Modern Industry and the UT Drone

Every industry across the globe has its own set of rules and regulations designed to ensure the safety of people, the environment, and the equipment being used. These regulations are typically established by governments, national agencies, international class societies, and multinational organizations.

Conducting an inspection requires reliable data, but gathering that data can be challenging, especially when dealing with hard-to-reach assets like ships or storage tanks. As a result, alternative methods of access are becoming more common, and drones have emerged as a powerful solution. They can reach high places, confined spaces, or even underground areas to collect critical data that is otherwise inaccessible. This is where UT drones come into play.

Caption: All industries set strict safety protocols. Some sectors, such as shipping, rely on ultrasonic testing equipment to certify the condition of assets.

What is a UT Drone?

A UT drone is an unmanned aerial vehicle (UAV) equipped to take ultrasonic thickness measurements. This technology allows for the collection of ultrasonic thickness (UT) data from locations that are difficult to access, such as chimney stacks, ballast tanks, or flue ducts.

UT drones can be part of drone-enabled non-destructive testing, which streamlines inspection processes. By providing safer and more efficient access to assets, they help improve overall asset management and reduce inspection time and costs.

Caption: The Elios 3, pictured here, is an example of a UT drone.

How Does a UT Drone Work?

UT measurements are taken using ultrasonic testing equipment, such as a UT probe or gauge. The probe sends ultrasonic waves through the material, and the reflection of these waves is measured to determine the thickness of the material.

Traditional drones often struggle with this task because they aren’t built to maintain contact with surfaces or hover in place for long periods. That’s why UT drones are specially designed to operate in various environments, making them ideal for precise and safe inspections.

Caption: A UT drone carries a special payload with an ultrasonic thickness measurement probe.

UT drones fly to a measurement point and attach their probe to the surface. The pilot applies couplant to ensure optimal sound transmission and then takes the measurement. Some models allow for adjusting gain and gates during the process, depending on the material being tested. After the measurement, the drone detaches and moves to the next location.

How Many Measurements Can a UT Drone Take?

The number of measurements a UT drone can perform depends on its flight time, the amount of couplant it carries, and the skill of the pilot. For instance, the Elios 3 UT drone can complete up to 40 UT measurements per flight.

Benefits of a UT Drone

As part of drone-enabled non-destructive testing, UT drones offer numerous benefits, including improved safety, efficiency, and access to difficult-to-reach areas. These advantages ultimately lead to lower costs and better asset management.

SAFETY

Using a UT drone reduces the risk of human exposure to dangerous environments. Many measurement points are located at heights or in confined spaces, requiring special permits and safety protocols. Finding qualified personnel for such tasks can be difficult, increasing the demand for skilled inspectors.

Caption: A UT drone can inspect confined spaces like this tank instead of sending people.

UT drones can navigate tight spaces as small as 50x50 cm (20x20 inches) and take dozens of measurements per flight. This eliminates risks like exposure to toxic gases or drowning. Similarly, they can access high areas such as inside chimney stacks or ship hulls, reducing the need for scaffolding or rope access. In some cases, like flue duct inspections, regulations require exits at both ends for human entry, which involves removing parts of the duct. A UT drone can do the same without human entry, minimizing downtime.

EFFICIENCY

UT drone inspections can be completed in under an hour, thanks to quick deployment and real-time data collection. Pilots can guide the drone beyond line of sight using HD cameras, and some models include live LiDAR scans for 3D mapping.

Drones can quickly move between measurement points, even if they’re far apart, which is much faster than traditional methods like scaffolding or rope access. Drones also outperform mobile elevated work platforms (MEWPs), flying freely without height or space restrictions.

Recording data with a UT drone is more accurate and efficient. Previously, technicians would shout measurements down to someone on the ground, leading to errors. Some would mark the asset with chalk, but that’s not weatherproof or clear for future inspections.

With a UT drone, each measurement is geotagged, making it easy to track corrosion or degradation. When combined with 3D scans, like those from the Elios 3 UT drone, a digital record of the asset is automatically created, allowing for easy updates and long-term tracking.

Caption: Here are ultrasonic thickness measurements that have been geotagged by a UT drone during flight.

Drones streamline the entire asset management process, helping to extend the life of equipment through better monitoring and maintenance practices.

ACCESS

UT drones can reach locations that traditional methods can't—whether it's inside stacks, confined spaces, or machinery. These UAVs enable new levels of access in non-destructive testing. Some UT drones can even operate in areas without GPS, opening up access to underground or confined spaces with ease.

This enhanced access means inspections can be done more frequently. If a UT drone can take measurements in minutes at height, where scaffolding would take days, it becomes easier to conduct regular checks. More frequent inspections lead to early problem detection and a more accurate view of an asset’s condition. UT drones support better asset management by making critical data accessible without costly downtime.

Caption: A UT drone can fly into complex environments and gather critical data that was not available before.

UT Drone Case Studies

⦁ How a UT drone saved 15,000 work hours in a ship hull

The Elios 3 UT was used for a periodic survey of cargo oil tanks in a medium-sized ship. Each tank required a visual inspection and UT measurements. Traditionally, this would involve scaffolding and a team of 16+ people. With the Elios 3, all measurements were collected efficiently using the UT drone.

An example point cloud with the Elios 3 UT payload with spot measurements located in the point cloud

Discover this UT drone for ship surveys.

⦁ A UT stack inspection with a drone

A stack at a power generation site needed inspection. External insulation made it hard to access, and the location in Northern Canada added weather challenges. The Elios 3 UT drone provided a safe and efficient alternative, flying inside the stack without needing to remove insulation or use scaffolding.

Thanks to the Elios 3's camera, it is possible to complete 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.

Read the full UT stack inspection case study.

⦁ Flue Duct and Silo UT measurements

In a cement plant in Germany, an inspection team wanted to test the viability of using a UT drone. They found that the Elios 3 UT could inspect standard assets like flue ducts and silos without the need for scaffolding or disrupting operations. It also provided access to areas that were previously difficult to reach.

The Elios 3 and UT payload reached inside the flue duct despite dust and the bends in the duct's shape

Discover the Elios 3 UT for cement plant inspections.

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