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. Access The Elios 3 could access the interior of the stack without requiring specialists to remove insulation. This streamlined the inspection process and reduced downtime. Safety By conducting flights from within a heated area, the team avoided working in cold outdoor conditions and eliminated the risk of working at heights. Adaptability The Elios 3 UT can operate beyond visual line of sight to capture UT measurements in areas where traditional methods are 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 performed multiple times a year, while more detailed structural analyses are conducted every 3 to 5 years. These checks help identify potential issues early, enabling proactive maintenance and reducing the risk of failures. When a visual inspection detects signs of damage, such as corrosion or cracking, a more precise method like ultrasonic testing (UT) is typically required. Ultrasonic thickness measurement (UTM) allows asset managers to assess the condition of the stack and compare it to historical data and industry standards. Accurate UT results determine if an asset is safe or requires urgent repairs. Osprey Integrity provides UAV solutions that reduce risks and offer cost savings for clients like BC Hydro, Suncor, Cenovus, Canadian Natural Resources, and Holcim across North America. In 2023, they were tasked with inspecting an industrial stack at a CNRL oil and gas facility in Northern Alberta. The stack was part of a once-through steam generator (OTSG), which heats water to produce superheated steam. The stack, insulated to manage high temperatures, posed challenges for traditional inspections. Removing the insulation required specialized personnel and equipment, increasing time, cost, and risk. Instead of removing insulation, Osprey Integrity used the Elios 3 for internal visual inspections. This allowed them to detect early signs of degradation that might be missed during external assessments. However, for precise measurements, they needed an alternative to traditional UT methods. A conventional UT inspection would involve lifting technicians via crane to strip insulation and take measurements. Osprey wanted to test the Elios 3 UT as a safer, faster, and more efficient solution. Thanks to the Elios 3's camera, it is possible to complete UT inspections beyond the visual line of sight. The Cockpit app allows manual adjustment of gain and gates, as shown on the left side of the screen. The main goal was to prove that the Elios 3 UT could match traditional UT procedures in accuracy and efficiency. The drone was able to enter the stack through a small access point, eliminating the need for cranes or elevated work platforms and avoiding any risk of working at height. Once inside, the pilot navigated to the targeted area and began taking measurements. The Elios 3 is designed to withstand contact, making it ideal for UT applications. It took four measurements in different directions, completing the task efficiently with the help of a couplant delivery system. The UT probe used in this project was a prototype of the final Elios 3 UT payload, but featured a similar magnetized probe hood that helped the payload attach to the inside of the stack After the flight, the results were quickly shared with the client. The entire process took under an hour, compared to the hours required for traditional methods. There was no disruption to the insulation on the outside of the stack, saving time and costs. Osprey Integrity highlighted several advantages of using the Elios 3 for UT inspections, which made the process faster and more effective than traditional methods. The Elios 3 UT payload was launched in March 2024, with deliveries expected later in the year. It offers a powerful solution that improves safety, saves time, and reduces costs without compromising data accuracy. This new tool enhances the capabilities of the Elios 3 and strengthens its value in non-destructive testing. 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 first mission with CNRL demonstrated the payload’s effectiveness. With two years of experience in drone-based UT inspections, Osprey Integrity’s endorsement highlights the Elios 3 UT as a game-changing addition to NDT across various industries. Discover more about the Elios 3 UT payload Surface Treatment Service Shenzhen Yuheng Precision Machinery Co., Ltd. , https://www.yhcncmachiningparts.comDrone Inspection of a Stack with the Elios 3 UT
Key Benefits at a Glance
Why a Service Provider Chose the Elios 3 UT for Inspection
The stack being inspected was one of these columns, each with protective insulation
Step-by-Step Ultrasonic Testing with the Elios 3
The Elios 3, equipped with its UT payload, flew inside the stack through this small access pointWhat Makes the Elios 3 UT Payload So Beneficial?
The Elios 3's articulated arm hosting the UT probe can be adjusted according to the asset being inspected
Learn More About the Elios 3 UT Payload