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

Industrial stacks undergo regular inspections to ensure they remain safe and functional. Visual inspections are typically performed several times a year, while more comprehensive structural assessments—combining both internal and external checks—are done every 3 to 5 years. These inspections play a crucial role in preventing failures and identifying issues early on.

When a visual inspection detects signs of potential problems—like corrosion or cracking—it often leads to a more in-depth analysis. That’s where ultrasonic testing (UT) comes into play. Using ultrasonic thickness measurement (UTM), asset managers can assess the condition of the stack against existing records and industry standards. Accurate UT data helps determine whether the structure is still safe or if immediate action is needed.

Why a Service Provider Chose a UT Drone Inspection

Osprey Integrity provides UAV-based services that reduce operational risks and deliver significant cost savings for clients 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, managed by Canadian Natural Resources Limited (CNRL).

The stack was part of a once-through steam generator (OTSG). Water is pumped through tubes inside the OTSG, where it is heated into superheated steam. The stack then serves as an exhaust for excess gases, reaching temperatures up to 180°C (350°F). Due to its insulation, traditional methods would require removing the protective layer and sending personnel up via crane or aerial work platform to take measurements.

The stack being inspected had protective insulation covering its surface

Instead of using traditional methods, Osprey Integrity decided to test the Elios 3 UT drone. This allowed them to gather UT data from the inside of the stack without needing to remove insulation or send people up at height.

The Cockpit app allows manual control over gain and gates during UT inspections, enhancing accuracy

How the Elios 3 UT Conducted the Ultrasonic Test

The goal of this project was to demonstrate how the Elios 3 UT compared to traditional UT methods. The drone needed to prove it could offer real benefits, justifying its use for at least some UT gauging tasks.

The Elios 3 was able to fly inside the stack through a small access point above the convection section, eliminating the need for cranes or elevated platforms. This not only improved safety but also reduced time and costs significantly.

The Elios 3 entered the stack through a small opening

Once inside, the pilot navigated to the targeted area and began taking UT measurements. The Elios 3 is designed to withstand contact, making it ideal for this type of task. It successfully took readings at four points around the stack, achieving a high level of efficiency—up to four measurements per minute.

This prototype UT probe used a magnetized hood to attach to the stack wall during testing

After completing the flight, the pilot returned the drone to the starting point, and the results were delivered to the client within minutes. The entire process took less than an hour, far faster than traditional methods, and avoided any disruption to the insulation on the outside of the stack.

What Makes the Elios 3 UT So Effective?

Osprey Integrity highlighted several key advantages of using the Elios 3 UT for ultrasonic testing:

1. Repeatability: The measurement process was fast and efficient, and could be repeated easily. The drone tagged each measurement location in its point cloud, allowing for quick and accurate follow-up inspections in the future.
2. Real-time visualization and recording: Pilots could view the A-scan in real time, ensuring proper contact and waveform quality. They could also review and adjust measurements if necessary, avoiding the need for re-inspections.
3. Enhanced access: The Elios 3 reached areas no other UT solution could, due to its compact size and ability to operate in confined spaces. It also captured LiDAR and visual data simultaneously, expanding its utility for multiple applications.
4. Flexible design: The Elios 3’s collision-tolerant build and adjustable UT probe arm made it easy to adapt to different inspection needs. Pilots could choose different transducers and position the probe precisely using the onboard laser pointer.

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 and safe alternative to traditional methods, helping companies save time, money, and resources without compromising on data quality.

At Flyability's User Conference in March 2024, Osprey Integrity shared their experience with the Elios 3 UT during its testing phase. Their first mission with CNRL was highly successful, demonstrating the payload’s capabilities and value.

Osprey has been using drones for UT inspections for two years and is excited about the Elios 3 UT’s potential to transform non-destructive testing across multiple industries.

Discover more about the Elios 3 UT payload

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