The Elios 3 UT drone managed to navigate inside the stack, eliminating the need for insulation removal on the exterior. This approach delivered precise results that could be consistently reproduced for regular inspections. Accessibility The Elios 3 could easily enter the stack, negating the requirement for specialists to remove insulation. This saved both time and effort compared to traditional methods. Safety No personnel were required to work at height. Instead, the team operated safely from within a warm environment, avoiding exposure to harsh outdoor conditions. Flexibility The Elios 3 UT was employed beyond the line of visual sight to obtain UT measurements inside the stack where external inspection was not feasible. Reporting The collected data was clear and provided valuable insights into the stack's condition for maintaining records and planning future maintenance activities.  Industrial stacks undergo various inspections to ensure they remain safe for use. Regular visual inspections are performed several times a year. A thorough inspection that includes both internal and external structural analysis is usually done every 3 to 5 years. These routine checks enable preventive maintenance and early fault detection. A visual inspection identifying a potential issue, such as corrosion or cracking, triggers a more detailed examination. This is where ultrasonic testing, or UT, comes in. Using an ultrasonic thickness measurement (UTM), asset managers can better assess the stack's condition and compare it with existing records and industry benchmarks. An accurate UT inspection determines whether an asset is safe to operate or if urgent action is needed. Osprey Integrity offers UAV services that minimize operational risks and provide significant economic benefits to clients. Their services include major asset inspections for clients like BC Hydro, Suncor, Cenovus, Canadian Natural Resources, and Holcim across Canada and the USA. In 2023, Osprey Integrity was tasked with inspecting an industrial stack. The stack was located at an oil and gas facility in Northern Alberta, managed by Canadian Natural Resources Limited (CNRL). It served as the outlet for a once-through steam generator (OTSG). Water is pumped through tubes inside the OTSG by a boiler feedwater pump. Inside the OTSG, the water turns into superheated steam. The stack releases excess or waste gas, reaching temperatures up to 180 degrees Celsius (350 Fahrenheit). Due to the insulation, Osprey Integrity conducts a visual internal inspection (VI) of the stack using Elios 2 or Elios 3. The VI can detect signs of degradation, such as dew point or general corrosion, which might be overlooked during an external visual inspection. These findings may indicate an unsafe condition requiring quantification to assess the risk level. The insulative material helps manage the stack’s temperature and condition, especially in Alberta's extreme climate. A conventional ultrasonic testing procedure would involve a certified insulation specialist being lifted to the stack with a crane (or aerial work platform) to remove the insulation. Then, a certified UT technician would be lifted up with the crane to take measurements before the insulation was replaced. Alternatively, a UT drone inspection with the Elios 3 could gather data from inside the stack instead of relying solely on external data collection. This is what Osprey Integrity wanted to explore. Thanks to the Elios 3's camera, it is possible to perform UT inspections beyond the visual line of sight. The Cockpit app can also be used to manually adjust the gain and gates, as shown on the left side of the screen here. The main goal of this project was to demonstrate to the client how a UT drone inspection compares to the established ultrasonic test procedure. The Elios 3 and its UT payload had to prove themselves as an alternative method offering enough advantages to warrant adopting drones for at least some UT gauging. The Elios 3 fit perfectly inside the asset, flying in from an access point above the convection section and up through the stack. This eliminated the need for a crane or mobile elevated work platform (MEWP) and any person working at height. Inside the stack, the drone pilot navigated to the level of concern regarding the stack's condition. From there, the Elios 3 began taking measurements. Designed for withstanding contact, the Elios 3 was perfect for UT measurements. The probe successfully measured at four points in the cardinal directions. This efficiency was remarkable, especially since the drone could complete four UT measurements per minute thanks to a comprehensive system design, including couplant delivery. The UT probe used in this project was a prototype of the final Elios 3 UT payload, featuring a magnetized probe hood that helped the payload attach to the test site – in this case, the inside of the stack. After completing the flight, the pilot guided the drone back to the takeoff location, and the results were quickly provided to the client. The entire process took less than 60 minutes, significantly faster than traditional methods and without disrupting the insulative layer on the stack’s exterior. Osprey Integrity emphasized several key features of the Elios 3 that made the UT inspection fast and effective, surpassing traditional methods. The Elios 3 UT payload was launched in March 2024, with deliveries expected later in the year. It presents a powerful tool that improves safety while saving time and costs without sacrificing data accuracy. Moving forward, this payload will enhance the capabilities of the Elios 3 and increase its value for non-destructive testing across multiple industries. Osprey Integrity recently presented at Flyability's User Conference in March 2024, sharing their experience with the payload during its testing phase and how it impressed CNRL during the first mission. Osprey Integrity has been performing drone UT inspections for two years now, and their approval of the Elios 3 UT payload highlights how this device represents an exceptionally exciting and capable addition to drone NDT across various sectors. Discover more about the Elios 3 UT payload Round Link Kiln Chains are one of our main products. Round Link Kiln Chains can be manufactured by investment casting and flash welding technology. We can produce many kinds of round link kiln chains to meet many industries' requirements, like cement, paper, metallurgical, mining and chemical industry, etc. We can manufacture many sizes ans materials of chains according to the drawings. Round Link Kiln Chains,Ni-Cr Alloy Round Link Kiln Chains,Welded Round Link Kiln Chains,Cast Round Link Kiln Chains Jilin Huanyu New Materials Manufacturing Co., Ltd , https://www.huanyufoundry.comInspection of a Drone Stack with the Elios 3 UT
Key Benefits at a Glance
Why Osprey Integrity Chose a UT Drone Inspection
The stack being inspected was one of these columns, each with protective insulation.
Steps for an Ultrasonic Drone Inspection
The Elios 3, equipped with its UT payload, entered the stack through this small access point.
Advantages of an Ultrasonic Drone Inspection with the Elios 3 UT Payload
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