UT Drone Inspections at a Cement Plant

Key Benefits in a Nutshell

Access The Elios 3 UT drone can enter an asset within minutes, whereas traditional methods often require at least one full day to set up and collect data.	Speed Using the Elios 3 UT significantly speeds up inspections, allowing multiple large assets to be checked in just one day.
Safety By using a UT drone for inspections, the need for scaffolding and rope access is eliminated, greatly reducing risks to workers.	Data Quality The Elios 3 captures ultrasonic thickness measurements inside structures to meet industrial inspection standards, enabling better digital asset management.

A cement plant depends on seamless connectivity between its various components — from the quarry to the crusher, mills to the kiln, and clinkers to silos. Each of these elements requires careful maintenance planning by plant managers to minimize operational disruptions when an asset is partially or fully out of service. Inspections are a critical part of this maintenance process. In many cases, visual checks are only a portion of the broader non-destructive testing (NDT) procedures. Gathering ultrasonic thickness (UT) measurements is also essential to monitor the condition of key assets. However, accessing these assets isn't always straightforward. Traditional methods like scaffolding or rope access can be slow and dangerous. Today, the Elios 3 with its UT payload offers a safer, more efficient alternative.

Why UT Drone Inspections Matter in Industry

The Elios 3 is a specialized drone designed to navigate complex and confined spaces without requiring human entry, significantly reducing staff risk. It can reach the interiors of stacks or silos to gather vital data that helps assess the condition of equipment and identify maintenance needs early. InspecDrone, a German inspection company, tested the new UT payload for the Elios 3. They visited a cement plant to inspect various assets and demonstrate how the drone could streamline and enhance the inspection process.

How the Elios 3 UT Drone Inspects Key Assets

1. Flue Duct

One of the first assets inspected was a flue duct. The duct starts as rectangular but transitions into a more rounded shape. Part of it had been replaced, and the client wanted to assess the degradation of the fixed steel. This duct carries hot, corrosive air and dust up to 300°C, making regular inspection crucial. Traditional methods required extensive preparation, including setting up ropes and safety protocols, which could take a full day. A team of three people was typically involved, with one climbing, another monitoring, and the third assisting. With the Elios 3, the process became much simpler. The drone entered the duct and flew through the target area under the control of a single pilot. The entire inspection took less than two hours. For this type of inspection, it's common to take five UT measurements per meter, plus additional spot measurements. The Elios 3 provided clear visual data, making it easy to identify areas for extra scans. Over four flights, the pilot collected over 20 measurements per flight, covering the first few meters of the duct. This efficiency allowed the team to perform additional demonstration inspections on other assets, impressing the site managers who were used to slower, traditional methods.

2. Silo Cones

Next, the Elios 3 was used to inspect the cones of limestone silos. These large steel structures were raised several meters off the ground, making access difficult. Traditionally, this would require scaffolding or elevated work platforms, which are time-consuming and costly. Instead, the Elios 3 completed the task quickly. With just one pilot, the drone could measure 25–30 points per silo in 1–2 flights. The results were stored digitally with geolocation, providing a clear record of measurement locations for future reference. Additionally, the drone was able to inspect small ducts in the building’s roof — previously difficult to access. Now, these areas could be inspected in minutes, offering insights that were previously unavailable.

Transforming Inspection Processes with Drones

The Elios 3 UT demonstrated remarkable speed, safety, and accessibility during a single day at the cement plant. It reduced the need for lengthy planning, special permissions, and extended downtime, allowing for quick and safe data collection.

Quality of results: with the Elios 3 UT, it is easy to localize and record UT points ready for analysis later in Inspector 5

Beyond efficiency, the drone’s ability to access hard-to-reach areas improves the overall operation of the site. More frequent inspections become feasible, leading to proactive maintenance rather than reactive fixes. This not only saves costs in the long run but also enhances productivity without compromising safety. InspecDrone’s client was so impressed that they wanted to explore further applications of the Elios 3 UT for other parts of the plant. From flue ducts to silos and smaller duct systems, the drone proved that inspections don’t have to be slow or complicated — they can be fast, accurate, and reliable.

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