Drone Inspection of a Stack with the Elios 3 UT
The Elios 3 UT performed an internal inspection of the stack, eliminating the need to remove external insulation and delivering precise, repeatable results ideal for routine checks.
Key Benefits at a Glance
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Access The Elios 3 was able to fly inside the stack instead of requiring access from the outside. This eliminated the need for specialists to remove insulation, saving time and reducing risk. |
Safety There was no need for workers to perform tasks at height, and the team could conduct flights from a heated area rather than working in cold outdoor conditions. This significantly improved safety and comfort. |
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Adaptability The Elios 3 UT could be used beyond visual line of sight to take UT measurements inside the asset where traditional methods were not feasible. |
Reporting The data collected was clear and actionable, providing detailed insights into the condition of the stack that can be used for maintenance planning and record-keeping. |
Industrial stacks require regular inspections to ensure safe operation. Visual inspections are typically conducted several times a year, while full internal and external structural assessments are done every 3 to 5 years. These routine checks help identify potential issues early and support proactive maintenance efforts.
When a visual inspection reveals signs of degradation—such as corrosion or cracks—an ultrasonic thickness measurement (UTM) is often needed. This allows asset managers to assess the stack’s condition accurately and compare it to historical data and industry standards. An accurate UT inspection can determine whether the stack is still safe to operate or if immediate action is required.
Why a Service Provider Chose a UT Drone Inspection
Osprey Integrity provides UAV services that reduce operational risks and deliver significant cost savings for clients. They have worked with major companies such as BC Hydro, Suncor, Cenovus, Canadian Natural Resources, and Holcim across Canada and the USA. In 2023, they were tasked with inspecting an industrial stack at an oil and gas facility in Northern Alberta managed 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 insulation, Osprey Integrity typically performs internal visual inspections using the Elios 2 or Elios 3. However, when a more detailed analysis was needed, they turned to the Elios 3 UT for ultrasonic testing.
The stack being inspected had protective insulation on the outside
Traditionally, ultrasonic testing would require a certified technician to climb the stack and remove insulation, which is both time-consuming and risky. Instead, Osprey Integrity opted for a drone-based solution, using the Elios 3 UT to gather data from the inside without disrupting the insulation.
The Elios 3's camera allows for UT inspections beyond the visual line of sight. The Cockpit app also lets users manually adjust gain and gates, as shown here.
How the Elios 3 UT Conducted Ultrasonic Testing
The main 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 work platforms. This made the process safer and faster.
The Elios 3 entered the stack through a small opening
Once inside, the pilot navigated to the critical area of the stack and began taking UT measurements. The Elios 3 is designed to withstand contact, making it ideal for this type of task. It successfully measured four points in different directions, completing the task efficiently and quickly.
This prototype UT probe features a magnetized hood that helps secure the payload to the inside of the stack
The entire process took under 60 minutes, far quicker than traditional methods. It also avoided disturbing the insulation on the outside of the stack, which is crucial in extreme climates like Alberta.
What Makes the Elios 3 UT Payload So Effective?
Osprey Integrity found several key advantages of using the Elios 3 UT for ultrasonic testing:
- Repeatability. The process was fast and efficient, and the same locations could be revisited easily using the drone's point cloud. This allows for long-term monitoring of corrosion rates and better maintenance planning.
- Real-time viewing and recording. Pilots could view the A-scan in real-time and even make adjustments during the flight. This ensures accuracy and eliminates the need for re-inspections due to errors.
- Enhanced access. The Elios 3 reached areas that other UT systems couldn’t, thanks to its compact design and collision tolerance. It also captured LiDAR and visual data simultaneously, making it a versatile tool for multiple applications.
- Flexible design. The UT probe was adaptable, with options for different transducers and an adjustable arm. Pilots could position the probe precisely using the laser pointer, ensuring accurate measurements every time.
The Elios 3's articulated arm allows for flexible positioning of the UT probe
Learn More About the Elios 3 UT Payload
The Elios 3 UT payload was launched in March 2024 and is now available for delivery later in the year. It offers a powerful, safe, and efficient alternative to traditional ultrasonic testing, saving time and costs without compromising data quality.
Osprey Integrity recently presented at Flyability’s User Conference in March 2024, sharing their positive experience with the Elios 3 UT during its testing phase. Their confidence in the technology highlights its potential to transform non-destructive testing across various industries.
Discover more about the Elios 3 UT payload
Luohe Letone Hydraulic Technology Co., Ltd , https://www.litonghose.com