A pipe with insulation damage identified by the Elios 3. (Image Credit: ©Turner Industries)
The Elios 3 drone helped inspect 600m of pipe racks, costing 60 per cent less than traditional inspection methods and taking just 2 days to complete, Eloise McMinn Mitchell, Content & Communications Manager at Flyability, tells OGN
Piper racks, though often overlooked, are the critical lifelines of industrial plants. These elevated structures, which organise and stabilise pipelines, are essential for the efficient operation of sites in various industries, including oil refineries, power plants, and chemical processing facilities.
However, the complexity of pipe rack infrastructure poses significant challenges for inspection and maintenance.
The raised nature of these structures necessitates the use of specialised equipment and techniques, such as cherry pickers, rope access, or scaffolding.
These methods, while essential to the inspection process, introduce inherent risks, including falls, electrical hazards, and exposure to hazardous substances.
Regular and thorough inspections are crucial to identify potential issues such as sagging, corrosion, structural fatigue, and leaks. Early detection of these problems can prevent costly repairs, environmental damage, and safety hazards.
Turner Specialty Services Inspection and NDE Industries, a division of Turner Industries Group, a leading provider of turnkey industrial services and solutions, was tasked with a significant inspection challenge: examining over 2,000 ft (600 m) of elevated pipe racks.
To address this complex task, the team leveraged the advanced capabilities of the Elios 3 inspection system by Switzerland-based drone specialists Flyability.
DRONE INSPECTION REVOLUTIONISES PIPE RACK INSPECTION
Since 1970, Turner Specialty Services (TSS) has been committed to ensuring the integrity and reliability of industrial assets through its non-destructive examination (NDE) and inspections group.
One such technology is drone inspection, which has revolutionised the way they approach complex inspection tasks.
TSS faced a complex challenge: Inspecting over 2,000 ft of elevated pipe racks, 50 ft above ground (600 m and 15 m respectively).
The intricate structure, with multiple tiers of pipes, valves, and electrical components, required a thorough and efficient inspection.
Traditional methods, such as cherry pickers or scaffolding, were time-consuming, costly, and posed significant safety risks.
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The piperack with corrosion damage on the right can be tagged with a point of interest in the LiDAR scan by the Elios 3, making it easy for engineers |
Taking an alternative approach, Turner Specialty Services turned to a new solution: A drone Inspection with Elios 3.
This advanced aerial platform, equipped with high-resolution cameras and sensors, offered a safer and more efficient approach to the inspection.
By eliminating the need for personnel to work at heights, the Elios 3 drastically reduced safety risks.
Additionally, it accelerated the inspection process, saving time and resources. The drone’s high-resolution cameras captured detailed images and videos, enabling a comprehensive analysis of the pipe rack structure and components.
The Elios 3 was selected due to its ability to provide safe access alongside accurate data. The drone can fly in tight, enclosed spaces with confidence.
The cage structure protects the drone from potential impacts, which is a particular challenge with close inspections of pipe racks.
In addition, the Elios 3’s LiDAR sensor ensured the Turner pilots could precisely locate any points of interest in a final point cloud.
As a result, all defects could be clearly shown to maintenance teams and streamline communication for the client.
The LiDAR point cloud would serve as a record of the work done and help determine rates of decay or damage for various equipment.
It also provided Turner with clear reporting of their results, helping prove the value of their work.
Turner Industries’ successful pipe rack inspection project is a testament to the power of drone technology.
By utilising the Elios 3 drone, the team achieved remarkable results in terms of safety, efficiency, and accuracy.
The inspection of 2,000 ft of pipe rack was completed in just 2 days and 39 flights, a substantial reduction compared to traditional methods.
This rapid inspection was made possible by eliminating the need for hazardous work at heights, and prioritising the safety of personnel.
Furthermore, the drone inspections were conducted without interrupting ongoing operations, minimising the impact on site productivity.
The Elios 3, with its advanced features and reliable performance, played a crucial role in this success.
Its compact design, robust build, and precise navigation capabilities made it the ideal tool for navigating complex pipe rack structures.
The drone’s high-resolution cameras captured detailed images and videos, providing valuable insights for analysis and reporting.
By embracing drone technology, Turner Industries demonstrated a commitment to innovation and safety, setting a new standard for industrial inspections.
THE FUTURE OF INDUSTRIAL ASSET INSPECTIONS
Turner Specialty Services successfully leveraged the power of drone technology to revolutionise pipe rack inspections.
By utilising the Elios 3 drone, they were able to deliver high-quality results, including 4K videos, 12MP images, and precise LiDAR point clouds.
These detailed data sets enabled a comprehensive analysis of the pipe rack infrastructure, identifying potential issues and informing maintenance decisions.
The Elios 3 proved to be a safer and more efficient solution compared to traditional methods. By eliminating the need for personnel to work at heights, the drone significantly reduced safety risks.
Additionally, its rapid deployment and data capture capabilities accelerated inspection processes, saving time and resources.
While weather conditions can impact drone operations, Turner’s team carefully planned their inspections to minimise disruptions.
By selecting days with lower wind speeds, they ensured optimal flight conditions and accurate data collection.
This successful project demonstrates the value of drone technology in the industrial sector.
By streamlining inspection processes and improving data quality, Turner Industries has set a new standard for efficiency and safety in pipe rack inspections.