Case study: Vattenfall deploys drones to map hazardous zones

Vattenfall, one of Europe’s largest producers and retailers of electricity and heat, has used Flyability’s Elios 3 drone to create 3D models of restricted areas inside a decommissioned power plant, improving its understanding of locations deemed unsafe for human entry.

Once decommissioned, power plants often remain untouched for extended periods due to safety hazards and security concerns. Large industrial facilities present risks such as falls, head injuries, and confined space dangers. Additionally, the proprietary designs and operational methods of power plants require protection, leading to further restrictions.

Despite these constraints, companies must continue maintaining decommissioned plants. However, limited access makes it difficult to assess structural conditions, posing challenges for routine inspections and long-term planning.

Leveraging drone technology for inspection

The decommissioned facility, no longer in operation, had been repurposed as a training site for firefighters, but certain sections were still off-limits due to falling debris risks.

A long-time Flyability customer, Vattenfall saw potential in the Elios 3, an indoor drone equipped with a LiDAR sensor, for creating precise 3D maps of no-go zones. The company conducted test flights at the plant to determine whether the Elios 3’s simultaneous localisation and mapping (SLAM) capabilities could generate usable models.

Using the FlyAware SLAM algorithm, the drone processed real-time LiDAR data, creating 3D visualisations of restricted areas. The collected data was later refined with FARO software for higher-resolution post-processed models, enhancing the team's ability to understand the facility’s layout.

The test flights focused on a deteriorating stairwell, an area deemed unsafe for human entry. The Elios 3 successfully navigated the confined space, flying 30-40 m (98-130 ft) up the stairwell while maintaining a strong signal and collecting high-precision data.

Vattenfall’s R&D team confirmed that both the SLAM-generated and post-processed models met their inspection needs, demonstrating the potential for broader applications across other decommissioned plants.

Anders Lindström, Digital Inspection Specialist in Vattenfall’s R&D Department, said,
“The LiDAR capability is a great addition to the Elios' capabilities and it is so far the only drone with LiDAR capability in this size segment”.

Without the Elios 3, personnel would have needed rope access or scaffolding to inspect the site manually, a process that could take weeks and incur high costs. Instead, the drone completed the task in just 30 minutes, showcasing significant time, cost, and safety benefits.