7 benefits of drone inspections for monitoring ageing and corrosion on steel tanks
Steel tanks are a central part of industrial storage – but ageing and corrosion threaten their integrity. Drone inspections make tank monitoring safer and shorter – no scaffolding, no rope access technicians: damage is documented at close range without anyone having to enter the tank. Read on to learn about the seven benefits drone technology brings to tank inspection.
Tank inspection by drone: what you gain against ageing and corrosion
Steel tanks are under constant stress from ageing and corrosion. These processes threaten structural integrity and require systematic monitoring. Drones offer two routes here: inspection drones such as the ELIOS 3 fly inside empty, released tanks, while underwater drones inspect filled water and sprinkler tanks without them having to be drained.
Early detection, access to critical areas and long-term digital records work hand in hand. Operators benefit from lower maintenance costs, greater plant safety and a longer service life for their tanks.
Christian Engelke
1. Detect corrosion before it becomes critical
The weak point of ageing steel tanks is creeping corrosion. Pitting and stress cracking often develop unnoticed into critical structural damage. Inspection drones such as the ELIOS 3 significantly improve early detection: their high-resolution cameras and on-board LED lighting reveal even small surface changes. Thermal images can provide additional clues. This means corroded areas can be documented early and maintenance can be planned in a targeted way before costly damage occurs.
2. Tank roof, floor, joints: reaching the critical points
The most critical areas of steel tanks are often the hardest to reach: tank roofs, floor zones and joints. Thanks to its collision protection, the ELIOS 3 reaches them without any risk to personnel. It flies through the manhole into the tank – without scaffolding and without man entry. The tank has to be out of service, emptied and released for the drone flight; the advantage lies in a considerably shorter shutdown. For filled water and sprinkler tanks we use our underwater drone Chasing M2 Pro Max. The tank does not have to be drained, and the fire water supply remains available. The combination of aerial and underwater drones therefore covers most types of tank.
3. Camera, thermal imaging and LiDAR in one flight
The ELIOS 3 combines a high-resolution camera with thermal imaging and LiDAR.
This allows us to capture:
- surface corrosion with 4K imaging
- anomalies in the thermal image
- geometry and deformation with 3D mapping
- coating damage with LED-assisted inspection
The digital records form the basis for detailed damage analysis by your expert assessors and for data-driven maintenance decisions. The inspection report locates the images in the point cloud and so supports preventive maintenance.
4. Safety: nobody has to enter the tank
Traditional tank inspections expose staff to considerable risks. Drone technology largely avoids these hazards: the ELIOS 3 inspects confined, dark and potentially hazardous areas of the tank while the inspection team stays safely outside.
For water tanks, underwater drones allow safe inspections without divers. Remote inspection not only reduces health risks but also allows longer and more detailed inspections.
5. Comparison over the years: tracking corrosion
Corrosion develops gradually, so comparable records are essential. A systematic drone inspection delivers an inspection report with photos, videos, a 3D point cloud and located anomalies. The data produces a digital model of the tank in which the progression of corrosion can be traced from one inspection to the next. Regular drone inspections thus provide comparable datasets for predictive maintenance planning.
6. Short preparation, early repair of damage
Time is critical when tanks are damaged. Drone inspections need little preparation: unlike conventional methods, which require scaffolding and elaborate entry permits, the ELIOS 3 is ready for use after a short set-up time. This flexibility changes tank maintenance: damage is detected and documented promptly, and maintenance teams can plan measures early. This helps to limit the spread of damage and avoid costly repairs.
7. Lower costs: no scaffolding, shorter shutdown
Drone inspections change the economics of tank maintenance. Whereas conventional methods require expensive scaffolding, safety equipment and long shutdowns, the ELIOS 3 enables regular inspections without elaborate infrastructure.
Your inspection costs can fall by up to 80% because scaffolding, cranes and rope access technicians are not needed. In addition:
- The inspection itself takes hours instead of days.
- Fewer emergency repairs
- Longer tank service life through early maintenance
Regular drone inspections pay off through lower total operating costs and a longer service life.
Monitor steel tanks without scaffolding and with a shorter shutdown
Drone technology makes the monitoring of steel tanks safer, without scaffolding and with a shorter shutdown. With high-resolution imaging, flexible deployment and systematic documentation, operators gain a sound basis for tank maintenance. Safe inspection without man entry, early detection of damage and targeted maintenance extend the service life of the tanks. Learn more about our inspection of tanks and silos by drone – or write to us by email or via the contact form, and we will advise you on the right inspection strategy for your plants.