Identifying chimney tower faults with the Elios 3 at a cement plant
Identifying Chimney Tower Faults With The Elios 3 At A Cement Plant
A cement plant faced a critical issue: a visible fault in a chimney stack that stood over 120 meters high. Traditional inspection methods would have required extensive setup and time, but the Elios 3 drone provided a fast, safe, and efficient solution. With 4K video footage and LiDAR scanning, the Elios 3 completed the inspection in just one hour, delivering detailed data for in-depth 3D analysis.
Key Benefits
|
Access
Inspecting at 120 meters is dangerous and typically requires crane operations. The Elios 3 offered a safer alternative, enabling quick access with a single flight instead of waiting for a crane to be set up. |
Speed
The Elios 3 collected all necessary data in just one hour, whereas traditional methods usually take a full day. This makes drones up to eight times faster, significantly reducing downtime. |
|
Cost Savings
Using the Elios 3 saved around 30,000 euros that would have been spent on a crane. The drone was ready to fly in minutes, cutting costs and minimizing production delays. |
Visualization
The 3D model generated by the Elios 3 allowed for quick decision-making and served as a valuable record for internal use and future reference. |
Introduction
In 2022, over 4.1 billion tons of cement were produced globally, highlighting its importance in construction. Any disruption in production can lead to serious consequences. Cement plants must maintain their complex machinery carefully to avoid unexpected shutdowns. One critical part of this process is the chimney stack, which handles hot gases from kilns and is rarely inspected due to its height and complexity.
When an engineer noticed a slight tilt in a 120-meter-high chimney stack, immediate action was needed. A faulty stack could cause major operational issues, including costly repairs and production halts. The challenge was to inspect the structure quickly and safely without disrupting ongoing operations.
How A Chimney Stack Works And What The Customer Needed
The chimney stack connected to two kilns, each requiring annual maintenance. To prevent both from being offline simultaneously, maintenance was scheduled in winter and summer. However, inspecting the chimney required shutting down all production, making it a high-stakes operation.
The chimney was 120 meters tall with a 4-meter diameter, built with inner and outer concrete sleeves to withstand extreme heat. The inner sleeve was particularly vulnerable to damage, which could lead to structural failure if not addressed promptly.
During a routine check in February 2023, the engineer spotted an unusual angle at the top of the stack. This raised concerns about potential structural issues that could impact safety and production. An immediate inspection was required to assess the situation and plan the necessary repairs.
Solution: Inspecting A Cement Chimney Stack With The Elios 3
The site had a trained drone pilot who used the Elios 3 to conduct the inspection. Unlike traditional methods, the Elios 3 could navigate the confined space inside the chimney and capture both visual and LiDAR data simultaneously. This allowed for a comprehensive 3D model of the stack’s condition.
Previously, a crane would have taken 1–2 days to set up and another day to complete the inspection, costing around 30,000 euros. The Elios 3 completed the task in just one hour, and after a short cooldown period, the chimney was back in service within three hours.
The enclosed design of the Elios 3 made it ideal for navigating tight spaces, ensuring accurate data collection even in challenging environments.
Results Of A Cement Stack Inspection With A Drone
After the flight, the LiDAR data was processed using GeoSLAM Connect 2.3 to create a high-density point cloud. This data was then analyzed in CloudCompare to visualize the chimney and identify any damage.
The results revealed that the inner sleeve of the stack had subsided in the top 7–10 meters, causing a 4-degree lean. Part of the concrete had shifted 150mm to the east, posing a significant risk to the structure. If left unaddressed, this could lead to partial collapse or damage to surrounding equipment.
The 3D model enabled the team to plan the repair efficiently. They identified the exact areas needing replacement and developed a clear strategy for removing and replacing the damaged section of the inner tube.
The maintenance team replaced the damaged portion in just 14 days, saving both time and money. The ability to visualize the problem in real-time allowed for precise planning and execution, avoiding unnecessary delays and risks.
Drone Programs In Cement Plants
This case demonstrated the value of using specialized drones like the Elios 3 in industrial settings. The cost savings, speed, and accuracy of the inspection were impressive, proving that drones are a game-changer in infrastructure monitoring.
The drone pilot praised the smooth flight experience and the effectiveness of the LiDAR SLAM system, which helped navigate the interior of the stack. Despite flying at 110 meters above the ground, the signal remained stable, ensuring reliable data collection.
This project will serve as a case study for other cement industry professionals, highlighting the importance of timely inspections and the benefits of using advanced technology. The Elios 3 not only saved time and money but also improved overall site awareness, allowing the team to resume production quickly and safely.
Discover more about the Elios 3 and how it can transform your inspection workflows today.
Bimetallic Alloy Screw & Barrel
Bimetallic Alloy Screw & Barrel,Injection Molding Screw Barrel,Bimetallic Screws And Barrels,Bimetallic Single Screw & Barrel
Zhejiang Jinhai Plastic Machinery Co., Ltd. , https://www.jinhaiextruder.com