What are the advantages of drone inspections compared with conventional methods?

Drones record hard-to-reach areas without scaffolding, cranes or rope access technicians, covering the entire surface rather than spot checks, in hours instead of days. Shutdowns become shorter, costs fall, and every anomaly is located in the 3D point cloud. Measurements in contact with the component and the assessment are carried out by your expert assessors.

Are drone inspections also possible in confined spaces?

Yes, purpose-built drones for internal inspection such as the ELIOS 3 are designed for inspections in confined or hazardous areas such as tanks, columns and reactors – in columns and reactors where the manhole and internals leave enough room.

Does the plant have to be taken out of service for a drone inspection?

That depends on the installation. Vessels, columns, reactors and chimneys are taken out of service and released for internal flights; the shutdown is shorter because scaffolding and man entry are not needed. We inspect pipe racks from the outside and many hall areas while the plant is running.

Which technologies are used in drone inspections?

In addition to high-resolution cameras, drones use LiDAR for 3D point clouds and thermal cameras for thermal anomalies. Where required, wall thicknesses are measured by the expert assessor by ultrasound, specifically at the points marked in the inspection report.

How long does a drone inspection take?

The duration depends on the size of the plant and how it is accessed. The flight itself usually takes hours rather than days.

What damage does the footage show?

The footage shows corrosion, cracks, deformation, deposits and thermal anomalies such as hotspots or heat losses on the surface. A drone does not record wall thickness, concealed damage or exact crack widths; these require measurements on the component.

How are the results of the drone inspection documented?

You receive an inspection report with high-resolution photos, videos and – depending on the deployment – LiDAR or thermal data with located anomalies. It serves your expert assessors as the basis for assessment and repair planning.

Are drone inspections possible in potentially explosive areas?

Our drones are not explosion-protected. Whether and under what conditions they may fly in a potentially explosive atmosphere is decided by the operator.

Which plants can be inspected with drones?

Drones can be used on a wide range of plant, including tanks, chimneys, pipework, pipe racks, cooling towers, columns, reactors, crane runways and industrial furnaces.

How often should drone inspections be carried out?

The frequency depends on the plant, the inspection intervals and the operator's requirements. It often makes sense to combine the flight with planned turnarounds and shutdowns.

Drone inspection in the process industry: 10 specific use cases

In the process industry, drones reach hard-to-access areas without staff having to climb scaffolding or enter vessels. This article presents 10 practical use cases – from tanks and chimneys to pipework and refractory linings. With high-resolution cameras, LiDAR and thermography, drones deliver detailed data, shorten shutdowns and improve safety.

Process industry: shorter shutdowns, inspections in hours instead of days

The process industry places high demands on safety and accuracy – especially for plant that is difficult to access or hazardous. Our drone keeps shutdowns short: vessels, columns and boilers are usually taken out of service and released for an internal flight, but the inspection itself takes hours instead of days. Some plants, such as pipe racks seen from the outside, can be inspected without interrupting operations.
In this article we present 10 specific use cases – from tanks and chimneys to pipework and refractory linings – and what a drone inspection achieves in each.

Christian Engelke

Pipe rack from below with marked concrete damage

Concrete base of a pipe rack with marked damage

ELIOS 3 during an internal flight in a tank

Inspecting the ceiling of a hall roof with the ELIOS 3

1. Inspection of tanks and vessels

The inspection of tanks and vessels in the process industry is an important element of operational safety. The tank is taken out of service, emptied and released for the internal flight. The drone then records the inner and outer walls completely, without scaffolding and without anyone having to enter – the shutdown is shorter.

Inspection challenges	Traditional methods After draining, manual inspections also require scaffolding and man entry. Increased risks for employees in confined and hazardous spaces. Laborious and time-consuming localisation of damage. Typical damage patterns Corrosion on inner and outer walls. Cracks in coatings or welds. Sediment deposits and contamination.
Advantages of drone inspection	Less effort No scaffolding and no man entry after the tank has been drained. Data capture in hours instead of days; the shutdown is shorter. Safety Nobody has to enter the tank. Lower risk for employees during the inspection. Precision Close-up footage with high-resolution cameras. LiDAR point cloud in which every anomaly is located.
Application examples	Material inspection Detection of corrosion and damage on inner walls. Inspection of coatings and welds. Cleaning requirements Identification of sediment or deposits in the tank. Long-term monitoring Documentation of the condition for comparison with earlier inspections.
Results of the drone inspection	Improved maintenance Early identification and targeted repairs. Better planning of maintenance work. Cost reduction Shorter shutdown, because scaffolding and man entry are not needed. Reporting High-quality documentation through image and video data.

2. Inspection of chimneys

Chimneys and flue gas ducts in the process industry are often exposed to great heat, chemical stress and the weather. Regular inspection is essential to detect damage early and ensure operational safety. From the inside, the ELIOS 3 records chimneys and flue gas ducts after shutdown and release – without scaffolding or rope access technicians. Learn more on our page on industrial furnaces, refractory and flue gas ducts.

Inspection challenges	Traditional methods Require scaffolding or industrial rope access technicians. High expenditure of time and money. Hazardous conditions due to great heights and pollutants. Typical damage patterns Cracks in the masonry or in coatings. Corrosion of metal bands and anchorages. Deposits of soot or chemical residues.
Advantages of drone inspection	Less effort Outside while the plant is running, inside with a shorter shutdown. No scaffolding or long preparation times needed. Safety No hazards from work at great heights. Lower risk for employees. Precision High-resolution cameras and zoom reveal even fine cracks. Thermography to detect hotspots or leaks.
Application examples	Structural analysis Inspection of the masonry for cracks and spalling. Detection of corrosion on metal components. Cleaning requirements Identification of soot deposits or chemical contamination. Thermal inspection Localisation of hotspots or insulation problems.
Results of the drone inspection	Improved maintenance Targeted repair of damage based on located findings. Better planning of repairs and cleaning work. Cost reduction Avoidance of costly scaffolding and long shutdowns. Reporting Detailed documentation with visual and thermal data.

3. Inspection of pipework, utility lines and pipe racks

Pipework, utility lines and pipe racks are central infrastructure in the process industry, transporting substances safely and with minimal losses. Regular inspections are crucial to detect damage such as corrosion, leaks or structural weaknesses early. Drones capture these often hard-to-reach areas from the outside, usually while operations continue.

Inspection challenges	Traditional methods Require elaborate scaffolding or industrial rope access technicians. Hazardous working conditions, e.g. at great height or near chemical substances. Manual inspections of long pipeline sections often take days and remain spot checks. Typical damage patterns Corrosion on pipe and rack structures. Leaks due to material fatigue or pressure loads. Deformation or weakening of beams and anchorages.
Advantages of drone inspection	Less effort Long pipeline sections and racks recorded in hours instead of days. External flights while the plant is running. Safety No rope access technicians or scaffolding required. Low risk for inspectors in hazardous environments. Precision High-resolution cameras and zoom reveal even fine damage. Thermography and LiDAR for comprehensive analysis.
Application examples	Corrosion inspection Identification of rust and weakening on pipes and anchorages. Leak detection Indications of leaks from visible escapes or anomalies in the thermal image. Structural analysis Inspection of beams and supports on pipe racks.
Results of the drone inspection	Improved maintenance Targeted repairs based on located findings. Early detection of weak points reduces risks. Cost reduction Less effort for access measures and shutdowns. Reporting Detailed documentation with images, thermal images and a 3D point cloud.

4. Inspection of columns and reactors

Columns and reactors in the process industry have to be taken out of service for an inspection in order to reliably detect damage such as material fatigue, corrosion or cracks. With camera drones and specially developed drones for internal inspection such as the ELIOS 3, columns and reactors can be inspected from the inside without anyone having to enter – where the manhole and the spacing of the internals leave enough room, for example in the sump, the head or empty shell sections. We clarify this in advance using the drawings.

Inspection challenges	Traditional methods Require scaffolding, rope access or specialised equipment. Long plant shutdowns increase costs. Hazards to inspectors from chemical residues or extreme conditions. Typical damage patterns Corrosion on inner and outer walls. Cracks in refractory linings or protective coatings. Material fatigue due to cyclic loads and great heat.
Advantages of drone inspection	Less effort Data capture in hours instead of days after release. Shorter shutdown, because scaffolding and rope access are not needed. Safety No man entry. Reduced risk through the use of drones such as the ELIOS 3. Precision High-resolution cameras with their own lighting reveal even fine damage. LiDAR records the geometry as a 3D point cloud with located anomalies.
Application examples	Structural analysis Inspection of internals and protective layers. Identification of corrosion, cracks and deformation. Thermal analysis From the outside while the plant is running: indications of insulation damage in the thermal image. Confined access Inspections in confined areas with the ELIOS 3 or other drones for internal inspection.
Results of the drone inspection	Improved maintenance Targeted repairs based on located findings. Better maintenance planning with the inspection report. Cost reduction Reduced shutdown times and lower inspection costs. Reporting Documentation with high-resolution images and a 3D point cloud.

5. Inspection of cooling towers

Cooling towers play a central role in the process industry, particularly in power stations and large industrial plants. Regular inspections are essential to detect structural weaknesses, corrosion or deposits early. Drones record cooling towers without scaffolding or rope access technicians: from the outside while the plant is running, and the inner shell after shutdown, because plumes and fans do not allow flights during operation.

Inspection challenges	Traditional methods Require elaborate scaffolding or industrial rope access technicians. Hazards to inspectors from work at great heights and in confined areas. High expenditure of time and money due to long preparation times. Typical damage patterns Cracks and spalling in concrete or steel structures. Corrosion on load-bearing elements or connection points. Deposits or blockages that impair the cooling process.
Advantages of drone inspection	Less effort Short preparation without erecting scaffolding. Data capture in hours instead of days. Safety No scaffolding or rope access technicians needed. Lower risk for employees, because nobody has to work at height. Precision High-resolution cameras and zoom reveal even fine cracks. Thermography to analyse temperature differences and hotspots.
Application examples	Structural analysis Detection of cracks and spalling in concrete or steel structures. Documentation of corrosion on load-bearing elements. Thermal analysis Identification of temperature deviations in the cooling process. Cleaning requirements Identification of blockages or deposits that impair cooling performance.
Results of the drone inspection	Improved maintenance Targeted repairs and maintenance based on located findings. Better maintenance planning with the inspection report. Cost reduction Avoidance of costly scaffolding and long shutdowns. Reporting Documentation with high-resolution images, thermal images and a 3D point cloud.

6. Inspection of heat exchangers and condensers

Heat exchangers and condensers are essential components in the process industry that ensure effective heat transfer. Regular inspections are needed to detect contamination, deposits or structural damage early. Drones record the outside and – when the units are opened and released – accessible internal areas, such as the water boxes of large condensers. A drone cannot reach the inside of individual tubes in the bundle; there are dedicated testing methods for this.

Inspection challenges	Traditional methods Sometimes require partial dismantling of the unit for a complete inspection. Hazards to inspectors from chemical residues or heat. High expenditure of time and money due to complex access routes. Typical damage patterns Contamination and deposits on the heat transfer surfaces. Cracks or material fatigue at critical joints. Corrosion due to chemical or damp environments.
Advantages of drone inspection	Less effort Accessible areas recorded without scaffolding. Shorter shutdown when units are opened. Safety No direct contact with hot or chemical areas needed. Reduced risks through remotely operated inspections. Precision High-resolution cameras show deposits and damage in detail. Thermography to analyse heat distribution and hotspots.
Application examples	Cleaning requirements Identification of deposits or blockages that impair heat transfer. Structural analysis Inspection of welds and joints for cracks and corrosion. Thermal analysis Indications of areas with poor heat transfer from temperature deviations.
Results of the drone inspection	Improved maintenance Targeted cleaning and repairs based on located findings. Better maintenance planning with the inspection report. Cost reduction Reduced shutdown times and lower inspection costs. Reporting Documentation with high-resolution images and thermal images.

7. Inspection of warehouses and production halls

Warehouses and production halls often house complex installations and infrastructure that must be checked regularly to ensure safety and operability. Inspections of roofs, load-bearing structures and technical installations can be carried out by drone without scaffolding or aerial work platforms; operations in the hall are barely affected.

Inspection challenges	Traditional methods Require aerial work platforms, scaffolding or industrial rope access technicians. Time-consuming access measures and possible interruptions to operations. Hazards to inspectors from work at great heights or in confined areas. Typical damage patterns Cracks and corrosion on load-bearing structures and connection points. Damage or deformation on roofs or crane runways. Accumulations of dust or other residues that pose safety risks.
Advantages of drone inspection	Less effort Large areas recorded in hours instead of days, without aerial work platforms or scaffolding. Operations in the hall largely continue. Safety Nobody has to go up on an aerial work platform or the roof. Reduced risk for employees through remotely operated drone deployments. Precision High-resolution cameras and LiDAR for detailed damage documentation. Thermography to analyse insulation problems or leaks.
Application examples	Structural analysis Inspection of beams, roofs and crane runways for cracks and deformation. Identification of corrosion or other material damage. Cleaning requirements Identification of accumulations such as dust, dirt or residues. Heat losses Analysis of heat losses or insulation problems by thermography.
Results of the drone inspection	Improved maintenance Targeted repairs and cleaning based on located findings. Better maintenance planning with the inspection report. Cost reduction Fewer interruptions to operations and lower inspection costs. Reporting Detailed documentation with images, thermographic images and LiDAR data.

8. Inspection of conveyor systems and crane runways

Conveyor systems and crane runways are critical components in warehouses and production halls and are often subject to high loads. Regular inspections are essential to avoid safety risks and failures. Drones record these installations without aerial work platforms or scaffolding, even in hard-to-reach areas.

Inspection challenges	Traditional methods Require aerial work platforms, scaffolding or rope access technicians. Time-consuming and often involve interruptions to operations. Hazards to inspectors from work at great height or moving parts. Typical damage patterns Corrosion and cracks on load-bearing structures and connection points. Damage to rollers, rails or drive components. Loosening or material fatigue at bolted connections.
Advantages of drone inspection	Less effort No aerial work platform, no scaffolding. Brief closure instead of long shutdowns. Safety Nobody has to go onto the crane runway. Reduced risks through contactless drone deployments. Precision High-resolution cameras and zoom show damage in detail. Thermal images taken directly after operation show conspicuous heating on moving parts.
Application examples	Structural analysis Inspection of supporting structures, rails and running wheels for cracks and corrosion. Visual check of bolted connections and wearing parts. Thermal analysis Detection of hotspots on moving components such as bearings or drives. Long-term monitoring Regular inspections to avoid failures and safety risks.
Results of the drone inspection	Improved maintenance Targeted repairs and maintenance based on located findings. Better planning of maintenance intervals with the inspection report. Cost reduction Less downtime and lower inspection costs. Reporting Detailed documentation with images, thermal images and located findings.

9. Detection of thermal anomalies

Thermal anomalies such as hotspots or heat losses can point to problems such as leaks, insulation defects or overheating. In the process industry, detecting them early helps to avoid failures and energy losses. Drones with thermal cameras reveal such anomalies from the outside without interrupting operations.

Inspection challenges	Traditional methods Require elaborate access methods, e.g. aerial work platforms or rope access technicians. Often only manual measurements at individual points are possible. Hazards to inspectors from heat or chemical residues. Typical problem areas Hotspots on electrical or mechanical components. Heat losses on poorly insulated pipes or installations. Thermal anomalies due to leaks or process disturbances.
Advantages of drone inspection	Less effort Complete coverage without interrupting operations. Recording the heat distribution of large areas in hours instead of days. Safety No direct exposure to hot or hazardous areas. Lower risk for inspectors thanks to contactless imaging. Precision Thermal cameras reveal even small temperature differences. Anomalies located in the inspection report.
Application examples	Leak detection Localisation of leaks in pipelines or tanks from changes in the thermal image. Heat losses Analysis of heat losses on insulation or pipes. Hotspot identification Detection of overheating on mechanical or electrical components.
Results of the drone inspection	Improved maintenance Targeted repairs based on located thermal findings. Early detection of heat losses and safety risks. Cost reduction Avoidance of expensive failures through timely repairs. Reporting Documentation with thermal images and located anomalies.

10. Inspection of refractory linings

Refractory linings in industrial furnaces, reactors and other thermally loaded installations are essential for protecting the structure and for safe operation. Regular inspections are needed to detect cracks, spalling or material fatigue early. After shutdown and release, the drone records these often hard-to-reach areas without scaffolding, even in complex geometries or confined spaces.

Inspection challenges	Traditional methods Require elaborate access with scaffolding or rope access technicians. Hazards to inspectors from residual heat or cramped conditions. Long plant shutdowns increase costs. Typical damage patterns Cracks and spalling in the refractory lining. Material fatigue due to thermal cycles and chemical influences. Voids or detachment between lining and structure.
Advantages of drone inspection	Less effort Data capture in hours instead of days, even with complex geometries. Shorter shutdown, because scaffolding and man entry are not needed. Safety Inspectors do not need to enter hazardous areas. Lower risk, because the ELIOS 3 flies into the installation instead of personnel. Precision High-resolution cameras reveal even fine cracks and spalling. LiDAR records the geometry as a 3D point cloud with located anomalies.
Application examples	Structural analysis Detection of cracks, spalling and visible detachment in the lining. Thermal inspection A thermal image of the outer shell during operation gives indications of a defective lining. Long-term monitoring Regular documentation so that your expert assessors can compare ageing and wear over the years.
Results of the drone inspection	Improved maintenance Targeted repairs based on located findings. Better planning of maintenance work. Cost reduction Reduced shutdown times and lower inspection costs. Reporting Detailed documentation with high-resolution images and a 3D point cloud.

Inspect tanks, pipe racks and linings – without scaffolding, cranes or rope access

Drones have become an established inspection tool in the process industry. They capture tanks, chimneys, pipe racks and refractory linings – even in hard-to-reach and hazardous areas.
High-resolution cameras, thermography and LiDAR deliver data that improves safety and makes it easier to plan maintenance and repairs. Compared with scaffolding, cranes and rope access technicians, drone inspections shorten shutdowns. Your inspection costs can fall by up to 80% because scaffolding, cranes and rope access technicians are not needed.
Whether for preventive maintenance, urgent damage analysis or documenting repairs: you receive an inspection report with photos, videos, a 3D point cloud and located anomalies, on the basis of which your expert assessors carry out their assessment. You will find more about internal flights on our page on inspection with the ELIOS 3.