Using Visual Inspection Robots for Turbine Generators

It sounds pretty sci-fi, but so-called visual inspection robots have the potential to make power plant operations easier, safer and more reliable.  Conducting generator inspections is a crucial activity for all power plants, but the process has historically been very time-consuming and expensive, and can lead to substantial downtime.  But it looks like those days may be coming to an end.

The Nuts and Bolts of Visual Inspection Robots

One of the most difficult aspects of generator inspections is the observance of the inner workings of the equipment, as this generally involves dissembling the unit to enable a visual inspection. 

Unfortunately, due to size limitations, there are limits to what a typical inspection bot can do in this regard.  Luckily, Siemens initiated a project in 2018 to develop a solution – miniature bots, affectionally called visual inspection robots.

The term visual inspection robot is more like a category than a specific description, as it can take multiple forms.  In the case of the Siemens initiative, the team honed in on a flat, wi-fi driven remote-controlled car with a USB endoscope on the front and a camera along the side that reflects off a movable mirror to adjust its vantage point.  The images sent back are high-definition, and the bot has the ability to navigate in 360 degrees (as well as sideways and upside down) across various magnetic configurations.

Thanks to 3D printing technology, once the design was finalized, a prototype was quickly built and validated over a 2-week period.  A commercial version quickly followed and the first real-world deployment occurred in Asia in Oct. 2019. 

The maximum height of Siemens’ visual inspection robots is 19mm, which ensures they can access the internal components of most turbine generators currently operational.  To begin an inspection, the device is inserted into the generator with a tool that can best be described as a flattened spatula.  The bot then navigates to the rotor, and drives along its entire surface.  This navigation can be either manual or autonomous.

I applaud this technology, because anything that reduces generation downtime can only help in terms of emergency preparedness.  And the best is yet to come, as the technology is constantly evolving, with advances already being pursued around artificial intelligence, analytical capabilities, and pattern recognition.  There’s little doubt, visual inspection robots are here to stay.