Case Study: Drones Inspect Condensers at Nuclear Plants - Faster, Safer, Cheaper
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From Flyability
In energy production, especially at nuclear facilities, downtime is costly, safety is paramount, and efficiency is everything. Traditional inspection methods for critical infrastructure like condensers often involve complex scaffolding setups, extensive labor, and shutdowns that last as long as inspections take. With drone technology, companies like Dominion Energy are rewriting the playbook on nuclear asset inspections.
The Challenge of Condenser Inspections in Nuclear Power Plants
Nuclear power plants operate within strict maintenance cycles, requiring detailed inspections when the plant is shut down, usually every 16 to 18 months. Condensers—essential components in the steam cycle—must be carefully examined during shutdowns for wall deterioration, cracks, leaks, and other defects. Historically, this process has been time-consuming and expensive:
Scaffolding Requirements: Building and dismantling scaffolding for inspections takes up to a week and costs thousands per hour.
Downtime Impact: Each day a nuclear plant is offline equals millions of dollars in lost revenue (for plants with two reactors, it’s an estimated $3 million per day in lost revenue).
Safety Concerns: Inspectors work in confined, dark, and wet spaces, putting them at risk and requiring expensive safety considerations.
Knowing all of these challenges first-hand, Dominion Energy was looking for a solution that could cut costs, improve safety, and accelerate the inspection process.
Drones in Action: The Elios 3 at Dominion Energy
The Dominion Energy Unmanned Systems Group has been using drones since 2014. Now, with the Elios 3 drone by Flyability, they've taken their program into small spaces for effective inspections.
At the Surry Power Plant in Virginia, Dominion Energy deployed the Elios 3 for condenser inspections, and has seen remarkable results:
Inspection time slashed from 8 days to 8 hours: With the Elios 3, Dominion can complete condenser inspections in two shifts instead of requiring a week-long process.
$200,000+ saved per shutdown: By eliminating the need for extensive scaffolding, Dominion significantly reduces costs and saves hundreds of thousands of dollars on condenser inspections alone.
Enhanced safety: Inspectors no longer need to enter hazardous confined spaces or work at 65-foot heights inside the condenser.
Inspection data tracking for digital twins: The drone collects LiDAR, visual, and ultrasonic thickness data, creating a digital twin for long-term monitoring and predictive maintenance.
Beyond Condensers: Expanding Drone Use in the Energy Industry
The success of the Elios 3 at Dominion Energy highlights a broader trend—drones are invaluable in energy infrastructure inspections. From nuclear plants to oil refineries, renewables, and gas-fired power stations, drones are proving indispensable.
Drones in Nuclear Energy
Cooling Tower Inspections: Drones inspect towering structures without the need for workers to scale dangerous heights.
Containment Vessel Monitoring: UAVs navigate reactor containment buildings, identifying structural weaknesses with precision.
Radiation Area Surveys: Specialized drones with radiation sensors can assess high-risk zones without exposing personnel.
Drones in Other Energy Sectors
Wind Turbine Assessments: Drones check for blade erosion and structural integrity in offshore and onshore wind farms.
Solar Panel Maintenance: UAVs equipped with thermal imaging detect faulty panels quickly and efficiently.
Oil & Gas Infrastructure Monitoring: Drones inspect pipelines, flare stacks, storage tanks, and more to reduce downtime and improve safety.
The Future of Drone Inspections in Energy
As drone technology advances, expect even greater adoption across the energy sector. AI-powered analytics, enhanced sensors, and automated flight paths will make inspections faster, smarter, and safer. Companies that embrace this shift will reap the benefits of reduced costs, improved worker safety, and more resilient infrastructure.
For Dominion Energy, the Elios 3 has already proven to be a game-changer. As more power plants and energy facilities integrate drones into their inspection workflows, the industry moves closer to a future where downtime is minimized, safety is maximized, and maintenance decisions are driven by real-time data.
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