ShenZhen Jakeconn Precision Technology Co., Ltd. , https://www.jakeconn.com
Over the past few years, inspectors in the cement industry have started to see major benefits from using indoor drones for data collection. These devices are transforming how internal inspections are conducted, making the process safer, faster, and more efficient.
Indoor drones are particularly useful for inspecting hard-to-reach areas within cement plants, such as cyclones, slurry tanks, and kilns. Instead of requiring inspectors to physically enter these spaces, drones can be flown inside to capture high-quality visual data. This not only reduces risk but also improves the overall inspection process.
Here are some key assets that are commonly inspected using indoor drones:
- Cement and clinker silos
- Slurry tanks
- Cyclones
- Tertiary air ducts
- Kilns
- Storage units
- Conveyor belts
Traditionally, inspectors would need to climb into these structures, often using scaffolding or rope access systems. This approach is time-consuming, costly, and poses serious safety risks. However, with the use of advanced indoor drones, many of these dangers can be avoided.
Drones allow inspectors to collect detailed visual data remotely, eliminating the need to enter hazardous environments. In cases where physical access is required, the drone’s pre-inspection data helps workers focus their efforts precisely where needed, reducing the time spent inside the asset.
Here are six ways indoor drones are changing the game in the cement industry:
**1. Enhanced Safety**
By sending a drone into confined spaces instead of a person, the risk of injury or even death is significantly reduced. Inspectors can now gather critical data from a safe distance, which is especially important in high-risk areas like kilns or tall storage units.
**2. Cost Savings**
Using drones can lead to substantial financial savings. One global cement company saved $50,000 in a single inspection by avoiding the costs associated with scaffolding and reducing downtime. Drones cut down on both setup and removal times, making inspections more efficient.
**3. Reduced Downtime**
With drones, there's no need to build temporary structures like scaffolding. This means inspections can be completed faster, minimizing production interruptions. For example, one company saved 16 hours during a cyclone inspection by using a drone instead of scaffolding.
**4. Improved Access**
Some areas within cement plants are too tight or dangerous for human inspectors to reach. Drones equipped with protective cages can navigate these spaces easily, providing clear views of critical components that would otherwise go unchecked.
**5. High-Quality Visual Data**
Drones capture detailed images and videos that allow inspectors to spot even the smallest defects. In one case, a drone was able to inspect an agitator arm in a slurry tank and confirm it was in good condition. Another inspection at the top of a refractory showed that the structure was intact and safe.
**6. Streamlined Processes and More Frequent Inspections**
Drones enable quicker, more frequent inspections without the need for plant shutdowns. This leads to better maintenance planning, increased productivity, and longer asset life. Real-time data helps plant managers make informed decisions about operations.
For those looking to implement indoor drones in their inspections, here are a few best practices:
- **Use fishing line**: Attach a fishing line to the drone to prevent loss, especially in dusty environments. Choose a line strong enough to support the drone’s weight.
- **Keep flights short**: Minimize dust disturbance by planning your flight path in advance and keeping inspections brief.
- **Clean the drone thoroughly**: After each flight, remove any dust to maintain performance and extend the drone’s lifespan.
By integrating indoor drones into their inspection routines, cement plants can enhance safety, reduce costs, and improve operational efficiency. It's a smart move that's quickly becoming the new standard in the industry.