Client: Cunard Line (via Asset Integrity Contractor)
Location: Southampton Port, United Kingdom
Service: Internal Scrubber Tower and Exhaust Duct Drone Inspection
Cruise Ship Scrubber Tower Inspection Using Drone Technology
Project Overview
DJM Aerial Solutions was commissioned to undertake a specialist internal inspection of the scrubber tower assemblies aboard the world-famous Queen Mary 2 cruise liner whilst the vessel was alongside in port.
The inspection focused on the internal exhaust gas cleaning system (EGCS), commonly referred to as the scrubber system. These assets are designed to reduce sulphur oxide emissions from marine engines by exposing exhaust gases to chemical treatment processes before discharge to atmosphere.
Whilst highly effective in reducing emissions and ensuring compliance with international maritime regulations, scrubber towers and associated ductwork operate in an extremely aggressive environment. Continuous exposure to elevated temperatures, acidic condensates, chemical wash water, vibration, and thermal cycling can result in accelerated deterioration of internal structures, weld seams, and shell plating.
The objective of the inspection was to assess the internal condition of each scrubber tower and associated ductwork, identify evidence of corrosion or structural degradation, and provide detailed asset integrity information to support maintenance planning.
Challenges of Traditional Marine Scrubber Inspections
Inspecting marine scrubber towers presents significant challenges due to the confined nature of the structures and their location within the vessel’s exhaust system.
Traditionally, inspections would require:
Rope Access and Confined Space Entry
Personnel would need to enter the scrubber towers and ducting systems under confined space conditions, often requiring specialist rescue teams, ventilation systems, gas monitoring equipment, and extensive permit controls.
Scaffolding Installation
Accessing elevated internal sections frequently requires scaffold installation within restricted environments, increasing both project duration and cost.
Limited Port Time
Cruise vessels typically have very limited periods alongside before returning to service. Traditional inspection methods often struggle to gather sufficient information within these narrow maintenance windows.
Safety Risks
Working at height inside confined marine structures introduces significant safety risks to inspection personnel, particularly within complex ducting arrangements and vertical exhaust systems.
DJM Aerial Solutions’ Approach
To overcome these challenges, DJM Aerial Solutions deployed the Flyability Elios confined space drone to conduct a comprehensive internal inspection of the scrubber towers and associated exhaust ducting.
The Elios platform was specifically selected due to its ability to operate safely within GPS-denied, confined environments whilst capturing high-definition visual data.
Key Inspection Capabilities Included:
- High-definition visual inspection imagery
- Real-time video transmission
- Access to elevated internal structures
- Inspection of inaccessible ductwork
- Identification of corrosion and weld degradation
- Safe operation without confined space entry
The drone was deployed through existing access points and navigated throughout the scrubber tower assemblies, capturing detailed imagery of structural welds, internal shell plating, support brackets, ducting interfaces, and corrosion-prone areas.
Initial Inspection Findings
During the initial inspection campaign, DJM Aerial Solutions identified several significant areas of concern.
Circumferential Weld Failures
Multiple weld seams exhibited advanced deterioration and cracking around the circumference of the scrubber assemblies.
Longitudinal Weld Defects
Numerous longitudinal seam welds showed evidence of fatigue, material degradation, and progressive failure mechanisms.
Corrosion and Material Degradation
The inspection identified extensive signs of environmental attack consistent with prolonged exposure to acidic exhaust by-products and chemical wash systems.
These findings were documented in a detailed asset integrity report and submitted to the client, highlighting areas requiring ongoing monitoring and maintenance intervention.
Subsequent Vessel Failure and Emergency Investigation
Several months following the initial inspection, the Queen Mary 2 experienced significant deterioration within the scrubber tower system whilst operating at sea.
The condition of the assets had progressed substantially beyond that observed during the original inspection, ultimately forcing the vessel to abandon its scheduled voyage and return to port for emergency investigation and repairs.
Due to our previous involvement and detailed knowledge of the assets, DJM Aerial Solutions was recalled to support further inspection activities alongside Lloyd’s Register Classification Society and the vessel’s engineering teams.
Follow-Up Inspection Findings
The subsequent inspection revealed catastrophic structural deterioration within the previously identified areas.
Complete Weld Separation
The circumferential and longitudinal weld seams originally highlighted during the first inspection had deteriorated significantly, with some sections exhibiting complete separation.
Major Structural Distortion
Large areas of shell plating and ductwork demonstrated severe deformation and structural instability.
Progressive Corrosion Damage
The deterioration mechanisms previously identified had accelerated considerably during continued service, resulting in extensive material loss and structural compromise.
The drone inspection provided critical visual evidence that assisted Lloyd’s Register and the vessel owners in assessing the extent of damage and developing an appropriate repair strategy.
Cost and Risk Comparison
Traditional Marine Inspection
Cost: Significant expenditure on scaffolding, confined space teams, rescue personnel, and vessel downtime.
Risk: High-risk confined space working environment with personnel exposed to elevated structures and restricted access conditions.
Operational Impact: Extended maintenance periods and reduced vessel availability.
Drone Inspection by DJM Aerial Solutions
Cost: Fraction of traditional inspection expenditure.
Risk: No personnel entry into hazardous confined spaces.
Operational Impact: Rapid deployment during limited port windows with minimal disruption to vessel operations.
Client Outcome
The inspections demonstrated the value of drone technology for marine asset integrity management and highlighted the importance of proactive condition monitoring within exhaust gas cleaning systems.
The findings provided early warning of critical structural issues that ultimately developed into major failures, validating the effectiveness of drone-based inspection methodologies for identifying developing defects before they become operationally critical.
The project further strengthened DJM Aerial Solutions’ reputation for delivering specialist confined space drone inspections within challenging marine and offshore environments.
Why Choose DJM Aerial Solutions?
DJM Aerial Solutions specialises in high-risk industrial and marine drone inspections throughout the UK and Europe.
Our Capabilities Include:
- Cruise ship scrubber inspections
- Marine exhaust stack inspections
- Confined space drone inspections
- Asset integrity inspections
- Ship exhaust duct inspections
- Elios drone inspections
- Structural condition assessments
- Emergency damage investigations
Our engineering-led approach enables vessel owners, classification societies, and maintenance contractors to obtain accurate condition data whilst reducing inspection costs, minimising downtime, and significantly improving safety.
Contact DJM Aerial Solutions
If you require a marine drone inspection, scrubber tower assessment, exhaust stack survey, or confined space inspection aboard a vessel, contact DJM Aerial Solutions today.
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