$420,000 Saved in Elios 1 Test by Argentinian Energy Company, Subsequently Invests in Elios 2

$420,000 Saved in a Single Test with Elios 1 Leads to Investment in Elios 2 by Argentine Energy Giant

Pampa Energía, Argentina’s leading independent energy provider, recently invested in the Elios 2 drone following a remarkable discovery during a trial run of the Elios 1. This initial test saved the company a staggering $420,000 at one of its major power plants.

Key Benefits in Brief

Safety First

Instead of sending inspectors up on scaffolding inside boilers, the Elios 1 allowed Pampa Energía to remotely gather visual data, keeping workers safe from hazardous environments.

Return on Investment

The Elios 1 inspection uncovered faulty burners in a boiler, which were still under warranty. Avoiding the need for scaffolding, downtime, and replacement parts saved the company $420,000.
Speed & Efficiency

Boiler inspections that previously took a full day were completed in just 20 minutes. Downtime was cut drastically from 7 days to 2 days.

 


Company Overview

Pampa Energía is Argentina’s largest independent energy company, operating across all segments of the country’s power generation sector.

Pampa-Energia-building

Part of their routine maintenance involves inspecting boilers at their power plants. Each plant houses multiple boilers, each containing several burners. Traditionally, inspectors would climb scaffolding inside these boilers with flashlights to visually assess the burners and other components. Building and dismantling scaffolding took two to three days each, while the actual inspection added another day, resulting in around seven days of downtime per boiler.

Customer Challenges

Seven days of downtime per boiler inspection equates to significant lost revenue for Pampa Energía. Per regulatory requirements, these boilers must be inspected twice yearly, adding up to about 14 days of downtime annually per boiler. Additionally, many plants can only handle one boiler shutdown at a time, creating logistical challenges.

Safety concerns, complex logistics, and the high costs of manual inspections prompted Pampa Energía to seek alternative methods. After exploring options, they learned about Flyability’s Elios 1 drone, designed specifically for indoor inspections in confined spaces like boilers. Impressed by its efficiency and affordability, they decided to try it at one of their facilities.

Elios 1 Trial at Bahía Blanca Power Plant

The first trial of the Elios 1 took place at Pampa Energía's Bahía Blanca power plant, one of the largest in Argentina. With two boilers, the initial plan was to inspect just one.

In mere 20 minutes, the Elios 1 gathered enough visual data for a comprehensive inspection. This efficiency amazed the team, who were accustomed to the week-long manual process.

A Surprising Discovery

During lunch, someone suggested checking the second boiler since the first inspection went so quickly. Surprisingly, the second boiler had already cooled down, allowing an immediate inspection.

Though the burners were relatively new, the Elios 1 revealed severe damage. Restarting them posed risks to personnel and the equipment. Fortunately, the warranty was still valid, enabling Pampa Energía to reclaim the full cost of the damaged burners.

Pampa Energia Case Study

An image captured by the Elios 1 showing one of the damaged burners

The visual evidence collected by the Elios 1 proved crucial for the warranty claim. More importantly, it prevented potential accidents involving workers near malfunctioning equipment. Here are the financial benefits realized:

  • Saved on scaffolding = $30,000
  • Avoided downtime costs = $290,000
  • Insurance savings = $100,000

Total Savings = $420,000

Transition to Elios 2

Impressed by the Elios 1's success, Pampa Energía quickly adopted it to enhance safety, reduce costs, and increase inspection frequency. When the Elios 2 launched in early 2019, they immediately tested it and were thrilled with its performance. Plans were quickly made to deploy it across their network of power plants nationwide.

Pampa Energia_Elios 2

A photo taken by the Elios 2 at one of Pampa Energía's plants

Currently, Pampa Energía schedules Elios 2 inspections during scheduled plant shutdowns, initially focusing on coal and gas plants before expanding to hydropower facilities. The Elios 2 offers superior visuals and advanced features such as oblique lighting, stabilization, and distance lock, making it user-friendly and reliable. Some inspection bodies have even recognized it as a formal inspection tool.

In the future, Pampa Energía aims to establish drone teams at each plant, equipped with their own Elios 2 drones and trained pilots. Given the immense savings from a single test flight, adopting the Elios 2 company-wide was an obvious choice.

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