Safety: no scaffolding, no work platform
Tank and silo inspections without scaffolding or aerial work platforms.
Inspect tanks and silos from the inside by drone – without scaffolding
With the Flyability ELIOS 3 we inspect tanks and silos in industrial plants, including hard-to-reach enclosed spaces – in hours instead of days, without scaffolding and without man entry. This makes the shutdown shorter.
- No scaffolding, nobody has to enter the vessel
- Wall, roof and floor in full instead of spot checks
- Hours instead of days, located findings
Watch the video on YouTubeA selection of Kopterflug clients and partners – operators in steel, chemicals, energy and logistics
Inspect tanks and silos without scaffolding and without man entry
Christian EngelkeGet in touch with our experts:[email protected]
Conventional inspections of tanks and silos are often time-consuming and costly, because scaffolding and aerial work platforms are needed. With the drone we inspect without erecting scaffolding and without man entry – in hours instead of days. Your inspection costs can fall by up to 80% because scaffolding, cranes and rope access technicians are not needed – more on this in our article on hybrid inspection in industry. Our footage and the inspection report serve inspectors and expert assessors as the basis for their assessment.
Every defect in the tank and silo located
Complete footage of the agreed areas and exact location of damage in tanks and silos.
Lower costs: no scaffolding, no man entry
No scaffolding, no aerial work platform, no man entry.
One report with photos and located findings
We fly – Inspectomatic, the reporting arm of our group of companies, analyses: located findings with photos, videos and a 3D point cloud, as an inspection report in the browser. More background on tanks and silos on inspectomatic.de (in German). The 3D point cloud with all located findings is produced by Inspectomatic – more on this at inspectomatic.de/punktwolken (in German).
What plants look like inside – footage from our inspections
Steel tank or plastic tank: how your tank ages and what the drone sees
Steel tanks and plastic tanks age differently because the two materials react differently to environmental influences and storage conditions. Steel tanks are mainly affected by electrochemical corrosion, while plastic tanks have weak points of their own.
Steel tanks: detect corrosion before the wall gives way
Steel tanks are particularly susceptible to corrosion due to frequent contact with water and chemicals. The main problems and protective measures:
- Electrochemical corrosion:
The biggest problem with steel tanks, especially in contact with water, moisture or aggressive chemicals. Rust can jeopardise the load-bearing capacity of the tank wall. - Microbiologically influenced corrosion (MIC):
Mainly affects tanks in the oil and gas industry or tanks containing organic substances or water. Sulphate-reducing bacteria (SRB) produce hydrogen sulphide, which accelerates corrosion. - Coatings and cathodic protection:
Protective coatings (e.g. epoxy resin or polyurethane) and cathodic protection (sacrificial anodes) extend the service life of steel tanks. Regular maintenance: without regular inspections, corrosion progresses unnoticed.
Plastic tanks: detect cracks and embrittlement before they start to leak
Plastic tanks (usually made of polyethylene, polypropylene or glass-fibre reinforced plastic) do not corrode in the conventional sense, but they have other weak points:
Chemical degradation:
Certain chemicals and solvents attack the plastic, weakening it or making it brittle – resulting in cracks or leaks.
Stress cracking: organic solvents in particular can trigger stress cracks, which spread over time and lead to leaks.UV degradation:
Outdoor tanks are exposed to UV radiation. Over time it breaks down the material and makes it brittle; this UV degradation considerably shortens the service life.
Solutions: UV stabilisers, paint coatings or covers.Heat and cold resistance:
In heat, plastic can deform or soften; in severe cold it becomes brittle and prone to cracking.Mechanical damage:
Plastic tanks are more susceptible to mechanical damage than steel tanks. Scratches or impacts can lead to cracks or leaks.Diffusion:
Due to the permeability of plastic, some chemicals can diffuse through the wall – relevant above all for flammable liquids or solvents.Long-term loading:
Under sustained load, for example from the weight of the contents, plastic gradually deforms (creep). This weakens large or highly filled tanks in particular.
Steel or plastic tank: which weak points to keep an eye on
| Aspect | Steel tanks | Plastic tanks |
|---|---|---|
| Susceptibility to corrosion | High risk of corrosion, especially with water and chemicals | No corrosion in the conventional sense, but chemical attack is possible |
| Protective measures | Protective coatings, cathodic protection, regular inspections | UV stabilisers, chemical resistance, mechanical protection |
| Chemical resistance | Depends on the coating; can be attacked by aggressive chemicals | Good resistance to many chemicals, but certain substances can cause stress cracking |
| Mechanical stability | Very high, resistant to mechanical loads | Sensitive to scratches, impacts and mechanical damage |
| Maintenance | Regular inspection and maintenance required to prevent corrosion | Less maintenance required, but regular checks for cracks and, from the outside, for UV damage |
The drone can make corrosion, cracks, blisters, delamination and coating damage visible, but not diffusion or creep deformation. Both steel and plastic tanks need their own protective measures: steel tanks are susceptible to electrochemical and microbiologically influenced corrosion, plastic tanks to chemical degradation, UV degradation and mechanical damage. How drones make the ageing of steel tanks visible is shown in our article 7 advantages of drone inspections for monitoring ageing and corrosion on steel tanks.
Tank inspection without scaffolding, with a shorter shutdown – write to our experts by email or via the contact form.
Detect damage and deposits in tanks and silos while repairs can still be planned
Damage, deposits and contamination in these vessels can impair operational safety and availability and lead to costly failures. Traditional inspection methods, however, can be expensive, result in long downtimes and pose safety risks for personnel.
- With drone inspections using the Flyability ELIOS 3, we capture high-resolution images and LiDAR data from inside tanks and silos. The footage and inspection report serve your inspectors and expert assessors as the basis for their assessment.
- Thanks to our many years of experience in tank inspection, we specifically examine and document typical defects such as corrosion on steel tanks, coating damage and damage to GRP tanks. This makes even minor defects visible and allows maintenance to be planned in a targeted way.
- We also inspect silos safely and without scaffolding. Drone inspection reveals abrasion and other structural damage early and documents it for long-term maintenance.
- Drone inspections with the Flyability ELIOS 3 mean no scaffolding, no man entry, shorter shutdowns.
Inspect tanks and silos without scaffolding – write to our experts by email or via the contact form.
Your tank goes back into service sooner
Hours instead of days: no scaffolding, no man entry.
Occupational safety: your staff stay outside
The drone flies into the vessel, personnel stay outside.
Every finding easy to locate again
The ELIOS 3 generates a point cloud showing the flight path and the position of any damage.
Your contacts from permit to inspection report
- Christian Engelke
Philipp von der Born
Dipl.-Wirt.-Ing. (FH) Juliana Engelke
Stefan Wolf
We plan inspections of tanks and silos to suit your plant, using the Flyability ELIOS 3 – including in hard-to-reach areas.
Inspect the tank wall and silo roof – without anyone having to enter the vessel
Inspecting industrial tanks such as steel tanks and GRP tanks with the Flyability ELIOS 3 drone allows a safe inspection of hard-to-reach areas without endangering employees. It visually records defects such as corrosion, cracks, osmosis and delamination, and from the outside also UV damage. The drone sees only surfaces: where required, wall thicknesses are measured by the inspector using ultrasound – specifically at the points marked in our report. With high-resolution cameras and LiDAR, the drone delivers accurate data for the condition assessment. The inspection takes hours instead of days, shortens the shutdown and helps to avoid expensive failures. The assessment is carried out by your inspectors or expert assessors on the basis of our inspection report.
Plan your next shutdown shorter – request a tank inspection
Tell us the asset and the occasion, and we will tell you which recordings and which report make sense.
Initial consultation: 30 minutes by video, pick a time directly.
- We look forward to your enquiry and will get back to you promptly.
Or write to us
Frequently asked questions
How does drone inspection differ from conventional inspection methods for tanks and silos?
Conventional inspections require scaffolding, aerial work platforms or rope access, and personnel have to enter the vessel. With drone inspection this is not needed: the tank has to be out of service and released for the drone flight, but the shutdown is considerably shorter. With a high-resolution camera and LiDAR, the Flyability ELIOS 3 records the entire internal surface rather than spot checks and reveals corrosion, cracks and deformation early; every anomaly is located in the 3D point cloud and can be compared at the next inspection. The drone has its limits wherever contact with the component is needed – wall thickness measurement, hammer testing, samples. These are carried out by the inspector specifically at the points shown in our inspection report.
Which tanks and silos can be inspected with the Flyability ELIOS 3 drone?
With the Flyability ELIOS 3 drone we inspect tanks and silos in industry and in power stations without scaffolding. Typical designs that can be flown:
- Storage tanks: cylindrical and rectangular tanks made of carbon steel, stainless steel, aluminium, GRP and concrete for raw materials, water, chemicals and fuels such as diesel or heating oil.
- Pressure vessels: cylindrical pressure tanks made of stainless steel, alloy steel and carbon steel for gases and liquids – depressurised, emptied and released for the inspection.
- Bulk material silos: cylindrical silos, bunker silos and cone silos made of concrete, steel, stainless steel and GRP for solids such as grain, cement, coal and chemicals.
- Spherical tanks: spherical tanks made of carbon steel, stainless steel and alloy steel for liquefied petroleum gas (LPG) on land – out of service, emptied and released for the inspection.
- Acid tanks and chemical storage tanks: tanks made of polyethylene, polypropylene, GRP and stainless steel for acids, alkalis and solvents.
- Biogas and fermentation tanks: gas-tight tanks made of steel, stainless steel, GRP and concrete in biogas plants.
- Sprinkler tanks: tanks made of steel, GRP and concrete that store water for firefighting. When they are full, we inspect them with our underwater drone.
In all these tanks and silos, the ELIOS 3 reveals corrosion, cracks, coating detachment, osmosis, delamination and other surface damage early. An entry opening such as a manhole is required; we clarify with you in advance whether a vessel can be flown.
How safe is the inspection of tanks and silos with the Flyability ELIOS 3 drone?
The Flyability ELIOS 3 inspects confined, hard-to-reach and hazardous areas without employees having to enter the vessel. Our pilots control it from outside the vessel, while the drone delivers high-resolution images and LiDAR data. A protective cage absorbs contact with walls and internals, and its own lighting makes even dark vessels visible. This is particularly suitable for chemically contaminated or hard-to-reach tanks and silos – always out of service, emptied and released for the drone flight. In potentially explosive atmospheres, the operator decides on the deployment.
How long does an inspection of tanks and silos with the Flyability ELIOS 3 drone take?
The duration depends on the size, condition and complexity of the tanks and silos. A drone inspection takes considerably less time than conventional methods, because scaffolding, aerial work platforms and rope access are not needed. Overall: hours instead of days – the shutdown is shorter, and several tanks can be inspected during one shutdown.
How are the objectives of a drone inspection of tanks and silos defined and monitored?
We define the objectives with you in advance. We clarify why the inspection is being carried out – routine check, damage documentation or preparation for a periodic inspection – and whether inspectors or external expert assessors are involved and what footage they need. We then plan the flight. During the inspection we continually check whether all agreed areas have been recorded and whether the data meets the defined objectives.
Is the ELIOS 3 easy to operate, and is special training required?
Inspection flights in confined spaces require experience – which is why our own pilots fly on our deployments. We do not offer pilot training. If you have your own ELIOS 3, we will be happy to advise you on how to use it.
What happens if defects or damage are found during the inspection of tanks and silos?
We show you obvious anomalies directly on the day of the deployment. High-resolution images and LiDAR data show the type and location of the damage; in the inspection report, all findings are located and explained with image and position. On request, we go through the report with you in a final meeting. The assessment is carried out by your inspectors or expert assessors, so that measures can be initiated in a targeted way.
Can tanks and silos also be inspected by drone while the plant is in operation?
No. For the internal flight, tanks and silos are always taken out of service, emptied and – depending on the contents – cleaned and released for the drone flight. This is the only way to record cracks, corrosion or deposits reliably. The advantage of the drone lies in the shorter shutdown: no scaffolding, no rope access technicians, no crane, no man entry. The inspection takes hours instead of days, and several vessels can be inspected during one shutdown. This is how our drone keeps the shutdown short.
How can I book a drone inspection for my tanks and silos?
Get in touch with us by email or via the contact form. We clarify the type and number of tanks or silos, the objectives of the inspection and the necessary preparation. You then receive a quotation and we agree a date that fits your shutdown.
Does the drone also measure wall thickness (UT measurement) during the tank inspection?
The ELIOS 3 records the surface: photos, videos and LiDAR data show corrosion, material loss and coating damage completely and with their location. It does not measure wall thickness. Ultrasonic measurements (UT) are carried out by your inspector or inspection service provider specifically at the points marked in our inspection report. This means measurements are taken only where they are needed.
What role does Kopterflug play in the inspection of tanks and silos?
Kopterflug flies tanks and silos with the Flyability ELIOS 3; the inspection report with photos, videos, a 3D point cloud and located anomalies is produced by Inspectomatic, the reporting arm of our group of companies. Your own expert assessors or appointed inspectors assess the condition on this basis. More on the inspection of industrial plants by drone.
What experience does Kopterflug have in inspecting tanks and silos in industrial plants?
Since 2017 Kopterflug has inspected tanks and silos in industrial plants, including steel tanks, GRP tanks and chemical storage tanks. We know the typical defects – corrosion, cracks, delamination or coating problems – and how to record them reliably. With the Flyability ELIOS 3 we also fly in tight spaces. More on the inspection of your industrial plants.
How does Kopterflug support cooperation with maintenance teams and plant managers when inspecting tanks and silos?
Before each inspection we define objectives and priorities with you, such as corrosion, cracks or coating problems. During the flight we capture all agreed areas; you receive the results as an inspection report with a 3D point cloud. This provides a clear basis for your maintenance team's decisions and for planning maintenance work.
What do you receive after the inspection of tanks and silos?
You receive an inspection report with high-resolution photos, videos, a 3D point cloud and located anomalies. The data is prepared so that inspectors and expert assessors can use it directly for their assessment.
How does Kopterflug take the requirements of inspectors and expert assessors into account?
Before each inspection, we clarify with you and, if applicable, your expert assessor what the footage is needed for – for example a periodic inspection, the search for specific defects or an inspection by the authorities. We then plan the flight and the inspection report accordingly. The assessment remains with the inspector or expert assessor.