BVLOS Connectivity for UAVs in Utility Inspections for a Safer Approach

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Utilities are the backbone of modern infrastructure, delivering electricity, water, gas, and telecommunications to millions. However, maintaining the safety and reliability of vast networks that stretch thousands of miles across challenging terrain is a constant challenge. Traditional inspection methods—relying on ground crews, helicopters, and manual labor—are slow, expensive, and pose safety risks to workers.

UAVs are transforming utility inspections, offering greater speed, efficiency, safety and facilitating regulatory reporting compliance. However, their true potential is yet to be unlocked with Beyond Visual Line of Sight (BVLOS) connectivity. BVLOS drones can cover extensive areas, offer more precise real-time data collection, without requiring an observer to maintain direct visual contact.

In this blog post, we’ll explore the challenges of utility inspections, and how BVLOS drone connectivity enhances inspection efficiency and safety. We’ll also share real-world examples of how different utility sectors leverage drones to improve operations.

The Challenges of Utility Inspections

Utility infrastructure – power lines, waterworks, pipelines, and communication towers – spans vast distances, often across remote, hazardous locations and rugged terrain. Maintaining these critical systems requires regular inspections, but traditional methods face several key challenges.

• Safety risks – Inspecting high-voltage power lines, communication towers, and gas pipelines often requires workers to operate in dangerous conditions, exposing them to hazards such as falls, electrocution, and hazardous material exposure.

Utility line work is among the most dangerous professions. According to the 2021 Bureau of Labor Statistics (BLS) data, the fatality rate for electrical power-line installers and repairers was 19.0 fatalities per 100,000 full-time equivalent workers, one of the highest rates across all occupations.

• High costs – Utility companies spend millions annually on inspection teams, helicopter surveys, specialized equipment, and labor-intensive ground patrols. Aerial inspections using manned aircraft are particularly costly, and ground inspections can take days or weeks to complete in remote locations.
• Time-consuming processes – Traditional inspection methods are slow and inefficient due to logistical challenges in sending crews to remote or hard-to-reach areas, terrain obstacles, requiring specialized vehicles or access permits, and manual equipment setup and analysis, delaying maintenance response times.
• Failure to detect subtle changes – Limited visual inspections may fail to identify subtle defects. Scheduled maintenance that follows fixed intervals doesn’t always align with emerging issues before they become critical failures.
• Environmental challenges – Utilities must operate in diverse environments, such as mountains, forests, deserts, and urban centers. Weather conditions such as extreme temperatures can make inspections even more difficult and dangerous, delaying inspection efforts.
• Regulatory compliance – Utility companies must adhere to strict safety, reliability, and environmental regulations, requiring consistent monitoring and accurate reporting. Maintaining compliance demands detailed, up-to-date inspection records, but traditional inspection methods—which rely on manual data collection and labor-intensive processes—are often time-consuming, costly, and prone to human error.

Five Ways UAV Technology Is Redefining Utility Inspections

UAV technology transforms utility inspections, providing a cost-effective, safer, and more efficient alternative to traditional methods.

• Increased safety – UAVs or drones reduce the need for workers to enter hazardous environments, such as high-voltage power lines, gas pipelines, or elevated towers, significantly reducing accidents, injuries, and exposure to dangerous conditions.
• Lower costs – A single drone can replace multiple ground crews and expensive aerial surveys, reducing labor, equipment, and operational costs.
• Faster and more frequent inspections – Drones perform inspections in hours rather than days, enabling more frequent assessments and early detection of potential issues, helping to prevent costly failures and operational disruptions.
• Accelerated damage assessments – Drones allow utilities to rapidly survey disaster-hit areas, reducing downtime and expediting repairs.
• High-quality data collection – Equipped with high-resolution cameras, LiDAR, thermal imaging, and gas detection sensors, drones capture detailed and actionable data that traditional methods often miss.

Expanding the Reach of Utility Inspections with BVLOS Connectivity

Traditional drone operations rely on LOS (Line-of-Sight) connectivity, where the UAV must remain directly visible to the pilot, or EVLOS (Extended Visual Line of Sight), where trained observers stationed along the flight path maintain visual contact and relay information to the pilot via radio communication. While LOS/EVLOS drone operations offer benefits, they limit the range and scalability of utility inspections.

Beyond Visual Line of Sight (BVLOS) connectivity unlocks long-range, remotely controlled inspections, taking utility inspections to the next level. Utilities can operate BVLOS drones from a centralized DNOC (Drone Network Operation Center), enabling experts to safely inspect high-quality video and sensor data without traveling to the field. BVLOS connectivity is particularly valuable while inspecting hard-to-reach infrastructure in remote, hazardous, or high-risk environments.

BVLOS drone connectivity offers significant advantages over LOS (Line-of-Sight) and EVLOS (Extended Line-of-Sight) connectivity:

• Expanded situational awareness – BVLOS UAVs and drones can cover large areas quickly, providing real-time data for faster and more accurate decision-making.
• Continuous monitoring in any environment – Utilizing all available wireless spectrum – cellular, satellite, and RF communication – BVLOS drones ensure uninterrupted data transmission, even in rugged, remote, or urban settings where connectivity is traditionally challenging.
• Safer, faster inspections – BVLOS-powered drones reduce the need for ground crews in hazardous areas, minimizing risk and speeding up the inspection process.
• One operator per drone fleet – A single operator can manage and control multiple drones simultaneously, streamlining operations, reducing labor costs, and enabling continuous, autonomous infrastructure monitoring with minimal human intervention.

However, the success of Beyond Visual Line of Sight (BVLOS) operations hinges on reliable connectivity. Uninterrupted communication is a key regulatory requirement for maintaining control, ensuring safety, and transmitting precise real-time inspection data.

BVLOS Drone Regulations and Infrastructure Inspections

Recent regulatory changes in the US (2024 FAA Reauthorization Act) and UK (CAA’s BVLOS exemptions) are shifting drone regulations from restrictions to enablement, accelerating adoption for infrastructure inspections. These changes are helping utilities, transportation agencies, and local governments improve efficiency and scale operations while increasing safety, speed, versatility, and accuracy.

The Part 91 exemption represents a significant leap forward in drone operations, allowing Southern Company to operate SwissDrones advanced vertical takeoff and landing platforms without requiring a pilot or visual observer to maintain a direct line of sight. Southern Company’s successful petition for a Part 91 exemption underscores its leadership in advancing regulatory frameworks for UAS operations.

Southern Company’s successful receipt of an FAA exemption for BVLOS operations is paving the way for broader adoption of utility drone operations and BVLOS regulatory progress. The exemption sets a precedent for other industries seeking to adopt BVLOS technology, signaling the FAA’s growing support for integrating drones into national airspace for commercial and industrial purposes.

Drones in Action: Transforming Inspections Across Utility Sectors

Across the utility landscape—from electricity to water, gas to telecommunications—drone technology redefines inspection operations, delivering unprecedented efficiency, safety improvements, and cost savings while capturing high-quality. Let’s explore how the different utility sectors harness this technology to transform their operations.

Power Utilities: Electrical Grid Inspections

Power utilities face the daunting task of maintaining numerous components across thousands of miles of transmission and distribution infrastructure. Traditional methods—relying on ground crews navigating rugged terrain or expensive helicopter flights—are rapidly being supplemented by drone technology that delivers superior results at a fraction of the cost.

Inspection drones deploy multiple specialized sensors, providing comprehensive data about electrical infrastructure. High-resolution cameras capture submillimeter defects, thermal sensors identify potential hotspots before they fail, and UV sensors detect corona discharge issues invisible to the human eye. This multi-layered approach enables utilities to detect and address emerging problems before they cause outages.

Elsight’s customer Censys Technologies was contracted by the Florida Department of Transportation to report on power lines that were still down in the months following Hurricane Helene. Censys used its Sentaero 5, a Vertical Take-Off and Landing (VTOL) fixed-wing drone, to offer unparalleled benefits for long linear power line inspections. More details are available here. By using Elsight’s BVLOS Halo, Southern Company, was approved as first utility to secure FAA Part 91 exemption for BVLOS operations using a 191-pound remotely piloted rotorcraft.

The Saudi Electricity Company (SEC) faced the challenge of inspecting 5,500 transmission towers and overhead lines (OHL) across more than 4,000 km. SEC’s traditional inspection methods would have taken over three years to complete. By deploying drones, they cut inspection time by 80%, completing the task in just 183 days. Beyond the time savings, the drone inspections delivered higher-quality data while significantly improving operational safety.

Water Utilities: Water Infrastructure Monitoring

Water utilities must regularly inspect pipelines, reservoirs, and treatment plants to detect leaks, maintain infrastructure, and comply with regulations. Drones equipped with thermal and multispectral sensors help water utilities locate leaks faster, assess structural integrity, and improve efficiency in water management.

​Severn Trent Water, one of Britain’s largest water companies, uses drones for pipe bridge and industrial inspections to enhance operational efficiency and safety, particularly in potentially hazardous situations.  The company reported £750,000 in documented savings during the second year of implementation, with projections reaching £1.5 million in the subsequent year.

The Otay Water District, a California-based water, recycled water, and sewer service provider, uses drones to inspect water facility assets, including 40 potable water reservoirs, four recycled water reservoirs, 20 pump stations, and a recycled water treatment plant, improving preliminary asset assessments and minimizing manual inspections.

Oil & Gas Utilities: Pipeline Leak Detection

Pipeline operators face unique challenges in monitoring tens of thousands of miles of infrastructure, often traversing remote and challenging terrain while adhering to federal safety and environmental regulations. Drone inspections incorporate specialized gas sensors capable of detecting methane and other emissions, thermal cameras that identify subtle temperature variations indicating potential leaks, and high-resolution imaging systems that spot physical damage or structural weaknesses.

Elsight’s customer Phoenix Air Unmanned (PAU) has announced the successful completion of a 320-mile pipeline patrol in just 7.6 flight hours using a single unmanned aircraft system (UAS). Conducted for Shell Pipeline Company (SPLC) in Louisiana, the achievement surpasses the project’s goal of patrolling 300 miles in a single flight day. The flights were performed under PAU’s nationwide beyond visual line of sight (BVLOS) regulatory approval, showcasing advancements in critical infrastructure inspection. It was achieved by Elsight’s customer Event 38 E455 UAS, a fixed-wing drone equipped with vertical takeoff and landing capabilities.

Telecommunications: Cell Tower Inspections

Telecommunications companies maintain tens of thousands of towers and masts—often in remote locations and at heights that pose significant safety challenges for human inspectors. Drones provide a faster, safer, and more cost-effective alternative to manual tower climbs, allowing companies to gather comprehensive inspections and schedule maintenance plans.

AT&T, one of the world’s largest telecommunications companies, has implemented drones for inspecting their 65,000-cell tower network across the United States, reducing the need for unnecessary hazardous climbs and cutting inspection times from a full day per mast to just hours. The company reported a 900% savings benefit since launching its drone program in 2016.

The Elsight’s Halo BVLOS Connection Confidence

For utility companies implementing BVLOS drone programs, reliable communication is the foundation of operational success. Elsight’s Halo BVLOS connectivity solution ensures seamless, uninterrupted communication, even in remote or challenging environments.

Key benefits for utility inspections:

• Multi-network bonding for continuous coverage: Halo seamlessly aggregates multiple communication links—including public and private cellular networks, satellite, and RF technologies—into a single, secure link. The multilink bonded pipe ensures communication availability even in remote or challenging environments. ​
• Automatic failover mechanism for always-on connectivity: Halo monitors all active connections preventing communication dropouts and ensuring uninterrupted data flow and control.
• High-bandwidth communication: Halo enables the transmission of high-definition video and large data sets, allowing for detailed visual assessments and in-depth analysis of utility infrastructure.
• Regulatory compliance facilitation: A secure and reliable communication link is key to meeting regulatory requirements for BVLOS drone operations. Halo helps operators gain approval for long-range drone missions by ensuring consistent, fail-safe connectivity.
• Rapid deployment: Halo minimizes setup time and operational delays, enabling fast and efficient deployment when needed most.

Elsight’s Halo lightweight and modular design enables seamless integration across diverse UAV platforms, regardless of size or form factor.

From power lines and pipelines to reservoirs and cell towers, BVLOS-powered inspection drones transform utility inspections, providing faster, safer, and more cost-effective solutions for maintaining critical infrastructure.

Contact us to power your drones with Elsight’s halo, the connectivity confidence you need for BVLOS inspections.

Key Takeaways

• Utilities must maintain the safety and reliability of vast networks across challenging terrain. Traditional inspection methods—ground crews, helicopters, and manual labor—are slow, costly, and hazardous.
• Drone technology transforms utility inspections, offering a safer, more efficient, and cost-effective alternative to traditional inspection methods.
• BVLOS (Beyond Visual Line of Sight) drone connectivity expands coverage beyond LOS (Line of Sight) and EVLOS (Extended Visual Line of Sight), allowing operators to inspect assets from a remotely located control center.
• Utilities are leveraging drones to inspect their infrastructure and detect potential issues before they escalate, improving efficiency, reducing costs, and enhancing workers and environmental safety.
• Elsight’s Halo ensures reliable BVLOS drone connectivity by providing continuous coverage, always-on connectivity, high bandwidth support, and regulatory compliance facilitation.

FAQs

1. How does Elsight support obtaining BVLOS regulatory approvals for utility inspections?

Reliable and redundant connectivity is a core requirement for BVLOS approval. Halo supports regulatory compliance by providing continuous C2, automatic failover, Remote ID, and traceable communication performance across long-range missions, helping operators build the safety case required by authorities such as the FAA and CAA.

2. Which UAV platforms are compatible with Halo?

Halo is designed for integration with a wide range of commercial and industrial UAV platforms. Its modular, low-SWaP design enables integration across different drone sizes and configurations. It supports high-bandwidth payloads, including LiDAR, thermal cameras, RGB imaging systems, gas sensors, and inspection-specific payloads used in utility operations.

3. How does Halo maintain reliable connectivity in remote utility corridors and challenging terrain?

Halo aggregates multiple communication links, including LTE, 5G, satellite, and RF, into a single logical connection. It continuously monitors link quality and dynamically reroutes traffic to maintain stable connectivity and sustain BVLOS operations in mountainous terrain, remote transmission corridors, and low-coverage areas.

4. How does Halo secure video and sensor data during BVLOS missions?

Halo’s secure communication architecture features encrypted VPN tunnels and multilink data distribution. Data is transmitted across multiple networks simultaneously, reducing interception risk and maintaining integrity even if one link is compromised. Logging and centralized management through the AllSight management platform support operational visibility and secure data handling.

5. How do BVLOS drones improve safety and efficiency in utility inspections?

BVLOS drone inspections eliminate the need for inspection crews to access hazardous or hard-to-reach infrastructure such as transmission lines, substations, and pipelines. They enable faster inspections over longer distances while capturing high-resolution visual and sensor data in real time. BVLOS inspections reduce labor costs, increase efficiency, and expedite real-time decision-making and remediation.