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 transforming how internal inspections are conducted, making the process safer, faster, and more efficient.
Indoor drones are particularly well-suited for inspecting hard-to-reach areas within cement plants, such as cyclones, slurry tanks, and kilns. Instead of requiring human inspectors to physically enter these structures, drones can be flown inside to collect high-quality visual data. This not only improves safety but also reduces the time and cost associated with traditional inspection methods.
Here are some of the key assets inspected using indoor drones in cement plants:
- Cement and clinker silos
- Slurry tanks
- Cyclones
- Tertiary air ducts
- Kilns
- Storage units
- Conveyor belts
Traditionally, inspectors had to climb into these spaces, often using scaffolding or rope access systems, which posed serious risks. They would carry flashlights and cameras, carefully scanning for signs of corrosion, rust, or damage. However, this method was time-consuming and exposed workers to hazardous conditions.
With the use of high-quality indoor drones, many of these tasks can now be completed remotely. Inspectors can fly a drone into the asset from the outside, collecting detailed images and videos without ever entering the space. This not only protects workers but also streamlines the entire process.
Here are six key ways indoor drones are changing the game in the cement industry:
**1. Safety**
By eliminating the need for inspectors to enter confined or dangerous spaces, drones significantly reduce the risk of injury. For example, instead of climbing into a large silo, an inspector can control a drone from a safe location. If a defect is found, they can then enter the area with precise knowledge of where the issue is, minimizing their exposure.
**2. Cost Savings**
One global cement company saved $50,000 in a single inspection by using an indoor drone. The savings came from reduced downtime and the elimination of costly scaffolding. Drones can complete inspections up to 50% faster than manual methods, cutting down on labor and equipment costs.
**3. Reduced Downtime**
Building and removing scaffolding can take hours—sometimes even days. Using a drone eliminates this step entirely. In one case, a company saved 16 hours of downtime during a cyclone inspection by avoiding scaffolding altogether.
**4. Improved Access**
Some areas in cement plants are too tight or dangerous for humans to reach. Drones, however, can easily navigate these spaces. Their protective cages allow them to move along walls or hover close to hard-to-reach spots, ensuring full visibility.
**5. High-Quality Visual Data**
Drones equipped with high-resolution cameras capture detailed images that help inspectors spot even the smallest defects. In one example, a drone was able to inspect the agitator arm in a slurry tank and confirm it was in perfect condition. Another inspection at a refractory wall showed that connections were secure and safe.
**6. Enhanced Inspection Frequency**
Drones make it easier to conduct more frequent inspections. Plant managers can quickly perform “spot checks†to monitor asset conditions in real time. This leads to better decision-making, increased productivity, and longer-lasting equipment.
**Best Practices for Using Indoor Drones**
If you're planning to use an indoor drone for your next inspection, here are a few expert tips:
- **Use fishing line**: Attach a fishing line to the drone to prevent it from getting lost, especially in dusty environments. Make sure the line is strong enough for your drone's weight.
- **Keep flights short**: Long flights can stir up dust, reducing visibility. Plan your route ahead to minimize flight time and maintain clear visuals.
- **Clean the drone regularly**: Dust can damage the drone’s components. Use a compressed air duster after each flight to keep it in top condition.
As technology continues to evolve, indoor drones are becoming an essential tool in the cement industry. By improving safety, efficiency, and data quality, they are helping companies operate smarter and more sustainably.
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