Cutting Costs by 60% for Piperack Inspections with the Elios 3

The Elios 3 was used to inspect 2,000 feet (600 meters) of piperacks to assess insulation, valves, and the condition of the material. Using the drone costs 60% less than traditional inspection methods and took just 2 days to complete.

Benefits In A Nutshell

Piperacks, though often overlooked, are the critical lifelines of industrial plants. These elevated structures, which organize and stabilize 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 piperack infrastructure poses significant challenges for inspection and maintenance. The raised nature of these structures necessitates the use of specialized 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 & 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 feet (600 meters) of elevated pipe racks. To address this complex task, the team leveraged the advanced capabilities of the Elios 3 inspection system.

Drone Inspections for Piperacks: A Case Study with Turner Industries

Turner Specialty Services is a leader in non-destructive testing and inspection services. With a focus on safety and efficiency, they have been at the forefront of adopting innovative technologies to enhance their operations. One such technology is drone inspection, which has revolutionized the way they approach complex inspection tasks.

The Turner Specialty Services ready for action with their Elios 3 drone

For this project, Turner Specialty Services needed to inspect elevated piperacks, which can be a time-consuming and hazardous task, often requiring traditional methods like rope access or scaffolding. These methods can be costly, labor-intensive, and pose safety risks to personnel.

Taking an alternative approach, Turner Specialty Services turned to a new solution: a drone Inspection with Elios 3. This advanced drone, equipped with high-resolution cameras and sensors, enables remote inspection of hard-to-reach areas, significantly reducing the need for risky and time-consuming traditional methods.

Drone Inspection Revolutionizes Piperack Inspection

Turner Specialty Services faced a complex challenge: inspecting over 2,000 feet of elevated pipe racks, 50 feet above ground (600m and 15m 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. To address these issues, Turner deployed the Elios 3 drone.

A pipe with insulation damage identified by the 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.

Feature Spotlight: Why the Elios 3? 

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 piperacks. 

The Elios 3 can fly close to assets without fear of collisions, giving pilots confidence in confined and complex environments such as piperacks 

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, any and 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. 

Successful Piperack Inspections with the Elios 3

Turner Industries' successful pipe rack inspection project is a testament to the power of drone technology. By utilizing the Elios 3 drone, the team achieved remarkable results in terms of safety, efficiency, and accuracy.

The inspection of 2,000 feet 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 prioritizing the safety of personnel. Furthermore, the drone inspections were conducted without interrupting ongoing operations, minimizing the impact on site productivity.

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 to locate it and plan repairs after the inspection 

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 revolutionize pipe rack inspections. By utilizing 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.

The Elios 3 provided easy access and clear results, making it easy for the Turner Specialty Services team to identify defects in a way the client could easily analyze and maintain with their engineering teams.

While weather conditions can impact drone operations, Turner's team carefully planned their inspections to minimize 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.

Interested in learning more? Discover the Elios 3 now!