Valmet, a leading provider of industrial technologies and services in the pulp, paper, and energy sectors, used Flyability’s Elios drone to inspect a recovery boiler. This innovative approach saved costs and provided access to areas that were previously difficult or dangerous to reach manually.

Key Benefits at a Glance

Overview

Valmet is one of the world's leading providers of industrial technologies and services, particularly in the pulp, paper, and energy industries. Their work includes delivering large-scale equipment such as boilers, tanks, and digesters, along with ongoing maintenance and support. Regular inspections are a crucial part of their maintenance strategy, ensuring that all systems operate safely and efficiently.

However, traditional inspection methods often require significant time and resources. For example, inspecting a large boiler can take days due to the need to build scaffolding, which not only increases costs but also leads to downtime. In some cases, shutting down a single boiler can cost up to a million dollars per day, making efficiency a top priority.

Customer Needs

As part of its commitment to improving operational efficiency, Valmet was always looking for new ways to conduct inspections more effectively. They explored the use of the Elios drone, which features a unique collapsible cage design that allows it to navigate tight spaces and continue flying even after collisions.

In Mörrum, Sweden, Valmet needed to inspect a recovery boiler. The structure was massive—over 60 meters tall—with a complex internal layout of pipes and nozzles. Traditional methods would have required building scaffolding, which could take two to three days and cost around $20,000. Given the high cost of downtime, any reduction in inspection time was highly valuable.

Solution

Instead of constructing scaffolding, Valmet opted to use the Elios drone for the inspection. This allowed them to begin the process immediately without delays. The drone flew into the boiler’s tight spaces, capturing high-quality video footage of every burner, pipe, and surface area.

This real-time data helped inspectors quickly assess the condition of the boiler and identify areas requiring closer attention. The information was then processed and included in a detailed inspection report, which was handed over to the next shift, allowing for immediate action on any identified issues.

Results

The inspection was a success, with Valmet inspectors expressing satisfaction with the quality of the images captured by the Elios. The drone provided clear visuals of areas that would otherwise be inaccessible, significantly reducing the time and effort required for manual inspections.

During the night shift, Valmet worked closely with the Flyability team to develop and follow an inspection plan that ensured comprehensive coverage of the entire boiler. Over two hours, the Elios collected footage of every component, providing a complete visual record of the asset.

This data was later analyzed to extract key insights, helping the morning shift team prioritize repairs and optimize the maintenance workflow. As a result, the overall process became faster and more efficient, minimizing downtime and maximizing productivity.

Conclusion

Valmet is already exploring additional applications for the Elios drone beyond recovery boiler inspections. Some potential use cases include:

• Checking the top of recovery boilers where deposits can accumulate, making manual entry risky. The Elios could help assess conditions before human entry.
• Inspecting circulating fluidized bed power boilers with cyclones, which are difficult to access manually. The Elios could provide safer and more efficient visual checks.
• Performing inspections in ash hoppers, which are hazardous environments. Using the Elios could eliminate the need for personnel to enter these areas directly.

By integrating drones like the Elios into their maintenance processes, Valmet is setting a new standard for efficiency, safety, and cost-effectiveness in industrial inspections. This case study demonstrates how technology can transform traditional practices, opening up new possibilities for the future of plant maintenance.

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