EfW Boiler Inspections with Elios 3: A Safer, Smarter Approach to Gas Pass Integrity Surveys

Advanced confined space drone technology for inspecting boilers in Energy from Waste and biomass plants

In Energy from Waste (EfW) and biomass power stations, boiler integrity is critical to plant performance, operational safety, and lifecycle planning. Routine inspections of internal boiler sections, particularly Gas Pass 1, 2 and 3, as well as economisers and superheaters, are essential for identifying issues such as refractory failure, exposed or leaking tubes, and corrosion in high-stress thermal zones.

At DJM Aerial Solutions, we utilise the Elios 3, a collision-tolerant, LiDAR-equipped confined space drone, to carry out detailed boiler inspections during planned outages. This cutting-edge technology offers a safer, more efficient, and highly detailed method of assessing internal boiler conditions, without the need for scaffold erection, rope access, or manned confined space entry.

Why Boiler Inspections Are Essential in EfW and Biomass Operations

Boilers operating in EfW and biomass plants are exposed to extreme internal temperatures, corrosive gases, and mechanical stress from continual thermal cycling. Over time, this can lead to:

• Refractory degradation or detachment

• Tube thinning or rupture

• Erosion from fly ash and slag

• Blockages in superheaters or economiser bundles

• Deformed structural steel components

Undetected damage can result in unplanned shutdowns, efficiency loss, and even catastrophic failure. That’s why thorough boiler surveys are a critical part of any outage scope — and why drone technology is now the inspection method of choice.

How the Elios 3 Enhances Internal Boiler Inspection

The Elios 3 confined space drone is designed to access tight, dark, and GPS-denied environments safely. It’s equipped with:

• 4K stabilised camera for high-resolution close visual inspection (CVI)

• 360° LED lighting array to illuminate large combustion chambers

• LiDAR payload to generate point clouds and digital twins of internal spaces

• Collision-tolerant cage enabling safe flight in restricted geometry

• Defect tagging and annotation tools for precise reporting

This makes the Elios 3 uniquely suited to fly within boiler spaces including:

• Gas Pass 1, 2 and 3

• Superheater bundles

• Economiser sections

• Refractory-lined combustion chambers

• Cyclone areas and upper ductwork

Common Issues Identified in Drone-Based Boiler Inspections

Our surveys regularly reveal:

• Spalling or complete loss of refractory lining

• Exposed boiler tubes and structural steel

• Cracking or scaling on superheater coils

• Corrosion in economiser elements

• Tube leaks and associated heat damage

• Ash or slag build-up restricting flow paths

• Misaligned or distorted supports and deflectors

All defects are annotated within a visual report that includes video evidence, LiDAR snapshots, and engineering commentary, allowing operators to make targeted maintenance decisions backed by clear data.

Benefits of Using Elios 3 for Boiler Surveys

Typical Inspection Workflow in EfW and Biomass Plants

1. Pre-inspection brief with client engineering and safety teams

2. Elios 3 deployment into gas pass and upper boiler zones via manways

3. Close visual inspection with 4K live-streamed feed

4. LiDAR data capture for structural assessment and digital twin creation

5. Post-flight debrief and review of initial findings

6. Full report delivery within 48–72 hours, including annotated imagery, video, and observations

Supporting Outage Planning and Asset Integrity

Drone-based boiler inspections are especially valuable before major deslagging or maintenance work. They help plant operators:

• Prioritise tasks based on actual defect locations

• Reduce unnecessary work in unaffected areas

• Minimise shutdown duration by streamlining the scope

• Improve budgeting and resource allocation

• Satisfy insurance and compliance documentation

Whether you’re operating under EEMUA, API, or internal OEM protocols, our inspections integrate seamlessly into your existing asset management strategy.