Drone Inspection of a Stack Using the Elios 3 UT

The Elios 3 UT was used to inspect the inside of a stack, eliminating the need for external insulation removal and delivering accurate, repeatable results ideal for routine inspections.

Key Benefits at a Glance

Access The Elios 3 could navigate inside the stack without requiring specialists to remove external insulation. This allowed for direct internal inspection, saving time and reducing risk.	Safety By conducting flights from within a heated area, the team avoided working in cold outdoor conditions and eliminated the need for work at height.
Adaptability The Elios 3 UT could operate beyond visual line of sight, enabling UT measurements in areas where external inspections were not feasible.	Reporting The data collected was clear and provided valuable insights into the stack’s condition, supporting maintenance planning and record-keeping.

Industrial stacks require regular inspections to ensure safe operation. Visual inspections are common, often conducted several times a year, while more detailed structural assessments occur every 3–5 years. These checks help identify issues early and support proactive maintenance strategies.

When visual inspections reveal potential problems like corrosion or cracking, a more detailed analysis is needed. This is where ultrasonic testing (UT) comes into play. Using ultrasonic thickness measurement (UTM), asset managers can assess the condition of the stack and compare it with historical data and industry standards. Accurate UT inspections determine if an asset is safe or requires urgent action.

Why a Service Provider Chose a UT Drone Inspection

Osprey Integrity provides UAV services that reduce operational risks and deliver significant cost savings. Their clients include major companies like BC Hydro, Suncor, Cenovus, Canadian Natural Resources, and Holcim across Canada and the U.S. In 2023, they were tasked with inspecting an industrial stack at an oil and gas facility in Northern Alberta, operated by Canadian Natural Resources Limited (CNRL).

The stack was part of a once-through steam generator (OTSG), which converts water into superheated steam. The stack serves as an exhaust system and can reach temperatures up to 180°C (350°F). Due to its insulated structure, traditional UT required removing insulation and using cranes or aerial platforms, posing safety risks and causing operational delays.

The stack being inspected had protective insulation on each column

Instead of traditional methods, Osprey Integrity opted for a drone-based approach using the Elios 3. This allowed them to inspect the interior without removing insulation, significantly reducing risk and disruption.

The Cockpit app allows manual adjustments to gain and gates during flight, enhancing accuracy

How the Elios 3 UT Conducted Ultrasonic Testing

The goal was to demonstrate how a drone-based UT inspection compared to traditional methods. The Elios 3 was able to enter the stack through a small access point, eliminating the need for cranes or elevated platforms. This made the process faster and safer.

The Elios 3 entered the stack through a small opening

Inside the stack, the drone pilot navigated to the target area and began taking UT measurements. The Elios 3 is designed to withstand contact, making it ideal for this type of inspection. It successfully measured four points in different directions, completing the task efficiently—up to four UT readings per minute.

The prototype UT probe used in this project featured a magnetized hood to attach to the stack's interior

After completing the flight, the drone returned to the starting point, and the results were delivered quickly. The entire process took under an hour, far faster than traditional methods and without disrupting the stack’s insulation.

What Makes the Elios 3 UT Payload Stand Out?

Osprey Integrity highlighted several advantages of the Elios 3 UT payload that made it superior to traditional UT methods.

1. Repeatability. The process was fast and efficient, and the measurements could be repeated easily. The drone created a point cloud, allowing future inspections to return to the same location for consistent data collection over time.
2. Real-time viewing and full A-scan recording. Pilots could view the ultrasonic waveforms in real time, ensuring proper contact and waveform quality. They could also review and adjust measurements if needed, avoiding the need for re-inspections.
3. Enhanced Access. The Elios 3 reached areas that no other UT solution could access so easily. Its ability to collect UT, LiDAR, and visual data simultaneously made it highly versatile for confined spaces and hard-to-reach areas.
4. Flexible Design. The Elios 3’s collision-tolerant design and adjustable UT probe arm allowed for customization based on the inspection needs. Pilots could position the probe precisely using the laser pointer and adjust settings mid-flight for optimal results.

The articulated arm adjusts to fit different inspection needs

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, safe, and efficient alternative to traditional UT methods, improving data accuracy while saving time and costs.

Osprey Integrity recently presented at Flyability's User Conference in March 2024, sharing their experience with the Elios 3 UT during its testing phase. Their success with CNRL marked a milestone in drone-based UT inspections. With two years of experience in this field, Osprey Integrity sees the Elios 3 UT as a game-changer for non-destructive testing across multiple industries.

Discover more about the Elios 3 UT payload

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