Over the past few years, inspectors in the cement industry have been discovering major advantages by using indoor drones to gather visual data. These devices are proving to be a game-changer, especially when it comes to inspecting hard-to-reach areas and improving overall safety.
Indoor drones are particularly useful for internal inspections of critical assets like cyclones, slurry tanks, and kilns. Instead of having workers physically enter these structures, which can be dangerous and time-consuming, drones can now collect high-quality visual data remotely. This not only enhances safety but also improves efficiency.
Here are some of the key assets that are commonly inspected using indoor drones in cement plants:
- Cement and clinker silos
- Slurry tanks
- Cyclones
- Tertiary air ducts
- Kilns
- Storage units
- Conveyor belts
Traditionally, these inspections required workers to enter the asset, often using scaffolding or rope access. This process was not only risky but also costly and time-intensive. Now, with the use of advanced indoor drones, many of these tasks can be completed without human entry.
Drones allow inspectors to fly into confined spaces, capturing detailed images and videos that help identify potential issues such as corrosion, cracks, or structural weaknesses. This data is crucial for maintenance planning and helps prevent unexpected failures.
Here are six ways indoor drones are transforming the cement industry:
**1. Enhanced Safety**
By eliminating the need for inspectors to enter hazardous environments, drones significantly reduce the risk of injury. Inspectors can now operate from a safe distance, collecting data without exposure to dangerous conditions.
**2. Cost Savings**
A global cement company recently saved $50,000 in one inspection by using an indoor drone. The savings came from reduced downtime and the elimination of scaffolding costs, which can run into the tens of thousands of dollars.
**3. Reduced Downtime**
Using drones instead of scaffolding cuts down on setup and teardown time. For example, one company saved 16 hours during a cyclone inspection by avoiding scaffolding altogether.
**4. Improved Access**
Drones can reach tight, confined spaces that are otherwise inaccessible. With their protective cages, they can navigate through narrow passages and provide clear views of critical areas.
**5. High-Quality Visual Data**
The clarity of data collected by drones is impressive. In one case, a drone captured images so detailed that inspectors could see if a tank's agitator arm had any damage or loose bolts.
**6. Increased Inspection Frequency**
Drones make it easier to conduct more frequent inspections. This leads to better monitoring of asset conditions and quicker identification of potential problems.
For those looking to implement indoor drones in their operations, here are some best practices:
- **Use fishing line**: Attach a fishing line to the drone to prevent loss, especially in dusty environments.
- **Keep flights short**: Minimize dust disturbance by planning your flight path in advance.
- **Clean the drone after each use**: Dust can damage components over time, so regular cleaning is essential.
With these benefits, it's no wonder that indoor drones are becoming an essential tool in modern cement plant operations. They offer a safer, faster, and more efficient way to maintain critical infrastructure.
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