Identifying Chimney Tower Faults Using the Elios 3 at a Cement Plant
A cement plant faced an issue with its chimney tower, which stood 120 meters high. A visible fault was noticed, but accessing it safely and inspecting it was challenging. The Elios 3 drone provided a fast and efficient solution by capturing 4K video footage and LiDAR scans in just one hour, enabling detailed 3D analysis of the structure.
Key Benefits in a Nutshell
Access
Inspecting a 120-meter-high chimney typically requires cranes or scaffolding, which are time-consuming and costly. The Elios 3 allowed for quick access without the need for heavy equipment, completing the inspection in just one hour. |
Speed
The Elios 3 completed the inspection in under an hour, compared to traditional methods that might take a full day. This makes drones up to eight times faster than conventional approaches, reducing downtime significantly. |
Cost Savings
By using the Elios 3 instead of a crane, the plant saved around €30,000 in setup and dismantling costs. Additionally, the quick deployment minimized production downtime, further saving time and money. |
Visualization
The 3D model created from the Elios 3’s data enabled quick decision-making and served as a valuable record for internal training and future reference. |
Introduction
In 2022, over 4.1 billion tons of cement were produced globally, highlighting its critical role in construction. Any disruption in production can lead to major consequences, making maintenance and inspections essential. Cement plants must balance high output demands with the need for regular and careful maintenance of complex machinery, especially structures like chimney stacks, which are vital to the production process.
Chimney stacks in cement plants are designed to handle extreme heat and pressure, often standing over 100 meters tall. These structures are usually low-maintenance, but any unexpected damage can cause severe disruptions. When an engineer at a plant noticed a slight tilt in the chimney stack, immediate action was needed to prevent potential failures and ensure safety.
How a Chimney Stack Works and What the Customer Needed
The chimney stack in question connected two kilns, each undergoing annual maintenance to avoid complete shutdown. The stack itself was 120 meters tall with a 4-meter diameter, built with inner and outer concrete sleeves to withstand high temperatures. Despite its robust design, a small tilt at the top raised concerns about structural integrity.
Given the tight schedule and the need for precision, a traditional inspection would have required a crane and days of preparation. Instead, the plant used the Elios 3, an enclosed-space drone capable of flying beyond line of sight, to quickly gather visual and LiDAR data for a comprehensive assessment.
Solution: Inspecting the Cement Chimney Stack with the Elios 3
The Elios 3 was chosen for its ability to navigate confined spaces and capture both visual and LiDAR data simultaneously. Unlike cranes, which could take up to two days to set up and another day for inspection, the Elios 3 completed the task in just one hour. This not only saved time but also reduced costs and minimized production downtime.
The drone’s cage structure and advanced scanning capabilities made it ideal for inspecting the narrow internal space of the chimney. After the flight, the LiDAR data was processed to create a detailed 3D model, revealing critical issues such as a subsiding inner sleeve and a 4-degree lean in the upper section of the stack.
Results of the Inspection
Using CloudCompare, the team analyzed the point cloud data and discovered that part of the inner concrete had collapsed, causing the upper section to lean. This posed serious risks, including further structural damage and potential collapse. However, the detailed 3D model allowed engineers to plan repairs efficiently.
With accurate measurements and visual data, the maintenance team was able to replace the damaged section within two weeks. The process included removing the old structure, cleaning the interior, and installing a new segment—each step carefully planned and executed based on the drone’s findings.
Drones in Cement Plants: A Game-Changer
The use of the Elios 3 proved to be a game-changer for the cement plant. It not only saved significant costs but also improved efficiency and safety. The drone pilot praised the smooth operation and the accuracy of the LiDAR SLAM system, which helped navigate the internal space with ease.
This successful inspection has now become an internal case study, demonstrating how drones can revolutionize maintenance processes in the cement industry. By cutting down inspection time and providing precise data, the Elios 3 enables faster decision-making and reduces the risk of costly delays.
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