July 12, 2025

Analyzing a 35-meter dam surge tank with the Elios 3 in Canada

Analyzing a 35-Meter Dam Surge Tank Using the Elios 3 in Canada

Key Benefits at a Glance

Safety

By using the Elios 3, the team was able to inspect and plan maintenance for a 35-meter-high surge tank from the safety of the ground. This eliminated the need for risky climbs or confined space entries.

Efficiency

A 7-minute drone flight provided detailed data that helped plan rope access routes, reducing time spent on planning based on assumptions or estimates.

Accuracy

The Elios 3 revealed that the surge tank wasn’t built exactly as designed. This led to updating site records and redoing flow calculations with real-world data.

Collaboration

Osprey Integrity worked with rope access specialists to plan the safest way to conduct maintenance. This collaboration improved safety and ensured quick, accurate data collection.

Hydroelectric power is one of the most closely monitored industries. Infrastructure is built with the best technology available at the time, but as technology evolves, it's essential to revisit and update these facilities. This includes upgrading systems to increase efficiency and capacity.

The Taltson Hydro Plant is located on the Taltson River in the Northwest Territories of Canada. It’s a 290-meter-long waterway that currently houses one hydroelectric station. The plant has been offline for six months to allow for a full refurbishment, including the installation of a new turbine, generator, and necessary repairs.

Planning Future Upgrades with Drone Mapping

As part of the Taltson Hydro Plant's upgrade, the turbine and generator are being modernized to increase the plant’s maximum output. A key part of this process involves inspecting the entire water conveyance system, especially the penstock surge tank. This structure acts as a damper during normal turbine operation and is crucial for ensuring safe and efficient performance.

IMG_1634 (1)The 35-meter-tall surge tank is difficult to access safely from the inside

Data collection plays a vital role in assessing asset conditions and planning upgrades. A team of experts was brought together to gather information both inside and around the plant.

Mark Horton from Dimension Consulting was tasked with digitizing the hydro plant, while Yannick Methot of GTA Hydro, the owner’s engineer, collaborated to assess and plan the upgrades. Mark Nevison of Crux Trades, a rope access specialist, was also involved, helping with high-access points across the site.

It was Mark Nevison who suggested using drones for data collection, particularly for the 35-meter-tall surge tank. Using drones allowed the team to plan safe and effective access methods for maintenance work at height.

IMG_1878 (1)

Access to the Taltson Hydro Plant is only possible by plane

Incorporating Drones into Inspection Workflows

Osprey Integrity’s president, Courtland Penk, visited the site, which is extremely remote and accessible only by small planes. The team needed to collect visual inspections and LiDAR data, making the Elios 3 an ideal choice. Its ability to operate safely in confined spaces like penstocks, tunnels, and the surge tank made it perfect for the job.

They focused on inspecting the orifice of the surge tower and then moving deeper into the penstock with the drone. The mission was completed quickly—just seven minutes to capture all the necessary data inside the 35-meter-high tank.

The Elios 3 captured areas of rust inside the surge tank

Results from the Elios 3 Surge Tank Inspection

The data collected by the Elios 3 proved incredibly valuable. Courtland used CloudCompare and Metashape for initial processing before sharing the data with a third-party contractor. The 3D scan was later used for CFD analysis of the orifice and tee joint losses, which will help optimize future operations of the surge tank.

Mark N. and his team used the drone data to plan rope access routes. They discovered that some structures intended for securing ropes had corroded, along with missing bolts and screws. This information was critical for ensuring safe access during maintenance.

Watch the LiDAR and visual scans of the Elios 3 inside the surge tank

Additionally, they found that the T-Joint was constructed differently from the original plans, which was important for verifying the penstock’s pressure capacity with the new installations.

Impact of the Drone Inspection

The collaboration between Courtland’s team and the rope access specialists demonstrated how drones can enhance safety and efficiency in inspection workflows. By providing accurate and timely data, the project was streamlined, allowing for smoother refurbishment and future upgrades.

Soon, the Taltson Hydro Plant will be back online with its new unit, ready to serve the local community. Steps are already being taken to upgrade the site from 18MW to 22MW, showcasing the long-term benefits of integrating drone technology into infrastructure maintenance and planning.

Learn more about the Elios 3 and its advanced surveying capabilities.

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