Power plant products |
Inspecting tall and complex vertical structures poses significant access challenges for non- destructive testing (NDT) activities. An answer to the problem has been produced by robotics innovator HausBots.
Wall climbing robots rise to the challenge Technological shift
The company has collaborated with EDF and NDT probe manufacturer ACS-Solutions on a potentially ground-breaking project looking at the viability of using wall-climbing robots for the inspection of large concrete infrastructure. The project has seen a series of trials being undertaken on a 200 metre concrete chimney stack located at an EDF facility. HausBots’ climbing robotic platform, integrated with ACS’s MIRA ultrasonic tomography system, was deployed on the structure, where it successfully carried out the full range of NDT inspections, reporting that they were completed in record time and with zero risk to life.
According to Jack Cornes, co-founder of HausBots, the results of the trial mark ‘a significant advancement in the application of robotics for infrastructure NDT’, demonstrating a safer, more efficient, and cost-effective solution for inspecting tall structures. By successfully integrating a high-resolution ultrasonic tomography device on to the stable, climbing crawler robot, the project exhibited a practical, safe, and scalable method for inspecting tall vertical concrete assets. Jack Comes again: “Through this project we have demonstrated that subsurface imaging can be automated and conducted at height without the limitations or risk of traditional access methods. From an operational perspective, it also significantly reduced inspection time and eliminated the need for working at height. In addition, it opens the door to higher-frequency inspections, enabling asset owners to adopt a more data- rich and proactive approach to structural monitoring. We believe it marks a significant advancement in the application of robotics for infrastructure NDT.”
Traditional methods of inspecting tall and complex vertical structures such as reinforced concrete chimney stacks, including rope access and scaffolding, are not only logistically and financially burdensome but also come with considerable safety risks.
These limitations can result in insufficient data collection, compromising the integrity assessments of critical structures. While aerial drones have gained traction for visual inspections, few solutions exist for direct- contact NDT on vertical concrete surfaces, especially where subsurface imaging is required.
The integration of robotics into NDT practices is believed to mark a substantial technological shift, with robotic platforms enabling the deployment of NDT probes and sensors in hard-to-reach or hazardous environments, increasing inspection coverage and repeatability. It is an approach that has broad potential for application across multiple sectors and industries globally.
Field testing
The proprietary ‘Aerogrip’ adhesion system combines controlled airflow and suction to create low-pressure zones beneath the robot chassis, enabling strong adhesion to various vertical and inverted surfaces, including rough and porous materials like concrete. The field test demonstrated the robotic platform’s ability to perform all assigned inspection tasks without failure. The adhesion system remained stable throughout the climb and scan procedures, even on rough concrete. The MIRA device, mounted on the robot, acquired high-quality tomographic scans at each test location. Key performance metrics included consistent scan resolution, significant deployment time savings, cost reductions, and zero personnel risk exposure for elevated positions.
Upgrade of island grid with remote meter reading
For some years, operational challenges on an (unnamed) Caribbean island caused power losses exceeding 20% in key areas. Manual meter reading proved to be inefficient and error-prone, while the island’s corrosive salt fog environment accelerated meter corrosion, driving up maintenance costs.
To answer these problems, Chint reached a co-operation agreement with the island’s government to install Chint’s Wi-SUN smart metering solution; it also introduced the idea of intelligent remote meter reading. This solution includes smart meter devices, the ‘Power Easy’ management system, on-site technical support,
installation guidance, and system operation training.
The project involves supplying over 3000 households with CHA120 smart meters, CHG540 concentrators, and CHG590 repeaters. Rolled out in phases, the project replaces traditional meters with a modern AMI system, enabling remote meter reading, real-time monitoring, and efficient grid management.
Operational improvements included a 99% on-demand remote operation rate, a 50 % O&M efficiency improvement, a 35 % reduction in manual labour costs and a 21 % drop in total line losses. Benefits of the smarter grid included
46 | November/December 2025|
www.modernpowersystems.com
remote meter reading and outage reporting, grid monitoring and data analysis, theft detection and system alerts, more durable devices (ie waterproof, dustproof, corrosion-resistant), a centralised, digital archive system and stable communication in a complex terrain. Local conditions on the island are harsh and the terrain is complex, with hills and dense jungles. Local technicians of the island confirmed the excellent performance of the new system and attached importance to its ability to judge the Wi-SUN signal strength at each point so that it would be possible to conduct independent field investigations in the future.
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