Access Speed Using the Elios 3 UT, inspections are significantly faster than traditional techniques, allowing multiple large assets to be checked in a single day. Safety By using a UT drone, the need for scaffolding and rope access is reduced, lowering the risk of injury for workers. Â Data Quality The Elios 3 collects precise ultrasonic thickness measurements inside structures, meeting industrial standards and supporting digital asset management systems. Safe Seal Technology Co., Ltd. , https://www.sprsealkits.comUT Drone Inspections at a Cement Plant
Key Benefits in a Nutshell
A cement plant relies on a seamless connection between various assets—ranging from the quarry to the crusher, mills to the kiln, and clinkers to silos. Maintaining each of these components is carefully planned by site managers to minimize operational disruption when an asset is partially or fully out of service.
Inspections play a vital role in this maintenance process. While visual checks are part of the broader non-destructive testing (NDT) process, it’s also essential to gather ultrasonic thickness (UT) measurements to monitor the condition of critical equipment.
However, accessing these assets isn’t always straightforward. Traditional methods like scaffolding or rope access are often required, which are time-consuming and pose risks to personnel. Today, the Elios 3 with its UT payload offers a safer and more efficient alternative.
Why Choose UT Drone Inspections?
The Elios 3 is a specialized drone designed to navigate complex and confined spaces, replacing the need for human entry and reducing staff exposure to hazardous environments. It can reach the interiors of stacks or silos, collecting essential data to assess asset conditions and identify potential maintenance needs early.
InspecDrone, a German inspection company, tested the new UT payload on the Elios 3. As part of this trial, they visited a cement plant to inspect key assets and demonstrate how the drone could enhance and streamline the inspection process.
How the Elios 3 UT Works in Practice
1. Flue Duct Inspection
One of the first assets inspected was a flue duct. The duct starts as a rectangular structure before transitioning into a more curved shape. Due to high temperatures and corrosive dust, monitoring its condition is crucial. The duct is 50 meters tall, has only one open end, and is difficult to access via traditional methods.
With the Elios 3, the inspection became much simpler. A single pilot guided the drone through the duct in under two hours. The drone collected over 20 UT measurements per flight, providing clear visual and ultrasonic data that helped identify critical areas.
This efficiency led to additional demonstration flights on other assets, impressing site managers who were used to longer, more labor-intensive processes.
2. Silo Cone Inspection
Next, the Elios 3 was used to inspect the cones of limestone silos. These structures are elevated and require scaffolding or elevated platforms for access. Traditional methods involved significant planning, cost, and time, with limited accuracy due to manual chalk markings.
The Elios 3 completed the same task in 1-2 flights per silo, collecting 25–30 measurements efficiently. The results were recorded digitally with geolocation, making future comparisons easier and improving overall asset tracking.
Additionally, the drone was able to inspect smaller roof ducts that were previously hard to reach, offering insights that had never been available before.
Transforming the Future of Industrial Inspections
The Elios 3 UT proved to be a game-changer in a single day at the cement plant. It delivered speed, safety, and access that traditional methods simply couldn't match. Instead of days of setup and downtime, the drone provided quick, accurate data without compromising quality.
This shift not only improves operational efficiency but also enables proactive maintenance, reducing long-term costs and increasing plant output. With the ability to inspect more frequently and with greater precision, the Elios 3 sets a new standard for industrial inspections.
InspecDrone’s client was so impressed that they wanted to explore further applications of the Elios 3 UT across the site. From flues to silos, the drone showed that inspections don’t have to be slow or complicated—they can be fast, safe, and reliable.
UT Drone Inspections at a Cement Plant