Thermography Inspection for Enfinium’s Air-Cooled Condenser (ACC)

DJM Aerial Solutions’ Approach

We deployed our advanced inspection drone equipped with a radiometric thermal camera to conduct a thorough thermal survey of the ACC system. The radiometric data allowed us to detect temperature variances across the cooling fins, highlighting any unusual heat signatures that might indicate a problem.

During the inspection, we identified a significant cold area along the top of one of the ACC modules, which was around 20 degrees Celsius cooler than the rest of the condenser. This anomaly raised suspicions of a potential issue, such as an air leak, which could reduce the cooling efficiency of the ACC.

To confirm our findings, the client conducted a secondary investigation using an optical gas monitoring system. This technology allowed us to detect the presence of escaping gases, which are invisible to the naked eye. The results revealed a weld failure in the area of concern, causing cool air to escape from the module.

Results:

The discovery of this weld failure was critical. Had the issue gone undetected, it would have led to a significant loss in efficiency over time, costing the operator tens of thousands of pounds in lost revenue over the course of a year. By identifying the issue early, DJM Aerial Solutions enabled the client to schedule immediate maintenance, preventing further damage and operational losses.

Key outcomes included:

• Cost Savings: By identifying the leak early, the client avoided costly long-term inefficiencies and potential equipment damage, saving tens of thousands of pounds.
• Increased Efficiency: Repairing the weld failure restored the ACC’s cooling efficiency, ensuring optimal performance and reducing the risk of further revenue loss.
• Minimal Disruption: The entire inspection was completed without requiring a system shutdown, allowing the client to maintain operations while diagnosing the issue.

Cost and Risk Comparison:

• Without Drone Inspection:
  • Cost: Tens of thousands in lost efficiency over the course of a year.
  • Risk: The undetected leak could have worsened, leading to more extensive repairs and further operational disruptions.
• With Drone Inspection:
  • Cost: A fraction of the potential revenue loss, with the inspection costing significantly less than the long-term inefficiency.
  • Risk: Minimal risk, as the drone inspection was completed safely and efficiently, with no need for personnel to access dangerous areas.

Pros and Cons of Drone Thermography Inspections

Pros:

• Early Detection of Issues: Radiometric thermal imaging allows us to detect heat anomalies that are often invisible to the naked eye. This provides operators with early warnings about potential failures or inefficiencies, allowing for proactive maintenance.
• Increased Efficiency: Identifying and fixing leaks or cooling inefficiencies ensures that the ACC operates at maximum performance, reducing unnecessary energy losses.
• Non-Intrusive Inspection: Drone inspections are carried out without disrupting operations, avoiding costly shutdowns and downtime.
• Cost Savings: By addressing issues early, operators can avoid long-term losses in efficiency and prevent more expensive repairs down the line.
• Comprehensive Data Collection: Radiometric data provides precise temperature measurements, allowing for detailed analysis and targeted repairs.

Cons:

• Weather Limitations: Thermal inspections can be affected by adverse weather conditions, such as high winds or rain, which can delay the inspection process.
• Data Interpretation: While thermal data is highly valuable, it requires skilled professionals to accurately interpret and correlate temperature anomalies with potential mechanical issues.
• Limited Flight Time: Drones are subject to battery limitations, meaning large systems may require multiple flights to complete a thorough inspection.

Conclusion:

This thermographic inspection for Enfinium demonstrates the immense value that drone technology brings to industrial inspections. By using advanced radiometric thermal cameras and optical gas monitoring systems, DJM Aerial Solutions was able to detect a critical weld failure that could have gone unnoticed, resulting in significant financial loss. The early identification allowed for timely repairs, ensuring continued efficiency and protecting the client’s revenue stream. Drone inspections offered a faster, safer, and more cost-effective alternative to traditional methods, solidifying our long-term partnership with Enfinium.