80% Cost savings: Modern hybrid inspection in the industry
Modern hybrid inspections are revolutionising industrial plant inspection. By combining drone technology and targeted traditional inspection, companies can reduce their inspection costs by up to 80% while increasing efficiency. Without costly scaffolding and expensive plant shutdowns, drones provide a fast and accurate initial assessment, followed by a pinpoint detailed inspection only where necessary. Find out how this innovative approach not only saves you time and money, but also provides comprehensive digital documentation for a sustainable maintenance strategy.
Reducing costs and increasing efficiency - the future of industrial inspection
Imagine that you could Inspection of your industrial plants in a fraction of the usual time - and at significantly lower cost. Modern hybrid inspections make this vision a reality. The intelligent combination of drone technology and targeted traditional inspection can achieve impressive savings. Find out how you can reduce costs by up to 80% and increase the efficiency of your inspection processes.
The challenge in the modern inspection of industrial plants
Industrial plants are under double pressure today: On the one hand, strict safety standards and increasing regulatory requirements demand regular and thorough inspections. On the other hand, rising costs and tight maintenance windows are putting companies under pressure to carry out inspections as quickly and efficiently as possible. Traditional methods are reaching their limits here, as they present time-consuming and costly challenges:
-
Scaffolding and safety measures:
Required for every inspection, cost-intensive and time-consuming. -
Plant downtimes:
Production losses mean direct losses. -
Lack of specialised personnel:
Skilled labour is in demand and expensive. -
Areas that are difficult to access:
This often requires complex and cost-intensive security measures.
Especially in Fuelling systems and large plant parks, these challenges are multiplied. With many identical systems, the question arises: Is it really necessary to carry out every inspection at full cost?
The hybrid approach using the example of tank inspection
With modern hybrid inspection, we offer an innovative solution. This approach combines the speed and flexibility of Drone inspections with the accuracy of classical methods and follows a proven three-stage process:
- Phase 1: Fast drone inspection:
A comprehensive overview of the condition of the system is possible in just a few hours. High-resolution images of critical areas such as weld seams and transitions, supplemented by thermographic analyses, provide early indications of potential damage. Equipped drones even carry out ultrasonic wall thickness measurements, providing precise measurement results even in areas that are difficult to access. The image analysis is available immediately after the flight, enabling quick decisions to be made.
- Phase 2: Targeted detailed inspection (by you):
The drone images are used to carry out further inspections precisely where anomalies are visible. Conventional inspection methods are used here, but only in a minimised area. This saves valuable time and significantly reduces the amount of scaffolding required. This targeted approach significantly shortens the inspection time and increases occupational safety.
- Phase 3: Transfer of the findings:
Once the inspection has been completed, the findings are used to assess other tanks or systems of the same design at the same location. Factors such as year of construction, product history and operating conditions help with the risk-based decision on further measures and enable the development of efficient inspection strategies. This allows future inspection intervals to be optimised.
When the hybrid approach is particularly worthwhile
A hybrid inspection approach pays off particularly in the following scenarios:
- Tank farm with several identical tanksDrones offer a quick initial assessment for all tanks or silos. A detailed inspection is only carried out in the event of anomalies, and the findings can be efficiently transferred to identical units, saving time.
- New systems or systems with a good maintenance historyFor systems that were inconspicuous during previous inspections, the drone inspection serves to confirm the expected condition. This minimises scaffolding costs and shortens inspection times.
- Difficult to access system partsHigher parts of the plant or complex pipework that would otherwise require expensive scaffolding or industrial climbers can be inspected quickly and easily using a drone.
Concrete savings potential
Die Qualität und Effizienz der industrial inspection hängt nicht nur von der Erfassung, sondern auch von der Analyse der gesammelten Daten ab. Drohneninspektionen bieten heute zahlreiche Möglichkeiten, um Daten effizient zu sammeln und zu verarbeiten.
Direct cost savings:
- Scaffolding costs: savings of up to 90% thanks to reduced scaffolding assembly.
- No need for cranes or industrial climbers.
- Reduced labour costs due to shorter inspection times.
- Reduction of the inspection time by 60-80%.
Reduced preparation effort:
- No time-consuming scaffolding erection and removal.
- Minimisation of ventilation and safety measures.
- Simplified coordination of the trades involved.
Indirect savings:
- Minimised system downtimes and reduced production losses.
- Faster reporting thanks to digital documentation.
Digital added value and future prospects
Through the use of LiDAR point clouds and the creation of digital 3D documentation, hybrid inspection not only offers short-term cost savings, but also a sustainable basis for future inspection planning. The traceability and comparability of different inspection times enable an optimised maintenance strategy and efficient use of resources.
Conclusion
The efficient way to modern system inspection
Hybrid inspection revolutionises the Industrial inspectionby combining the advantages of modern drone technology and classic inspection methods. With cost savings of up to 80% and a drastically reduced inspection time, this approach brings clear benefits for companies with large plant fleets or hard-to-access plant components. Rely on the future of inspection - for a safe, efficient and cost-effective inspection. Maintenance of your systems.
Interested in modern inspection solutions? Let's talk about it!
- We look forward to your enquiry and will respond promptly!
Frequently asked questions
Yes, modern drones often deliver higher image quality than the human eye, complemented by sensors such as Thermography and UT measurement.
No aviation authorisations are required indoors. Outdoor no-fly zones must be checked.
Indoor inspections are not dependent on the weather. Outdoor flights require stable weather conditions.
A detailed inspection is carried out directly on site and measures can be planned immediately.
Inspection costs can be reduced by up to 80% as scaffolding and deployment times are minimised.
Yes, our specialised drones can operate safely in confined spaces manoeuvre.
All data is recorded digitally and can be saved in 3D models and used for future inspections.
Yes, specially equipped drones, such as the Flyability ELIOS 2 are suitable for use in Tanks or closed rooms.
Neben Cameras sind Thermografie, UT measurements and LiDAR scans are possible.
The job often only takes a few hours - a fraction of the time required for a conventional inspection.
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