Back in the UK, our inspection reporting team worked methodically through the visual inspection data to create detailed engineering reports for the client. Any priority areas were flagged up to the client while the reporting was taking place, so that repair works could be planned and targeted correctly.

Reports on all 23 turbines, blades and towers were delivered via iHawk, our cloud-based asset management software, which allows clients to view assets on a map-based interface, identify the severity of any damage or integrity problems using a traffic light colour coded system and drill down into detailed visual inspection imagery, which can be used to improve decision-making and maintenance planning.

This example proves an important point. It demonstrated that an experienced UAV inspection team can not only match the quality of traditional inspection methods, but can actually identify defects which may not previously have been picked up – without requiring technicians to work at height.

Upon review of the GENSIP reporting template, Cyberhawk recommended using our internally developed reporting standard as this exceeded the requirements set out by GENSIP, which the client agreed to. The report provided highlighted the location of defects and areas which required further tactile inspection and/or maintenance.

This project not only highlighted Cyberhawk’s ability to quickly and safely collect inspection data using UAVs, but also demonstrated the quality of our reporting by exceeding an existing industry standard.

It’s important to remember that drones collect a huge volume of data, however a high-quality engineering report can make all the difference. This allows the client to easily assess the condition of the structure and plan any maintenance based on the data. The final reports provided 100% visual coverage of the dome with exact sizing of defects and a 3D model of the structure. This was delivered to AEP through Cyberhawk’s cloud based iHawk visual asset management system.

As a UAV company that has extensive experience within multiple projects and sectors, Cyberhawk’s pilots and engineers have a varied and very experienced skillset. This allows them to successfully undertake projects of challenging nature, that no one has attempted before.

READ MORE ABOUT THIS PROJECT AND WHAT AMERICAN ELECTRIC POWER THOUGHT OF THE RESULTS IN INSIDE UNMANNED SYSTEMS MAGAZINE.
https://www.neimagazine.com/features/featureeye-in-the-sky-6136284/

The use of UAVs mitigated the risks of working at height and reduced downtime, meaning lost production was minimised for the client. Siemens Gamesa also reported a high level of image quality providing confidence in inspection results.

For this project, Cyberhawk developed a tailored app to meet Siemens requirements. The requirement was a 25% overlap between images and no missing areas of the blade with processing and uploading on the same day as the inspection

Challenges involved high wind speeds and limited space to land the UAV. However, the experienced pilot and inspection engineer managed to gather all the data in the time agreed by using weather windows.

Multiple defects were quickly identified, and the client managed to plan required maintenance effectively and at lower costs.

The project was delivered successfully and on time, with the client reporting significant cost savings. Cyberhawk provided orthophoto imagery in tiled .jpeg format, as well as a digital Surface Model in .csv format on a 1m grid spacing and 3D Pointcloud in las format.

Cyberhawk’s solution not only mitigated the risks associated with this method, such as working at height, but reduced the inspection times as well. Normal timescales for this type of inspection would take more than 10 days per chimney, however, Cyberhawk carried out the inspection in just six days for both assets.

A number of imperfections consistent with the age of the structure were highlighted by the inspection. This allowed the client to become aware that structural maintenance was required and so had adequate data to outsource this work to a third-party provider. The results were delivered through Cyberhawk’s asset management software, iHawk. Utilising this software allowed the team to provide the client with detailed location and accurate defect sizing to +/- 10mm.

The high quality of images delivered through iHawk allowed Drax to provide structural repair companies with detailed visual data and in turn obtain accurate repair quotations. This information allowed the client to significantly minimise costs.

Cyberhawk’s solution not only mitigated the risks associated with confined space and working at height, but also provided a detailed inspection report on the condition of the asset. This allowed the client to prioritise maintenance decisions and thus minimise costs. Finally, there was minimal disruption to other work activities in the refinery during the drone operations.

Thanks to the skill and ability of Cyberhawk’s pilots, the inspection of the critical components was successfully completed within two days. This compares with rope access which would usually take weeks to complete the same workscope.

The results were delivered through Cyberhawk’s asset management software, iHawk. Utilising this software also allowed the team to provide the client with detailed location and accurate defect sizing to +/- 10mm.

The high quality of images delivered through iHawk allowed the client to provide structural repair companies with detailed visual data and in turn obtain accurate repair quotations. This information, along with the successful completion of the project, allowed the client to significantly minimise costs.

More on the DRAX website https://www.drax.com/technology/youre-afraid-heights-dont-job/.

Cyberhawk’s reputation of successfully inspecting confined spaces at industrial sites, along with our highly skilled pilots and engineers, saw the team emerge as the preferred provider for this challenging work scope. This inspection technique was also favored as it meant minimal risk to personnel, versus the working at height issues associated with conventional inspection and access techniques such as rope access or gantry basket.

The inspection methodology had also limited impact on plant production as the stack could be inspected by UAV by only shutting the bypassed dampers, which significantly reduced, but didn’t eliminate throughput of flue gas to the stack. For a manned entry to the stack to be undertaken a total plant/production outage would have been required to fully isolate the stack.

Thanks to the skill and ability of Cyberhawk’s pilots, the inspection of the critical components was successfully completed within a day, in comparison with rope access which would usually take between three to four days for the same workscope.

The results were delivered through Cyberhawk’s asset management software, iHawk. Utilising this software also allowed the team to provide the client with detailed location and accurate defect sizing to +/- 10mm.

The high quality of images delivered through iHawk allowed the client to provide structural repair companies with detailed visual data and in turn obtain accurate work quotations. This information, along with the successful completion of the project, allowed the client to significantly minimise costs.

Traditionally, the inspections would have been carried out using rope access technicians, however this technique increases man hours on site and in turn, increases the risk and likelihood of injury. The use of UAVs mitigated these risks, and also meant reduced downtime for the client. One of Cyberhawk’s key USPs is the ability to inspect three to five turbines per day, compared with rope access which will typically only inspect one.

The client also reported that Cyberhawk’s technology made a significant improvement to project safety. On at least two occasions, turbines were not re-started on site after an inspection was carried out and revealed a safety critical defect.

Cyberhawk’s certified technicians and trained inspection engineers allowed the inspections to take place with minimal client supervision. The client reported a high level of confidence in the autonomous role given to the company’s inspection teams and based on this, as well as other positive feedback, Cyberhawk has been given the opportunity to perform a larger work scope in 2016.

Surveying the stockpiles remotely provided a huge benefit to health and safety by removing the need for ground-based surveyors to work amongst heavy plant on this busy site.

A Digital Elevation Model (DEM), a detailed orthophoto (at 3cm ground resolution) and comprehensive volume report were provided to the client.

The use of UAVs mitigated the risks of working at height and meant reduced downtime and lost production for the client.. The use of iHawk allowed the client to access high definition images of the whole turbine and quickly see the defects identified. This in turn helped the client make quick and effective asset management decisions.

Traditionally, the inspections would have been carried out using rope access technicians, however this technique increases man hours on site and involves working at height. With the use of UAVs and a two-man team of a skilled pilot and inspection engineer, it took just one day per met mast for the inspection, which would have otherwise taken at least double the time.

This detailed reporting allowed Drax to evaluate its assets and make critical operational maintenance decisions. This service was vital to reduce the potential risk of costly delays or surprises during their planned shutdown.
With accurate condition information in hand, during the shutdown, the necessary repairs and maintenance was completed by a specialist chimney repair company.