Client: Kanadevia Inova and Vital Energi
Location: Middlesbrough, North East England
Service: Confined Space Drone Inspection of Energy from Waste Boiler
Energy from Waste Furnace Drone Inspection
Project Overview
Our team was engaged by Kanadevia Inova (KVI) and Vital Energi to conduct a confined space drone inspection of an Energy from Waste (EfW) boiler located in Middlesbrough, North East England. The inspection formed part of the pre-commissioning programme for the facility, which had originally been constructed as a biomass energy plant but had never entered full operation due to historical structural concerns.
Following engineering remediation and redesign works, the plant has now been reconfigured to operate as an Energy from Waste facility, allowing it to generate energy from municipal waste streams rather than biomass feedstock. As part of the commissioning process, the engineering teams required an independent internal inspection of the boiler structure to confirm the condition of critical components prior to the system entering service.
The objective of the inspection was to assess the boiler tubes, structural framework, welded connections, and internal components, ensuring the asset was fit for purpose ahead of operational commissioning.
Project Context & Scope
Energy from Waste facilities utilise high-temperature boiler systems to convert heat generated from waste combustion into steam, which is then used for electricity generation or district heating. Given the extreme thermal loads and mechanical stresses placed on these systems, it is essential that the internal condition of the boiler is verified prior to commissioning.
Our scope included a detailed internal drone inspection of both the first gas pass and second gas pass, capturing high-resolution imagery of critical boiler infrastructure including:
Boiler tube banks
Tube panels and assemblies
Header connections
Weld seams and joints
Structural steelwork
Internal supports and boiler furniture
The inspection provided the engineering team with visual evidence of the internal condition of the boiler, supporting their assessment that the system was ready to proceed with the commissioning programme.
Challenges
Inspecting large industrial boilers presents a number of technical and safety challenges, particularly within Energy from Waste facilities.
Confined Space Environment
Boiler gas passes contain dense arrays of tubes, structural members, and internal components, creating complex internal geometries that are extremely difficult to inspect using conventional access methods.
Traditional Access Limitations
Manual inspection would typically require scaffolding installation or rope access teams operating within the confined structure, introducing significant safety risk and extended downtime.
Complex Structural Layout
Navigating through tube banks, headers, and internal steelwork requires precise positioning and stable flight control to ensure safe access to inspection points.
Data Requirements for Commissioning
The commissioning team required clear, high-definition visual documentation of key components in order to verify the boiler’s condition before entering service.
Our Technical Approach
To safely complete the inspection, our team deployed the Elios 3 confined space inspection drone, a collision-tolerant UAV specifically designed for industrial environments such as boilers, tanks, silos, and ducting systems.
The platform allowed our pilots to navigate safely through the first and second gas passes, capturing high-quality visual data while avoiding the need for confined space entry.
Key capabilities used during the inspection included:
Collision-Tolerant Flight
The Elios 3 protective cage allows controlled contact with surrounding structures, enabling safe manoeuvring through tight tube banks and structural frameworks.
High-Intensity LED Lighting
Integrated lighting provided clear visibility throughout the dark internal environment of the boiler.
High-Resolution Visual Inspection
The drone’s camera system enabled close visual assessment of tube condition, weld seams, header connections, and internal structural components.
Real-Time Inspection Viewing
Engineering teams from Kanadevia Inova and Vital Energi were able to observe the inspection live, allowing them to guide the pilot to areas requiring closer review.
Inspection Findings
The confined space drone inspection provided comprehensive visual coverage across both gas passes and enabled the engineering team to assess the condition of key structural components.
Key observations included:
Boiler Tube Condition
Tube banks across both gas passes were found to be in good overall condition, with no visible deformation, corrosion, or structural damage observed during the inspection.
Weld Seams and Header Assemblies
Welded joints and header connections were visually inspected and showed no visible cracking, distortion, or structural anomalies.
Structural Steelwork and Internal Furniture
Internal supports, structural members, and boiler furniture were found to be correctly installed and structurally sound.
The inspection provided the client with the visual confirmation required to progress the commissioning programme, verifying that the internal boiler structures were in suitable condition for operational use.
Project Outcome
The inspection was completed efficiently during the pre-commissioning phase, providing Kanadevia Inova and Vital Energi with a retainable inspection dataset documenting the internal condition of the boiler.
By using confined space drone technology, the inspection was delivered:
Without confined space entry
Without the need for scaffolding or rope access
With minimal time required inside the boiler structure
While delivering high-quality visual evidence of asset condition
The data captured during the inspection allowed the client’s engineering team to confirm that the boiler tubes, structural elements, and internal components were in appropriate condition ahead of plant start-up.
Key Benefits Delivered
Safe inspection of boiler gas passes without confined space entry
High-resolution visual assessment of boiler tubes, weld seams, headers, and structural components
Rapid inspection supporting the commissioning of a newly reconfigured Energy from Waste plant
Reduced inspection risk compared with traditional manual access methods
Retainable inspection data supporting asset integrity verification
Supporting the Commissioning of Energy from Waste Infrastructure
Inspections such as this play a critical role in the safe commissioning of Energy from Waste plants, particularly where facilities have undergone redesign or modification during their development lifecycle.
Confined space drone technology provides plant owners and operators with a safe, efficient, and highly effective solution for inspecting complex boiler systems, delivering valuable condition data while significantly reducing inspection risk.
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