Saving 50% on costs and inspection time on Wind Turbine Generator mast inspection
How an Engineering Firm Boosted Safety and Revolutionized Wind Turbine Inspections
Flight time
19 min
Drone
ASIO
Savings
$7,500 per tower
Industry
Energy Production
Challenges & Objectives
Our client, a leader in construction and engineering, faced considerable challenges while inspecting bolts on platforms and lift structures within wind power towers. The traditional inspection methods were fraught with difficulties
Manual Climbing Inspections: Inspectors had to manually climb each tower to inspect the bolts, which was a labor-intensive and time-consuming process. This method not only slowed down operations but also demanded significant physical effort from the inspection team.
Safety Risks: The manual inspection process posed substantial safety risks. Inspectors were required to work at great heights, exposing them to potential falls and other hazards associated with working in elevated, confined spaces.
Objectives
- Faster Inspections: The client sought a faster method to conduct bolt inspections that would reduce the overall inspection time.
- Enhanced Safety: Finding a safer alternative to manual climbing inspections was paramount to minimize the risk to human inspectors.
- Improved Efficiency: A more efficient inspection process that could cover more ground in less time was essential to optimize operations.
Overcome Challenges
The deployment of the ASIO drone revolutionized the inspection process by leveraging several key features:
Long Flight Time: The ASIO drone’s impressive 24-minute flight time allowed for thorough inspections in a single flight. This capability enabled it to cover extensive inspection areas without frequent interruptions for battery changes. The longest flight required for their inspections was 19 minutes.
Efficient Inspection Process: The ASIO drone could quickly navigate through sections and inspect all bolts on platforms and lift structures. This rapid inspection process reduced the total inspection time by 50%, allowing inspections to be completed much faster than with traditional methods.
Enhanced Safety: The use of the ASIO drone eliminated the need for human inspectors to climb the towers. This significant change drastically reduced safety risks, ensuring that personnel were not exposed to the dangers of working at heights.
Solutions & Results
50%
reduction of the total inspection time
Savings per tower
$7,500
Quantified Results:
- Time Savings: The ASIO drone cut the inspection time in half compared to traditional methods. The traditional inspection process took approximately 8 hours per tower, while the ASIO drone completed the inspection in just 4 hours per tower. This efficiency boost allowed for a significant enhancement in overall operational productivity.
- Cost Savings: The substantial reduction in inspection time and manpower led to significant cost savings. The traditional method cost around $15,000 per tower, while the ASIO drone reduced this cost to $7,500 per tower, resulting in a 50% cost reduction.
- Safety Improvements: By eliminating the need for human climbers, the ASIO drone reduced the number of personnel exposed to heights from 10 inspectors per project to 1. This change drastically improved safety and minimized the risk of accidents.
Qualitative Improvements:
- Operational Efficiency: The streamlined inspection process allowed the client to reallocate their workforce more effectively, optimizing overall project timelines and resource management.
- Data Accuracy: The high-resolution 4K video and powerful lighting provided by the ASIO drone enabled the detection of even the smallest signs of wear and tear on bolts, ensuring more accurate and comprehensive inspections.
- Immediate Decision-Making: On-site data visualization with ASIO Explore facilitated quicker decision-making and response times, enhancing the client’s ability to address potential issues promptly.
Conclusion
Integration of Inspection Drones in Industrial Operations
The ASIO drone from Flybotix has transformed the client’s inspection processes, offering unmatched efficiency, safety, and reliability. Its advanced features, such as extended flight time, rapid inspection capabilities, and high-resolution imaging, have enabled the client to overcome significant challenges and achieve outstanding results. For any organization facing similar inspection difficulties, the ASIO drone provides a superior solution that enhances operational efficiency, safety, and cost-effectiveness.
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