Inspecting a 35-Meter Surge Tank with the Elios 3 in Canada

Key Benefits at a Glance

Safety By using the Elios 3, the team was able to inspect and plan maintenance for a 35-meter-high surge tank without ever having to enter the structure. This significantly reduced the risk of injury and ensured that all work could be done from a safe, ground-level position.	Efficiency A single 7-minute drone flight provided all the necessary data to plan rope access routes. This eliminated the need for time-consuming estimations or on-site guesswork, saving both time and resources during the planning phase.
Accuracy The Elios 3 revealed that the surge tank had not been constructed as originally designed. This discovery led to the updating of site records and the re-evaluation of flow calculations to match the actual conditions on-site.	Collaboration Osprey Integrity worked closely with rope access specialists to develop the safest and most effective approach for maintenance. This teamwork ensured that data collection was accurate and that the rope technicians could operate more efficiently and safely.

Hydroelectric power is one of the most rigorously regulated industries. Infrastructure is built with the best technology available at the time, but as new advancements emerge, it becomes essential to revisit and upgrade existing systems. This is especially true for aging plants looking to increase efficiency and capacity.

The Taltson Hydro Plant is located on the Taltson River in the Northwest Territories of Canada. It's a 290-meter-long waterway that currently supports a single hydroelectric power station. The facility has been offline for six months to undergo major refurbishment, including the installation of a new turbine and generator, along with necessary repair work.

Planning Future Upgrades with Drone Mapping

Part of the refurbishment includes upgrading the turbine and generator to increase the plant’s overall capacity. As part of this process, the entire water conveyance system needed inspection, with special attention given to the penstock surge tank. This structure plays a crucial role in stabilizing pressure during normal turbine operation.

The 35-meter-tall surge tank is difficult to access from the inside

Data collection was a critical component of this project. A team of experts was brought in to gather detailed information about the plant’s infrastructure, including the surge tank.

Mark Horton from Dimension Consulting was tasked with digitizing the plant, while Yannick Methot of GTA Hydro, the owner’s engineer, helped assess and plan the upgrades. Mark Nevison of Crux Trades, a rope access specialist, was also involved, working on high-access areas around the site.

It was Mark Nevison who suggested using drones for data collection, particularly for the 35-meter-tall surge tank. Using a drone allowed the team to plan safe access points without risking personnel exposure to dangerous environments.

Integrating Drones into Inspection Workflows

Osprey Integrity, a drone service provider, was brought in to collect visual and LiDAR data. Given the remote location of the site, which is accessible only by small aircraft, they needed a reliable and compact solution. The Elios 3 was chosen for its ability to safely navigate confined spaces and collect high-quality data from heights.

The team focused on inspecting the orifice of the surge tower and moving further into the penstock and tunnels. The flight took just 7 minutes, yet it captured all the necessary details for planning future work.

The Elios 3 captured rust on the interior walls of the surge tank

Results from the Elios 3 Surge Tank Inspection

The data collected from the Elios 3 flight proved invaluable. Courtland Penk, president of Osprey Integrity, used CloudCompare and Metashape for initial processing before sharing the data with a third-party contractor. The 3D scan was then used for CFD analysis to evaluate the performance of the orifice and tee joint under future operating conditions.

Mark Nevison and his team used the drone data to plan access for the rope engineers. They discovered that some structural elements intended for securing ropes had corroded and were missing bolts. This information was critical in ensuring the safety of the maintenance crew.

Watch the Elios 3’s LiDAR and visual scans of the surge tank

In addition, the team found that the T-Joint had been constructed differently than the original plans indicated. This finding was crucial for understanding the maximum pressure capacity of the penstock after the new installations.

Impact of the Drone Inspection

This project demonstrated how drone inspections can enhance collaboration between technical teams and improve the safety and efficiency of maintenance operations. By providing accurate, real-time data, the Elios 3 helped streamline the refurbishment process and reduce potential risks.

Courtland and Osprey Integrity delivered more value than expected, helping the team move forward with confidence. Soon, the Taltson Hydro Plant will be back online with a new unit, increasing its capacity from 18MW to 22MW. This upgrade is a step toward a more efficient and sustainable energy future for the local community.

Learn more about the Elios 3 and its advanced surveying capabilities.

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