Drone Inspection of a Stack with the Elios 3 UT
The Elios 3 UT was deployed inside the stack, eliminating the need to remove external insulation and delivering precise, repeatable results ideal for routine inspections.
Key Benefits at a Glance
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Access The Elios 3 could access the interior of the stack directly, removing the need for specialists to remove insulation. This made the process more efficient and less disruptive to the structure. |
Safety By flying inside the stack, the team avoided working at height and stayed in a heated environment, reducing exposure to harsh outdoor conditions and improving overall safety. |
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Adaptability The Elios 3 UT could operate beyond visual line of sight, enabling ultrasonic thickness measurements in areas that were previously inaccessible from the outside. |
Reporting The data collected was clear and actionable, providing valuable insights into the stack’s condition for record-keeping and future maintenance planning. |
Industrial stacks require regular inspections to ensure they remain safe and operational. Visual inspections are conducted multiple times a year, while more detailed internal and external assessments are typically done every 3 to 5 years. These inspections help identify potential issues early and support proactive maintenance strategies.
When visual inspections detect signs of wear—such as corrosion or cracking—a more detailed analysis is needed. That's where ultrasonic testing (UT) comes in. Using ultrasonic thickness measurement (UTM), asset managers can assess the structural integrity of the stack and compare it to historical data and industry standards. Accurate UT results can determine if an asset is safe to use or if immediate action is required.
Why a Service Provider Chose a UT Drone Inspection
Osprey Integrity provides UAV-based inspection services that reduce risk and improve efficiency for clients like BC Hydro, Suncor, and Canadian Natural Resources Limited. In 2023, they were tasked with inspecting an industrial stack at an oil and gas facility in Northern Alberta managed by CNRL.
The stack served as the exhaust for a once-through steam generator (OTSG), which converts water into superheated steam. The stack operates at high temperatures, up to 180°C (350°F), and is protected by insulative material. Traditionally, this would require specialists to remove the insulation and conduct UT tests manually, often involving cranes or aerial work platforms.
Instead, Osprey Integrity used the Elios 3 UT to perform the inspection internally. This approach eliminated the need for physical access and allowed them to gather accurate data without disrupting the insulation or exposing personnel to hazardous conditions.
The stack being inspected had protective insulation covering its surface
Using the Elios 3, Osprey Integrity performed an internal visual inspection and then conducted UT measurements using the drone’s specialized payload. This method proved faster, safer, and more cost-effective than traditional approaches.
The Cockpit app allows for real-time adjustments to the UT probe settings during flight
How the Elios 3 UT Conducts Ultrasonic Testing
The goal of the project was to demonstrate how the Elios 3 UT could match or exceed traditional UT methods. The drone entered the stack through a small access point, eliminating the need for cranes or elevated platforms. Once inside, the pilot navigated to key measurement locations and took UT readings at four points in different directions.
The Elios 3 is designed to withstand contact, making it ideal for UT testing. It also features a couplant delivery system that enables rapid and accurate measurements. The entire process took under an hour, significantly faster than conventional methods.
The Elios 3 flew through a small opening to reach the interior of the stack
The UT probe used in this test was a prototype of the final payload, but it already demonstrated strong performance. Its magnetized hood allowed it to attach securely to the inner walls of the stack, ensuring stable and accurate measurements.
The UT probe was mounted on an articulated arm, allowing for flexible positioning during the inspection
What Makes the Elios 3 UT Unique?
Osprey Integrity found several advantages in using the Elios 3 UT for ultrasonic testing:
- Repeatability. The Elios 3 creates a point cloud that marks each measurement location, making it easy to return for future inspections. This helps track corrosion rates and plan maintenance over time.
- Real-time viewing and recording. Pilots can view A-scan data in real time and review recordings to make adjustments if necessary. This reduces the need for re-inspections and improves accuracy.
- Enhanced access. The Elios 3 can reach tight spaces that other UT solutions cannot, thanks to its compact design and collision tolerance. It also collects LiDAR and visual data simultaneously, increasing its versatility.
- Customizable design. The UT probe can be adjusted based on the inspection requirements, and the pilot can control gain and gate settings during flight. This ensures reliable and consistent data collection.
The articulated arm allows the UT probe to adjust to different inspection points
Learn More About the Elios 3 UT Payload
The Elios 3 UT payload was launched in March 2024, with deliveries expected later in the year. It offers a powerful solution for ultrasonic testing, improving safety, saving time, and maintaining data accuracy. As one of the first companies to test the payload, Osprey Integrity has seen firsthand how it enhances non-destructive testing across industries.
At Flyability's User Conference in March 2024, Osprey Integrity shared their positive experience with the Elios 3 UT, highlighting its effectiveness in the field. With two years of experience in drone-based UT inspections, they believe the Elios 3 UT represents a major advancement in the field.
Discover more about the Elios 3 UT payload
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