Specialty Products and Services

Rope Access India

Rope Access in Industrial Maintenance

Industrial maintenance demands efficiency, safety, and cost-effectiveness. Among the various methods for working at height, rope access has emerged as a preferred choice due to its flexibility, speed, and reliability.

Unlike traditional methods such as scaffolding, which involve time-intensive setup and occupy significant space, rope access offers a streamlined and efficient solution. Certified technicians trained under IRATA or SPRAT use advanced equipment and techniques to carry out maintenance tasks in hard-to-reach areas. This method eliminates the need for bulky structures, reducing setup time and costs while ensuring minimal disruption to ongoing operations.

This process is especially effective for inspection, cleaning, painting, welding, and repairs in industries such as power generation, petrochemicals, mining, and commercial buildings. Its ability to provide safe and efficient access to difficult areas makes it the ideal solution for maintenance projects where precision is key.

In contrast, scaffolding can be more time-consuming and expensive, often requiring additional space and resources. Scaffolding and other conventional methods of working at height, like man-lifters, are also severely constrained by height; these are usually rendered ineffective by a height of 40-60m, but rope access can enable work even at heights of more than 400 meters. While scaffolding provides a stable platform for large-scale, stationary tasks, it is not always practical for confined spaces or projects with tight timelines. This method overcomes these challenges, delivering unmatched efficiency and adaptability.

At SPS, we specialise in rope access solutions tailored to your industrial maintenance needs. Our certified technicians adhere to strict safety standards and use cutting-edge equipment to ensure high-quality results. Whether you need inspection, maintenance, or repairs, our rope access services provide a cost-effective and reliable option for your business.

Choose rope access for your industrial maintenance projects and experience the benefits of speed, safety, and efficiency. SPS is here to support your goals with expert solutions designed to meet your specific requirements.

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Accidental Site Inspection at NTPC Thermal and Solar Power Installation Plant

Introduction
The Specialty Products and Services (SPS) team conducted a detailed site inspection at the NTPC Thermal and Solar Power Installation Plant in Solapur District, Maharashtra. This state-of-the-art facility, operated by GE Power India Limited, recently experienced a fire outbreak in the chimney’s internal chamber. The primary objective of the inspection was to evaluate the extent of the damage caused by the incident and implement a safe and efficient repair strategy.
Inspection Findings
The SPS team’s meticulous inspection revealed that the internal chamber of the chimney had suffered extensive damage. The fire had severely burned electrical cables and pipes, leaving them charred and tangled. This, in turn, led to the accumulation of significant debris within the chamber. The compromised condition posed challenges for repair, especially given the confined space and elevated height of the affected area.
Solution Implementation
Rope Access techniques were strategically employed to address the situation. This method, known for its safety, versatility, and efficiency in confined and high-altitude environments, was deemed the most suitable approach for repairing the damaged chimney chamber. A highly skilled team of 15 professionals, equipped with advanced Rope Access gear, worked diligently to clear the debris and restore the damaged section.
The SPS team meticulously executed the cleaning and repair tasks, demonstrating unparalleled expertise and precision. Thanks to their rigorous efforts and the adaptability of Rope Access methods, the entire restoration process was completed in under 10 days—a remarkable turnaround time for such a challenging project.
Recognition
Abhishek Kumar Singh, Senior Manager at GE Power India Limited, commended the SPS team for their exceptional performance. He highlighted the effectiveness of Rope Access in enabling a safe and timely repair and praised the team’s commitment to excellence. This acknowledgment underscores the reliability and professionalism of the SPS team in handling critical repairs under challenging circumstances.
By leveraging Rope Access technology, the SPS team reaffirmed its capability to deliver superior results, even in complex industrial environments.

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Rehabilitation of RCC Water Tank at TSLPL Using Rope Access and Work at Height Techniques

Introduction
The RCC overhead water tank at TSLPL plays a critical role in supplying water for process operations. Over time, structural distress, such as cracks in the ring beams and columns, threatened the integrity of the tank. A comprehensive rehabilitation was undertaken, leveraging advanced techniques like rope access and work at height solutions to ensure safety, efficiency, and effectiveness during the repair process.
The Issue
A visual inspection revealed extensive cracking in the tank. The outer side walls exhibited more pronounced cracks compared to the inner walls. Additionally, signs of chlorination and concrete degradation were evident inside the upper water tank. These issues compromised the structural reliability and functionality of the tank.
Structural Assessment
To evaluate the extent of the damage, non-destructive testing (NDT) was conducted, with rope access technicians enabling inspections of challenging, elevated areas. The tests included:
● Rebound Hammer Test to assess concrete hardness and strength.
● Carbonation Test to measure carbonation depth and detect deterioration.
● Ultrasonic Pulse Velocity Test to locate cracks and evaluate concrete quality.
● Rebar Mapping to identify the condition of reinforcement bars.
● Chemical Tests to analyse concrete composition.
The results confirmed structural weaknesses, with significant cracks and deteriorated concrete in various sections.

Solution Provided
The repair process employed rope access and work at height techniques, ensuring safe and efficient access to the damaged areas. Key steps included:
1. Concrete Removal: Degraded concrete was carefully chipped away.
2. Surface Preparation: Exposed steel was cleaned and treated with a rust remover compound.
3. Corrosion Protection: Two coats of epoxy-based zinc primer were applied to reinforce corrosion resistance.
4. Bonding Agent Application: An epoxy bonding agent was used to secure adhesion with the new material.
5. Polymer Modified Mortar (PMM): The cracks and damaged areas were restored using PMM, ensuring structural integrity and durability.
Conclusion
The rehabilitation project restored the RCC water tank’s strength and functionality. Rope access and work at height methods proved instrumental, enabling precise, safe, and efficient repairs in elevated and confined spaces. By addressing structural concerns with advanced materials and techniques, the tank was returned to operational reliability, ensuring its longevity and performance for years to come.

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Dismantling of COG Gas Pipeline at LD Heat Area

Introduction
Specialty Products and Services (SPS) successfully dismantled a 40-metre-high, 72-metre-long Coke Oven Gas (COG) pipeline within a strict 24-hour shutdown window. The project, located in the high-risk LD#2 Heat Area, required precision planning and execution to address the challenges of working at height and ensuring safety in a hazardous environment.
Findings
Project Scope: The pipeline, divided into 12 sections of 6 metres each, was situated 40 metres above the ground. The operation had to be completed within a critical 24-hour window after a 2-year wait for shutdown approval.
Challenges: Working at height in the LD Heat Area posed significant risks, including exposure to flammable gases, high temperatures, and the need for precise rigging in an active industrial zone. The continuous movement of personnel and vehicles added to the complexity of the task.
Assessment
A comprehensive working at height risk assessment was conducted to evaluate the logistical and safety challenges. The assessment emphasised the importance of secure rigging points, crane operations, and strict adherence to safety protocols. A total of 24 team members were deployed in shifts to maintain steady progress while ensuring safety.
Solution Provided
Strategic Planning: A meticulous plan was formulated to address the high-risk nature of the project. The team prioritised safety, efficient access to height, and precision rigging operations.
Execution: Utilising crane support and precise coordination, the SPS team dismantled and safely lowered the pipeline sections within the 24-hour shutdown period. The operation minimised disruption to the plant’s activities, reflecting the team’s expertise in high-risk, time-sensitive projects.
Recognition by Customer
The Field Maintenance Mechanical Department awarded SPS a certificate of appreciation for its exceptional performance, dedication, and ability to overcome significant challenges in a high-risk environment. This recognition reinforces SPS’s reputation as a trusted partner for complex industrial operations involving access at height and stringent risk management.

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THE SOARING GROWTH OF THE DRONE INDUSTRY: FACTORS DRIVING ITS EXPANSION

The implementation of drones in industrial operations can have numerous benefits. Drones can be used to safely inspect dangerous areas, such as oil rigs and power plants, without exposing personnel to potential harm. They can also provide accurate data for monitoring equipment, increasing productivity by reducing the time it takes to conduct inspections manually. Drones equipped with thermal imaging cameras can detect anomalies, enabling operators to make informed decisions about maintenance and repairs before issues become critical.

Drones in industrial operations provide valuable benefits such as increased safety, cost savings through reduced inspection times, increased productivity due to efficient services such as data collection, and assisting smart decision-making through real-time accurate insights into large-scale operations and factories alike!

REVOLUTIONISING ASSET INSPECTION WITH SPS’s CUSTOM-DEVELOPED DRONES

Asset inspection is a critical task in many industries, including oil and gas, utilities, and infrastructure. It assists in ensuring that assets such as pipelines, power lines, and buildings are operationally sound, in good condition, and safe to use. Traditional asset inspection methods, on the other hand, can be time-consuming, costly, and dangerous to workers. SPS (Specialty Products and Services) is a company that specialises in developing innovative technologies to assist customers in inspecting their assets more quickly, efficiently, and safely.

SPS (Specialty Products and Services) has a dedicated in-house R&D team and facilities that allow them to design and develop cutting-edge technologies. They have used their expertise to create custom drones and train DGCA-certified pilots capable of performing asset inspection tasks with unrivalled precision and efficiency. These drones are outfitted with high-resolution cameras, sensors, and other advanced technologies that can collect detailed data about the assets being inspected.

One of the primary benefits of SPS’s custom-developed drones is their ability to access difficult-to-reach or dangerous areas that humans or traditional inspection methods would find difficult to access. Drones, for example, can inspect oil and gas pipelines or power lines for damage, corrosion, or other issues without disrupting operations or putting workers in danger.

SPS also offers ultrasonic thickness (UT) measurement services, UT measurement through drones is a significant advancement in the asset inspection industry, SPS provides highly accurate data allowing customers to take proactive measures to address them before they become critical.

SPS’s commitment to innovation and technology has enabled them to revolutionise asset inspection, providing customers with unparalleled precision, efficiency, and safety. As technology advances, SPS will continue to develop new and innovative solutions to meet the changing needs of their customers.

Asset Inspection (1)
DGCA Certified Pilots (1)
Innovation & Technology (1)
Oil Rig (1)
Power Plant (1)
Specialty Products and Services (1)
Thermal Imaging (1)
UT Measurement through drone (1)

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