Case Study - Sutton Bridge Power Station

Case Study: Sutton Bridge Power Station Drone Inspection to BS EN 13018

How UAV Inspection Technology Delivers Compliant Visual Testing for Power Generation Infrastructure

In October 2022, Sutro Group was commissioned to carry out a drone inspection of Sutton Bridge Power Station in accordance with European Standard BS EN 13018.

About Sutton Bridge Power Station

Sutton Bridge is an 819 MW gas-fired power station located in Lincolnshire, UK. Situated on Centenary Way close to the River Nene, the facility provides critical power generation capacity for the UK grid.

Inspection Standards and Scope

European Standard BS EN 13018 specifies the general principles for visual testing—both direct and remote—when used to determine product compliance with specified requirements. This standard provides the framework for systematic visual inspection of industrial assets.

The drone inspection focused on valves, vents, and stacks which were isolated and offline during the assessment.

Technology: DJI Matrice 30T Drone

Sutro Group deployed the DJI Matrice 30T, DJI Enterprise’s flagship inspection drone, for this power station assessment.

Wide Camera Specifications:

12 MP 1/2″ CMOS sensor
24 mm equivalent focal length
84° diagonal field of view
4K/30fps video resolution

Zoom Camera Specifications:

48 MP 1/2″ CMOS sensor
5×-16× optical zoom
200× maximum hybrid zoom
8K photo resolution
4K/30fps video resolution

Thermal Imaging Camera Specifications:

640×512 resolution
40 mm equivalent focal length
30fps frame rate
±2°C or ±2% measurement accuracy

Why the DJI Matrice 30T for Power Station Inspection

The Matrice 30T offers several advantages for industrial power generation inspection:

Portability and Deployment: Compact design fits in a backpack for rapid mobilisation to site. Can also integrate with DJI Dock for autonomous deployment.

Multi-Sensor Capability: Integrates multiple high-performance sensors into one camera payload, eliminating the need for multiple drone flights or equipment changes.

Harsh Environment Operation:

IP55 weather rating for operation in challenging conditions
Operating temperature range: -20°C to 50°C
Suitable for UK weather conditions year-round

Safety Features:

Three-propeller emergency landing capability
Health Management System
Six-way obstacle avoidance sensors
Enhanced first-person view pilot camera for low-light conditions

Reliable Communication: Four-antenna OcuSync 3 Enterprise transmission provides strong signal redundancy with LTE link backup—essential for complex industrial environments.

Inspection Findings

Structural Condition: No areas of damage or deformation were identified in the valves, vents, or stacks. All asset connections appeared secure and in acceptable condition with no signs of deformation or extensive corrosion.

Lattice structures across all assets were in acceptable condition with only isolated areas of surface corrosion. No structural deformation was recorded.

Corrosion Assessment: Widespread surface corrosion was noted throughout all inspected assets. Key findings included:

Surface corrosion on numerous bolts and welded seams
Isolated areas of surface corrosion on lattice structures
Surface corrosion on several relief valves
Corrosion could be addressed through cleaning and repainting maintenance regime

Maintenance Recommendations: Individual assets would benefit from a cleaning and fabric maintenance programme to prevent further corrosion progression. Relief valves in particular should be included in a cleaning regime to prevent deterioration.

Operational Issues: A foreign object was noted on the relief valve of one stack. Removal should be considered at the earliest opportunity to prevent inadvertent interference with plant operations.

Widespread pigeon guano was observed across relief valves, which should be addressed through a cleaning programme.

Benefits of UAV Inspection for Power Stations

This inspection demonstrates several advantages of drone technology for power generation facilities:

Safety: Personnel remain at ground level—no working at height or confined space entry required for visual assessment.

Speed: Comprehensive inspection completed during planned isolation without extensive access equipment or scaffolding.

Compliance: BS EN 13018 compliant visual testing delivered through remote inspection technology.

Data Quality: High-resolution visual, zoom, and thermal imaging provide detailed condition assessment from multiple perspectives.

Cost Efficiency: Reduced inspection duration and elimination of access equipment requirements lower overall inspection costs.

Power Generation UAV Inspection Services

Sutro Group provides BS EN 13018 compliant drone inspection services for power stations, gas turbines, cooling towers, chimneys, and associated infrastructure across the UK.

Our UAV inspection capabilities support: