Every industry around the world has its own set of rules and regulations to ensure the safety of people, the environment, and the equipment involved. These guidelines are established by a variety of entities, including governments, national agencies, international class societies, and multinational organizations.

Effective inspections rely on accurate data, but gathering that information isn’t always straightforward. For assets like ships or storage tanks, accessing certain areas for inspection can be dangerous or impractical. As a result, alternative methods of access are becoming more common, with drones playing a key role in this shift. Drones 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) designed to take ultrasonic thickness measurements. This technology allows it to gather ultrasonic thickness (UT) data from hard-to-reach locations, such as chimney stacks, ballast tanks, or flue ducts.

These drones are often used in drone-enabled non-destructive testing, which helps streamline the inspection process. By providing safer and more efficient access to assets, they make asset management more effective and reduce overall costs.

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

How Does a UT Drone Work?

UT measurements are taken when an ultrasonic testing device (a UT probe or gauge) is placed against the surface. Ultrasonic waves pass through the material, and the probe measures how the sound waves reflect back to determine the material’s thickness.

Traditional drones are not typically equipped to handle this kind of work, as they aren’t designed for prolonged hovering or contact with surfaces. That’s why UT drones are highly specialized, built to operate in environments where standard drones would struggle.

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

UT drones fly to a measurement point and place their probe or gauge against the surface. The pilot then applies couplant to ensure optimal sound transmission and takes the UT measurement. Some models allow for adjustments to gain and gates during the test based on the material being measured. After completing the measurement, the drone detaches and moves to the next location.

How Many Measurements Can a UT Drone Take?

The number of UT measurements a UT drone can take depends on its flight time, the amount of couplant it carries, and the skill of the operator. 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 significant advantages in terms of safety, efficiency, and access, all of which help reduce the overall cost of inspections.

SAFETY

Using a UT drone reduces the risk of human exposure during inspections. Some measurement points are located at heights or in confined spaces, requiring special permits and safety procedures. Finding qualified personnel who are also trained in rope access 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 enter spaces as small as 50x50 cm (20x20 inches) and take dozens of measurements per flight, eliminating risks like toxic gas exposure, suffocation, or drowning. They can also access high areas such as inside chimney stacks or ship hulls, where scaffolding or rope access is usually required. In some cases, like flue duct inspections, regulations require exits at both ends, which can involve removing parts of the duct. A UT drone can fly in and out without human entry, reducing downtime.

EFFICIENCY

UT drone inspections can be completed in under an hour. Drones can be deployed quickly upon arrival, and pilots can guide them beyond line of sight using high-definition cameras. Some models even have live LiDAR scans that create 3D maps of the surroundings.

Drones can move quickly between measurement points, even if they’re far apart. This is much faster than traditional methods, where inspectors have to navigate scaffolding or adjust between locations. Drones also outperform mobile elevated work platforms (MEWPs), flying freely without height or area limitations.

The recording process is also more efficient. Previously, UT measurements were shouted down from heights, making it hard to track exact locations and increasing error chances. Some inspectors marked values on the asset with chalk, but this was not weatherproof or clear for future use.

With a UT drone, each measurement is tagged, making it easy to identify areas with higher corrosion rates and send maintenance teams directly. When integrated with 3D scanning, like with the Elios 3, a digital record of the asset is automatically created, enabling updates and long-term tracking.

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

Overall, using a UT drone streamlines asset management, extending asset lifetimes through better monitoring and control.

ACCESS

UT drones can access areas that traditional methods cannot. Whether it's confined spaces, inside stacks, or within machinery, these UAVs enable new levels of non-destructive testing. Some models can even operate in GPS-free environments, making it easier to access underground or enclosed areas.

This enhanced access means inspections can be done more frequently. With a UT drone, measurements can be taken in minutes at heights where scaffolding would take days to set up. This allows for more frequent checks, helping to detect issues early and keep asset conditions up-to-date. UT drones support better asset management by providing critical data without causing downtime or extra costs.

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 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 needed a close visual inspection and UT measurements. Traditionally, this would require scaffolding and a team of 16+ people. With the Elios 3, all measurements were collected efficiently.

An example point cloud with the Elios 3 UT payload showing spot measurements.

Discover this UT drone for ship surveys.

⦁ A UT stack inspection with a drone

A power generation site had a stack that needed inspection. External insulation made it difficult, and harsh weather in Northern Canada added to the challenge. The Elios 3 UT drone provided an ideal solution, flying inside the stack where there was no insulation, eliminating the need for removal or 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

At a cement plant in Germany, an inspection team wanted to test the viability of a UT drone. They found that the Elios 3 UT could inspect flue ducts and silos without scaffolding or disrupting operations, offering easy access to areas that were previously hard 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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