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When talking about the primary advantages of using drones for inspections, cutting costs always tops the list. But does this cost-saving benefit apply universally across all industries, or is it limited to just a few?
The short answer to that is yes, the cost savings associated with using drones for inspections can apply to nearly every situation where industrial inspections are necessary. Whether the inspection happens indoors, like inside boilers or pressure vessels, or outdoors, such as checking power lines or cell phone towers, drones can gather visual data faster and more efficiently than humans. This efficiency directly translates into lower overall inspection costs, regardless of the specific setting.
So, how exactly are drones helping companies reduce inspection expenses? Here’s a detailed look at the various ways drones are contributing to cost reductions in the inspection process.
### 1. Lowering the Demand for Scaffolding
One of the most significant cost-saving factors when using drones for inspections is the reduced need for scaffolding. Depending on the complexity of the inspection, companies can save anywhere from tens to hundreds of thousands of dollars per inspection by eliminating or minimizing the use of scaffolding.
Why is this so impactful? Scaffolding is a costly, one-time expense designed specifically to provide inspectors with a platform to manually collect data within an asset. With drones, there's no need for human operators to physically interact with the structure, drastically reducing the reliance on scaffolding.
The costs associated with scaffolding stem from three main areas:
- **Material costs** for the scaffolding itself.
- **Labor costs** for assembling and dismantling the scaffolding.
- **Lost operational time** due to the asset being out of commission during the scaffolding setup.
Even in cases where scaffolding is still required—for example, to perform additional maintenance—a drone inspection can first identify the precise areas needing attention, minimizing both the material requirements and the total time spent.
#### Real-world Examples:
Two notable case studies highlight the substantial savings achieved by leveraging drones instead of traditional scaffolding:
- **Oil & Gas Industry:** A marine inspection service helped an oil tanker operator save $2 million by using the Elios 2 drone for a cargo tank inspection. This included $400,000 in material and labor savings, plus $1.6 million in reduced downtime costs.
- **Power Generation:** Pampa EnergÃa, Argentina’s largest energy company, saved $320,000 in a boiler inspection using the Elios 1 drone. The savings came from a combination of $30,000 in material and labor cuts and $290,000 in reduced downtime.
These examples underscore the dramatic impact drones can have on reducing inspection-related expenses.
### 2. Decreasing Downtime
Another major contributor to cost savings when using drones for inspections is the reduction in asset downtime. Drones not only eliminate the time-intensive process of scaffolding installation but also expedite data collection compared to human inspectors. This means shorter periods during which assets must remain offline, translating into significant financial gains.
For instance, in the oil tanker case mentioned earlier, switching to a drone inspection saved $1.6 million by cutting downtime from eight days to just hours. This underscores the immense value of drones in maintaining operational continuity.
### 3. Cutting Labor Hours
Drones also reduce the total number of labor hours required for inspections. By doing away with the need for scaffolding assembly and disassembly, drones minimize the workforce needed on-site. Additionally, drones can capture visual data far more quickly than human inspectors, further decreasing the time inspectors spend on-site.
Consider this example: At a power plant, the Tennessee Valley Authority (TVA) used the Elios 2 to inspect a scrubber. The manual inspection took 280 hours, whereas the drone inspection required only 10 hours—a staggering 98% reduction in labor hours.
### 4. Lowering Insurance Costs
Drones also contribute to cost savings by enhancing safety. By eliminating the need for confined space entry, rope access, or working at dangerous heights, drones reduce the risks faced by inspectors. As a result, companies can lower their liability insurance premiums, offering yet another avenue for savings.
### 5. Reducing Safety Equipment Needs
In many inspection scenarios, inspectors must wear protective gear. Using drones to remotely collect visual data removes the necessity for personnel to physically interact with hazardous environments, thereby reducing the need for safety equipment and lowering costs.
### 6. Increasing Inspection Frequency
Lastly, drones make inspections more affordable, enabling companies to conduct them more frequently. Regular inspections allow for earlier detection of issues, preventing small problems from escalating into costly repairs. This proactive approach not only extends the lifespan of assets but also contributes to environmental sustainability by reducing waste.
A study by Boiler Room Consulting found that increasing inspection frequency through drones could decrease CO2 emissions by up to 649 metric tons annually.
In conclusion, drones offer a multitude of benefits that translate into tangible cost savings across virtually every industry requiring industrial inspections. From reducing scaffolding needs to cutting downtime and insurance costs, drones are revolutionizing how businesses approach inspections.
If you're interested in learning more about commercial drones in the industrial sector, download our comprehensive guide [here].