explored two conventional inspection methods, both of which posed considerable drawbacks:
Option 1: Manual Confined Space Entry:
This method requires a team of personnel to enter the digester with safety equipment, including gas monitors, breathing apparatus, and harnesses. The process is labour-intensive, time-consuming, and poses significant safety risks such as exposure to toxic gases and confined space entrapment. Additionally, the digester must be thoroughly cleaned and ventilated prior to entry, resulting in operational downtime and increased costs.
Option 2: Scaffolding and Rope Access:
An alternative approach involves erecting scaffolding or using rope access for inspection. However, this is an expensive and time-consuming endeavour. Erecting scaffolding inside a confined space is inherently dangerous, requiring additional safety precautions. Rope access, while more flexible, still involves personnel working at height within a hazardous environment, increasing the risk of accidents.
Both traditional methods presented substantial safety risks, high costs, and significant operational disruption.
DJM Aerial Solutions’ Approach
DJM Aerial Solutions proposed a more innovative solution by utilising the Elios 3 confined space drone. The Elios 3 is specially designed for confined space inspections, featuring a rugged caged design, advanced collision avoidance sensors, and a high-resolution LiDAR sensor for detailed 3D mapping. This technology enabled us to perform a comprehensive internal inspection without the need for personnel entry.
Our approach enabled us to:
- Eliminate the need for confined space entry: This significantly reduced safety risks and eliminated the requirement for breathing apparatus or harness systems.
- Avoid scaffolding and rope access: By using a drone, we minimised the setup time and costs associated with scaffolding and specialised access equipment.
- Reduce downtime and operational disruption: The inspection was conducted without the need to shut down the digester, ensuring continuous facility operation.
- Capture high-quality data: The Elios 3 provided detailed 3D LiDAR mapping and high-resolution imagery, enabling precise assessment of the digester’s internal condition, including structural integrity, weld integrity, and signs of corrosion or damage.
Cost and Risk Comparison
Utilising confined space drone technology for this inspection led to substantial cost savings and risk reduction compared to traditional methods:
Traditional Manual Entry Method:
- Cost: £25,000 GBP (including equipment, safety personnel, and operational downtime)
- Risk: High risk to personnel due to confined space hazards, including toxic gas exposure and potential entrapment.
- Operational Disruption: Significant downtime required for cleaning, ventilation, and inspection.
Scaffolding and Rope Access:
- Cost: £50,000 GBP (including scaffolding erection, rope access technicians, and safety protocols)
- Risk: High risk of accidents from working at height and within a confined space.
- Operational Disruption: Prolonged downtime due to setup and dismantling of scaffolding.
Drone Inspection by DJM Aerial Solutions:
- Cost: £5,000 GBP
- Risk: Minimal risk to personnel as no confined space entry was required.
- Operational Disruption: No downtime; inspection was conducted during normal operations.
Results and Benefits
Cost Savings: By choosing DJM Aerial Solutions’ drone inspection, the client achieved an 85% cost reduction compared to traditional methods.
Enhanced Safety: The inspection was completed without personnel entering the hazardous environment, eliminating the risk of confined space accidents.
Operational Continuity: The digester remained fully operational throughout the inspection, ensuring no loss of production or revenue.
High-Quality Data: The Elios 3 captured high-resolution imagery and accurate 3D LiDAR data, providing the client with comprehensive and actionable insights into the digester’s internal condition.
Pros and Cons of Drone Inspection vs. Traditional Methods
Pros of Drone Inspection:
- Cost-Effective: Drone inspections are significantly cheaper than traditional methods, with up to 85% cost savings.
- Enhanced Safety: No personnel were required to enter the hazardous confined space, eliminating confined space entry risks.
- Minimal Disruption: The inspection was conducted without interrupting facility operations.
- Comprehensive Data Capture: High-resolution imagery and 3D LiDAR mapping provided detailed and accurate insights.
Cons of Drone Inspection:
- Limited Flight Time: The Elios 3’s battery life required multiple flights to cover the entire internal structure.
- Flight Skill Requirement: Precise navigation within the confined space required highly skilled and experienced drone pilots.
- Data Processing Time: Post-processing of the 3D LiDAR data required time to generate accurate digital twins for condition assessment.
Conclusion
DJM Aerial Solutions successfully demonstrated the efficiency, cost-effectiveness, and safety advantages of using the Elios 3 confined space drone for inspecting an anaerobic digester. By eliminating the need for confined space entry, scaffolding, and operational downtime, we provided the client with high-quality data and actionable insights at a fraction of the cost of traditional methods.
This case study illustrates the transformative potential of advanced drone technology for confined space inspections, positioning DJM Aerial Solutions as a leader in innovative and safe inspection solutions.
Case Studies
Related Projects
Internal Inspection of Queen Mary 2 Scrubber Towers Reveals Critical Weld Failures
DJM Aerial Solutions conducted a confined space drone inspection of the scrubber tower assemblies aboard the Queen Mary 2. Using Elios drone technology, critical circumferential and longitudinal weld failures were identified within the exhaust gas cleaning system. Several months later,...
View Project Details
Stanlow Refinery Thermal Drone Inspection
DJM Aerial Solutions completed a thermal drone inspection of heat exchangers at Stanlow Refinery using radiometric UAV technology. The inspection identified thermal anomalies and potential insulation degradation while the refinery remained fully operational, eliminating the need for scaffolding, rope access,...
View Project Details
Inspecting Spring Hanger Systems Using the Elios 3 Drone
Spring hanger assemblies are critical components within industrial pipework systems, allowing pipework to expand and contract safely during temperature changes while maintaining correct load distribution. In this case study, DJM Aerial Solutions deployed the Flyability Elios 3 confined space drone...
View Project Details