Drone Cuts Scrubber Inspection Time by 98%, Saving 470 Hours of Work
The Tennessee Valley Authority (TVA) recently tested the Elios 2 drone for inspecting a scrubber at one of its power plants and found that it significantly improved safety while drastically reducing inspection time.
Key Benefits in One View
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Safety Traditional scrubber inspections require workers to use scaffolding up to 80 feet high, which poses significant risks. By using a drone, TVA employees avoided dangerous heights and reduced exposure to hazardous environments. |
Speed A manual scrubber inspection can take around 480 hours. With the Elios 2, the same task was completed in just 10 hours—cutting inspection time by 98% and saving 470 work hours. |
Maintenance Improvements Drones allow TVA to collect visual data without setting up scaffolding, enabling quick spot checks for leaks or issues. This makes maintenance more efficient and proactive. |
About the TVA
The Tennessee Valley Authority (TVA) is the largest public power provider in the United States, serving over 10 million people across seven southeastern states. It supplies electricity to 153 local power companies and large industrial customers.
Since its founding in 1933, the TVA has focused on innovation to lower energy costs and improve employee safety. In recent years, the organization has explored drone technology as a way to enhance operational efficiency and reduce risk.
Why Scrubber Inspections Matter
Scrubbers, or flue gas desulfurization (FGD) units, are essential in coal-fired power plants, removing sulfur dioxide from exhaust gases. The TVA uses massive scrubbers that resemble caverns, filled with limestone slurry to clean emissions.
Inspecting internal components like spray headers is critical but risky. Workers typically need to climb 80-foot scaffolds, which poses fall hazards. This made scrubber inspections an ideal candidate for drone testing.
The Drone Solution
TVA’s UAS Program Manager, James Manni, chose the Elios 2 drone for a test at the Cumberland Fossil Plant. Designed with a protective cage, the Elios 2 can navigate tight spaces safely, making it perfect for scrubber inspections.
The goal was to see if the drone could collect visual data efficiently and support the existing inspection process. The Unit 2 scrubbers were over 100 feet tall, presenting a large area to cover. The drone promised both speed and safety.
Results and Real-World Impact
The first flight uncovered a maintenance issue in a spray header, which was quickly resolved. The team then completed the full inspection in 8–10 hours, collecting all necessary data remotely without scaffolding.
Later, the Elios 2 was used to locate a fluid leak in Unit 1. Without the drone, the team would have had to drain the entire scrubber and set up scaffolding inside—a much longer and riskier process.
Watch the inspection footage:
Why Drones Are a Game-Changer
The biggest benefit of using the drone was safety. No scaffolding was needed, and no personnel had to work at dangerous heights. This eliminated many risks associated with traditional inspections.
Time savings were also impressive. A manual inspection took 480 hours, while the drone cut this down to just 10 hours. That's a 98% reduction, saving 470 work hours per inspection.
Looking Ahead
Since the initial success, James Manni has continued using the Elios 2 during routine maintenance at the Cumberland Fossil Plant. The drone has proven invaluable for identifying leaks and other issues quickly.
As the TVA expands its drone program, more applications are being explored. Drones offer a fast, safe, and cost-effective way to monitor equipment and address potential problems before they escalate.
With its ability to cut time and improve safety, the Elios 2 is helping the TVA move toward a smarter, more efficient future in power generation.
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