Client: Stanlow Oil Refinery, in collaboration with CTP Environment
Location: Stanlow Refinery, Ellesmere Port, Cheshire, United Kingdom
Service: Industrial Thermal Drone Inspection and Aerial Thermography Survey
Thermal Drone Inspection of Heat Exchangers at Stanlow Refinery
Project Overview
DJM Aerial Solutions recently completed a detailed thermal drone inspection of multiple heat exchangers at Stanlow Refinery in Ellesmere Port, Cheshire. Working alongside our strategic partners at CTP Environment, the objective of the inspection was to identify thermal anomalies, insulation failures, process inefficiencies, and potential leaks across critical refinery infrastructure while the plant remained operational.
The inspection was carried out using advanced aerial thermography techniques, combining drone technology with high-resolution radiometric thermal imaging sensors to safely capture detailed thermal datasets across elevated and difficult-to-access refinery assets.
Operating within a live petrochemical environment presents significant challenges for traditional inspection methods. Accessing elevated heat exchangers, pipework, and process equipment would typically require scaffolding, rope access, elevated work platforms, or shutdown periods, all of which introduce increased costs, operational disruption, and safety risks.
By deploying drone-based thermal inspection technology, DJM Aerial Solutions provided a rapid, non-intrusive, and highly effective inspection solution capable of identifying developing issues before they escalate into unplanned failures or production losses.
Why Thermal Drone Inspections Are Critical in Refinery Operations
Heat exchangers are critical process assets within oil refineries and petrochemical facilities. Any reduction in thermal efficiency, insulation performance, or flow characteristics can significantly impact:
- Energy efficiency
- Process reliability
- Production output
- Operational costs
- Environmental performance
- Asset integrity
Over time, process equipment can develop:
- Fouling and blockages
- Insulation breakdown
- Internal leaks
- Uneven thermal distribution
- Corrosion under insulation (CUI)
- Abnormal heat signatures
If left unidentified, these issues can lead to reduced process efficiency, increased fuel consumption, costly downtime, or catastrophic equipment failure.
Routine industrial thermography inspections are therefore essential for preventative maintenance and long-term asset management strategies.
Challenges of Traditional Thermal Inspection Methods
Traditional refinery inspection methods often involve significant logistical and safety challenges:
Scaffolding and Access Equipment
Inspecting elevated heat exchangers and associated pipework typically requires large scaffold structures or elevated work platforms. These methods are expensive, time-consuming, and disruptive to refinery operations.
Rope Access Risks
Rope access inspections expose personnel to additional working-at-height risks within live operational environments, particularly around hot process equipment and congested infrastructure.
Limited Inspection Coverage
Manual thermal inspections from ground level can restrict visibility and reduce the accuracy of thermal analysis, particularly around elevated assets and congested process areas.
Operational Downtime
Traditional inspection methods frequently require shutdown periods or restricted operational access, impacting production and increasing operational costs.
DJM Aerial Solutions’ Drone Inspection Approach
To overcome these challenges, DJM Aerial Solutions deployed the DJI Matrice 300 RTK drone equipped with a high-resolution radiometric thermal sensor.
This advanced aerial thermography platform allowed our team to safely inspect multiple heat exchangers and associated refinery infrastructure from optimal inspection angles while maintaining safe stand-off distances from live operational equipment.
Key Inspection Capabilities Included:
- High-resolution radiometric thermal imaging
- Precise thermal anomaly detection
- Real-time thermal analysis
- Visual inspection imagery
- Access to elevated and restricted areas
- Rapid deployment within live operational environments
The drone-based inspection methodology enabled comprehensive thermal assessments without requiring scaffolding, rope access, or operational shutdowns.
Inspection Findings
During the refinery drone inspection, several temperature anomalies and thermal inconsistencies were identified across multiple heat exchanger assets.
Key Findings Included:
- Areas of elevated surface temperatures indicating potential insulation degradation
- Localised thermal inconsistencies suggesting reduced heat transfer efficiency
- Abnormal thermal signatures potentially associated with process inefficiencies
- Early-stage hotspots requiring further monitoring and maintenance planning
The radiometric data allowed the client’s engineering and maintenance teams to accurately assess the condition of each asset and prioritise maintenance activities accordingly.
By identifying these anomalies early, the refinery can proactively address developing issues before they escalate into larger operational problems or unplanned outages.
Benefits of Drone Thermal Inspection at Stanlow Refinery
The use of drone thermography technology provided substantial operational and safety advantages compared to traditional inspection methods.
Enhanced Safety
The inspection was completed without requiring personnel to work at height or access hazardous elevated structures directly.
Reduced Operational Disruption
The refinery remained operational throughout the inspection process, avoiding costly shutdowns or interruptions to production.
Rapid Data Capture
Large sections of refinery infrastructure were inspected efficiently within a significantly reduced timeframe compared to traditional access methods.
Accurate Thermal Diagnostics
Radiometric thermal imagery provided detailed and measurable temperature data, supporting informed engineering decisions and predictive maintenance planning.
Cost Savings
By eliminating scaffolding, rope access, and extended labour requirements, the client achieved substantial cost savings while improving inspection efficiency.
Applications for Industrial Thermal Drone Inspections
Drone-based aerial thermography inspections are highly effective across a wide range of industrial assets, including:
- Heat exchangers
- Pipe racks
- Pressure vessels
- Storage tanks
- Steam systems
- Boilers
- Air cooled condensers (ACC)
- Process pipework
- Flare systems
- Petrochemical infrastructure
- Refineries and chemical plants
Why Choose DJM Aerial Solutions?
DJM Aerial Solutions specialises in industrial drone inspection and aerial thermography services throughout the UK. With extensive experience operating within petrochemical, oil and gas, power generation, and heavy industrial environments, we provide safe, accurate, and commercially focused inspection solutions.
Our Capabilities Include:
- CAA-approved drone operations
- Radiometric thermal imaging
- Industrial asset inspections
- Refinery drone inspections
- Confined space drone inspections
- Asset integrity support
- Rapid mobilisation nationwide
- High-resolution reporting and actionable datasets
Our engineering-led approach ensures clients receive practical, data-driven insights that support maintenance planning, operational efficiency, and long-term asset reliability.
Client Outcome
The client was highly satisfied with the quality of the thermal data and the speed at which the inspection was completed. The project demonstrated the effectiveness of aerial thermography within live refinery environments and reinforced the value of drone technology for proactive industrial asset management.
The inspection provided actionable thermal intelligence that will support future maintenance planning, improve operational efficiency, and help minimise the risk of unexpected equipment failures.
Call to Action
Contact DJM Aerial Solutions
If you require a thermal drone inspection for refinery infrastructure, heat exchangers, storage tanks, or industrial process equipment, contact DJM Aerial Solutions today.
Request a Quote
Discover how aerial thermography and industrial drone inspection can reduce costs, improve safety, and optimise asset performance across your facility.
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