Drones in Chimney Inspections: Elios 2 Helps Personnel Avoid Dangerous Climbs
DTEK, a leading energy company based in Ukraine, recently tested the use of the Elios 2 drone for chimney and boiler inspections at one of their power plants. The results were impressive, with the drone collecting visual data much faster than traditional methods while significantly improving safety for the inspection team.
Key Benefits at a Glance
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Safety Using a drone eliminates the need for personnel to climb 180 meters (590 feet) up a chimney or navigate scaffolding three stories high to inspect a boiler. This reduces exposure to dangerous environments and potential accidents. |
ROI By using drones instead of professional climbers or building scaffolding, DTEK can save up to $50,000 per inspection. This makes drone-based inspections a cost-effective alternative for large-scale operations. |
Efficiency The Elios 2 collects visual data quickly without the need for extra equipment like ladders or scaffolding. It’s a fast, reliable solution that cuts down on time and effort during inspections. |
About DTEK
DTEK is the largest private investor in Ukraine's energy sector, operating power plants across the country. These facilities rely on massive chimneys and boilers to generate electricity. Regular inspections are crucial to maintaining safe and efficient operations.
Without proper maintenance, even minor issues—like a small scratch on a boiler’s steel pipe—can lead to major failures over time. That’s why DTEK has been actively seeking safer and more efficient inspection alternatives.
Challenges of Traditional Inspections
Inspecting chimneys requires trained climbers to scale the structure, often using long ladders and ropes. For boilers, teams must build scaffolding inside, which takes eight workers a full day and involves moving thousands of kilograms of metal parts.
These processes are not only time-consuming but also costly. Downtime from inspections means lost revenue, especially for boilers, which require two additional days offline for setup and removal of scaffolding.
Furthermore, only about 20% of inspections result in actual maintenance needs. This means that 80% of the time, visual data alone is sufficient. DTEK saw an opportunity to reduce risk and costs by using remote visual data collection instead of physical access.
The Drone Solution
A year ago, DTEK considered using drones for inspections but found most models unsuitable for confined spaces. Then they discovered the Elios 2—a compact, durable drone designed for indoor inspections.
Unlike standard drones, the Elios 2 can fly without GPS and is protected by a cage, allowing it to safely navigate tight areas. It features distance lock, stabilization, and oblique lighting, which mimics the way inspectors use flashlights to reveal texture and depth.
Results from the Field
DTEK tested the Elios 2 on both a chimney and a boiler. For the chimney, the drone made three flights, capturing high-quality visual and thermal data in just 30 minutes. A manual inspection would have taken several hours.
For the boiler, the Elios 2 completed a full inspection in one hour, whereas a manual process would have required a full day. The drone was able to capture detailed images of the internal pipes, helping detect potential leaks or damage that could cause future failures.
Chimney Inspection with the Elios 2
Boiler Inspection with the Elios 2
With its ability to maneuver through complex structures, the Elios 2 proved to be a game-changer. It not only saved time but also provided consistent, high-quality data that could be reviewed remotely.
Looking Ahead
The success of the Elios 2 tests has led DTEK to consider making drone inspections a regular part of their maintenance routine. With faster, safer, and more cost-effective inspections, the company believes it can conduct more frequent checks, identifying issues before they become serious.
This shift not only improves safety for employees but also helps extend the life of critical infrastructure. As technology continues to evolve, drones like the Elios 2 are proving to be essential tools in modern industrial maintenance.
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