Wind Turbine Maintenance Efficiency: How AssetTech Uses Voliro T to Cut Costs by 50% and Boost Inspection Speed 16x

Case Study Overview

AssetTech, a Brazilian-based leader in high-tech inspection solutions for wind turbines, has successfully implemented the Voliro T drone to streamline Lightning Protection System (LPS) inspections in the country’s rapidly growing wind energy sector. By leveraging Voliro’s advanced drone technology, AssetTech significantly reduced inspection times, enhanced worker safety, and minimized operational costs. This case study highlights how the integration of drone-based inspections has transformed wind turbine maintenance, setting new benchmarks for efficiency and sustainability.

Summary of Key Outcomes

Ensuring Wind Turbine Integrity in Brazil: Mitigating Lightning and Storm Risks Through Advanced Inspections

The structural integrity of wind turbines is critical to their performance and longevity, particularly in regions like Brazil, where coastal storms and frequent lightning strikes pose substantial risks. AssetTech focuses on inspecting WGT blades, which are their core business. The company has inspected around 150 wind turbines (GWT) from GE and Nordex Acciona fabricants to date.

Traditional LPS inspections involve:

• High costs: Manual inspections cost between $1,000 and $1,500 per turbine.
• Safety hazards: Rope-access technicians work at heights of 100+ meters, exposing them to extreme weather conditions.
• Time-intensive processes: Each turbine inspection requires a team of three, taking up to a full day per unit.

AssetTech’s Experience with Voliro T for LPS Wind Turbine Inspections

• Enhanced efficiency in data collection, analysis, and interpretation, significantly accelerating the inspection process.
  
• Reduced inspection complexity, fewer personnel needed, and minimized risky tasks.

• Inspection time per turbine reduced from one full day to just 30 minutes.

By leveraging the Voliro T, AssetTech achieved:

• Traditional methods cost approximately $1,000 per turbine, while the Voliro T costs $500, cutting costs by 50%.
  
• Required personnel reduced from three to two, lowering operational expenses.

Why LPS Inspections Are Essential for Wind Turbine Safety and Performance

Lightning Protection System (LPS) inspections are conducted every three months to safeguard wind turbine blades from lightning damage, ensuring long-term operational efficiency. A well-maintained LPS is critical for preventing costly failures, adhering to IEC 61400-24 regulations, and maximizing asset longevity.

Traditionally, LPS inspections have been labor-intensive, time-consuming, and highly dependent on weather conditions, requiring professional climbers to descend turbine blades manually. However, advancements in drone technology now offer a safer, faster, and more efficient alternative. Below is a comparison of the conventional rope-access method versus the cutting-edge Voliro T drone inspection process.

Traditional LPS Inspection Process

1. A professional Climber N3 prepares the descent and ensures all safety procedures are in place.
2. Climber N1 and Climber N3 descend the turbine blade using ropes.
3. An inspector inside the HUB connects the Ohmmeter cable to the root of the blade.
4. Climbers manually attach cables to the blade’s receivers, requiring constant radio communication.
5. The inspector evaluates test results in real time.
6. Due to the labor-intensive process and weather-dependent constraints, only 1 to 2 wind turbines can be inspected per day.

Voliro T Drone Inspection Process

1. The Voliro T drone, equipped with an LPS probe, is launched.
2. The drone inspects the turbine blade in just 30 minutes while operators monitor from the ground.
3. The entire inspection is completed without any climbing or manual cable connections, significantly reducing risk and labor effort.

By embracing drone-based inspections, wind farm operators can enhance safety, improve efficiency, and dramatically reduce downtime while maintaining regulatory compliance.

As Brazil’s wind energy sector continues to expand, drone-enabled inspections will play a pivotal role in maintaining industry standards while optimizing performance and sustainability. By integrating Voliro T drone technology, AssetTech has reinforced its position as an industry leader in renewable energy inspections.