Drone Inspection of Spring Hanger Assemblies in an Industrial Power Generation Facility
Spring hanger assemblies play a critical role in maintaining the structural integrity of pipework systems operating within Energy from Waste plants, biomass facilities, and conventional power generation sites. These engineered supports are designed to accommodate thermal expansion and contraction that occurs as pipework systems transition between cold shutdown conditions and full operating temperatures.
DJM Aerial Solutions were recently commissioned to carry out a drone inspection survey of multiple spring hanger assemblies located throughout a complex industrial power generation facility. Many of these hanger systems were positioned in elevated and extremely difficult to access areas of the plant infrastructure, presenting significant challenges for traditional inspection methods.
By deploying the Flyability Elios 3 confined space inspection drone, the inspection team were able to safely capture detailed visual data of each hanger assembly, providing engineers with valuable information to support the facility’s asset integrity and maintenance programme.
Understanding the Importance of Spring Hanger Systems
Spring hanger assemblies are designed to support pipework systems that experience significant vertical movement as a result of thermal expansion and contraction.
During plant operation, pipework carrying high temperature steam or process gases expands in length and can shift vertically depending on the system layout and support arrangement. When the plant cools during shutdown periods, the pipework contracts back towards its original cold position.
Spring hangers are engineered to accommodate this movement while maintaining consistent support loads across the pipework system.
Typical functions of spring hanger assemblies include maintaining constant support loads on pipework, allowing controlled vertical movement during thermal expansion, preventing excessive loads being transferred into anchors and guides, protecting critical equipment such as boilers, turbines, pumps, and valves, and supporting long spans of high temperature pipe systems.
Each spring hanger assembly is designed to operate within a specific travel range, which is typically displayed using indicator plates that show the cold position and the hot operating position.
If a hanger becomes seized, incorrectly set, mechanically damaged, operating outside its designed travel range, or misaligned due to structural movement, undesirable load transfer can occur within the pipework system. This may place additional stress on pipe supports, anchors, guides, or connected equipment.
Routine inspection of these assemblies therefore forms an essential part of industrial maintenance and asset integrity strategies.
Access Challenges Within Complex Industrial Infrastructure
The facility contained numerous spring hanger assemblies located throughout dense pipework corridors, structural steel frameworks, and elevated plant areas.
Many hanger systems were positioned at significant height above working platforms, behind congested pipework installations, within restricted structural spaces, or in locations where conventional access would be extremely difficult.
Under traditional inspection methods, accessing these areas would typically require extensive scaffold erection, rope access teams, temporary working platforms, and isolation of nearby plant equipment.
Scaffolding installation alone may take several days to design, erect, inspect, and certify, with structures often remaining in place for extended periods while inspection and maintenance planning takes place.
These access requirements introduce additional working at height risks, operational disruption, logistical complexity, and significant cost.
Drone Based Inspection Approach
To overcome these access challenges, DJM Aerial Solutions deployed the Flyability Elios 3 confined space inspection drone.
The Elios 3 is specifically designed to operate safely within complex industrial environments where access is limited. Its protective collision tolerant cage allows the aircraft to safely interact with surrounding structures while maintaining stable flight.
The platform is equipped with high intensity LED lighting for operation in low visibility environments, ultra stable flight control systems, high resolution visual inspection cameras, real time live video feedback to the inspection team, and precise manoeuvrability around dense infrastructure.
This capability allows inspection engineers to access areas that would otherwise require intrusive physical access solutions.
Inspection Methodology
The inspection programme was carefully planned to ensure safe drone operation within the plant environment while capturing detailed imagery for the engineering team responsible for evaluating the pipe support system.
The survey focused on documenting the condition and positioning of each hanger assembly, with particular attention given to the indicator plates and load position scales.
Inspection objectives included identification of spring hanger indicator positions, verification of cold or hot load positions where visible, visual assessment of structural condition of hanger assemblies, inspection of rods, brackets, and support structures, identification of mechanical damage or misalignment, and detection of seized or restricted hanger movement indicators.
Using the Elios 3 drone, the team were able to navigate safely around complex pipework infrastructure and capture high resolution imagery of each hanger assembly.
Real time video feedback allowed the inspection team to precisely position the drone to obtain clear views of the indicator scales that are critical for engineering evaluation.
Inspection Efficiency
One of the most significant advantages of drone inspection was the speed at which the survey could be completed.
Traditional access methods would likely have required multiple days of scaffold installation, extensive permit coordination, and prolonged working at height exposure for inspection personnel.
In contrast, the drone based survey was completed within a matter of hours.
This rapid inspection approach enabled engineers to obtain the required inspection data quickly without disrupting plant operations or introducing unnecessary safety risks.
Supporting Asset Integrity and Engineering Assessment
The imagery and video footage captured during the inspection was delivered to the client for engineering review.
The inspection data allows engineers to verify hanger travel positions, identify abnormal loading conditions, plan maintenance adjustments or repairs, confirm correct support behaviour during operation, and integrate findings into wider pipework inspection programmes.
Drone inspection does not replace engineering assessment but instead provides critical visual intelligence that supports informed decision making within asset integrity programmes.
Safety Benefits of Remote Inspection Technology
The use of remotely operated inspection drones significantly reduces personnel exposure to common industrial hazards.
Traditional inspection methods often involve working at height, complex scaffold systems, manual access within congested plant environments, and prolonged exposure of personnel within operational facilities.
Drone inspection removes many of these risks by allowing the inspection to be conducted remotely while operators remain in a safe control location monitoring the live video feed.
This approach aligns with modern industrial safety strategies that prioritise the elimination or reduction of personnel exposure wherever possible.
The Value of Drone Inspection for Industrial Facilities
The successful completion of this inspection demonstrates how drone technology is becoming increasingly integrated within industrial inspection and asset integrity programmes across the United Kingdom.
Facilities such as Energy from Waste plants, biomass power stations, conventional power generation facilities, petrochemical installations, and heavy industrial manufacturing plants contain large volumes of elevated or inaccessible infrastructure.
Drone inspection provides a practical method of accessing these areas safely while delivering high quality visual inspection data that supports maintenance planning and engineering decision making.
Frequently Asked Questions for Industrial Drone Inspection
A spring hanger assembly is a pipe support component designed to accommodate vertical movement caused by thermal expansion and contraction in high temperature pipe systems.
Spring hanger assemblies maintain correct load distribution within pipework systems. If they become seized, misaligned, or incorrectly set, excessive loads may be transferred into anchors, guides, or connected equipment.
They are typically installed in Energy from Waste plants, biomass power stations, conventional power generation facilities, and other industrial environments with high temperature pipework.
Drones allow inspectors to access elevated or congested areas safely, capturing detailed imagery of hanger assemblies without requiring scaffold or rope access.
Drone inspections can identify seized hangers, incorrect indicator positions, structural damage, misalignment, corrosion, or mechanical wear on hanger components.
No. Drone inspection provides visual inspection data that supports engineers responsible for evaluating pipework loading and support performance.
Many inspections that would traditionally require days of access installation can be completed within hours using drone technology.
Yes. The Elios 3 is designed for confined space environments and can safely navigate around complex pipework infrastructure to capture detailed imagery.
Energy from Waste, biomass power generation, petrochemical facilities, manufacturing plants, and heavy industrial sites.
Yes, depending on site safety procedures and operational conditions. It is generally advised to take a reading during operational whilst pipework is at operating temperature and then during planned outage when the pipework is cold
Supporting Long Term Asset Performance
The inspection of spring hanger assemblies within this complex industrial facility highlights the growing importance of drone technology in modern plant maintenance strategies.
By combining high resolution visual inspection with engineering expertise, operators gain improved visibility of pipework support systems, earlier identification of anomalies, reduced inspection timeframes, and enhanced confidence in the operational behaviour of critical infrastructure.
This approach allows engineering teams to optimise maintenance planning while maintaining the highest safety standards.
Planning Your Next Industrial Inspection
Whether your facility operates within Energy from Waste, biomass power generation, petrochemical processing, or heavy industrial manufacturing, DJM Aerial Solutions provides specialist drone inspections designed for complex plant environments.
We offer nationwide mobilisation, CAA authorised drone operations, experienced inspection pilots familiar with high risk industrial sites, high resolution visual reporting aligned with asset integrity programmes, and efficient inspection deployment designed to minimise disruption.
If you are reviewing inspection strategies or seeking safer alternatives to traditional access methods, contact DJM Aerial Solutions to discuss how drone inspection can support your asset integrity objectives.