Drone Inspection – Chemical Industry – WITHOUT Entry into Toxic & Contaminated Facilities

Kopterflug inspects reactors, columns, process vessels and storage tanks in the chemical and petrochemical industry – without human entry, without scaffolding, without decontamination of personnel. 4K documentation, thermography and LiDAR 3D scanning in a single flight.

• No human entry – DGUV confined space entry procedures are eliminated
• GPS-free navigation in closed metallic structures (SLAM + LiDAR)
• 4K + Thermography + LiDAR in one flight
• Fully decontaminable – no cross-contamination between plant sections
• Up to 80% cost savings compared to conventional confined space entry

Drone Inspection in Chemical Plants: Safe, Without Entry, with Reliable Data

The ELIOS 3 with its collision-safe carbon cage – built for contaminated reactors, columns and process vessels.

Chemical plants are among the most demanding inspection environments: toxic atmospheres, strict explosion protection requirements, narrow gaps between columns and pipelines – and maintenance teams that must keep every shutdown as short as possible. Conventional access requires elaborate gas-free measurements, protective equipment, scaffolding and coordinated lockouts. With the Flyability ELIOS 3, the bulk of this overhead disappears.

The collision-protected drone navigates GPS-independently through reactors, columns, pressure vessels and shafts – delivering 4K video, radiometric thermography and optional LiDAR data without any employee entering the hazardous area. The inspection takes place after gas-free measurement by your HSE department; we coordinate closely with your safety officer.

Typical damage patterns in chemical plants that we specifically inspect for: corrosion and pitting on vessel walls and nozzles from aggressive media, coating damage in reactors and storage tanks, deposits and encrustations in column internals affecting process performance, and cracks and deformations in refractory linings in high-temperature zones. Hotspots on heat exchangers and pipelines are captured via thermography.

Technical assessment of findings remains with your process engineers, TÜV inspectors and DEKRA experts – we deliver the data foundation: 4K images, thermography evaluations and, on request, centimetre-accurate LiDAR point clouds, processed ready for CAD and BIM.

What We Inspect in the Chemical Industry

Chemical plants are highly complex and often contaminated. We inspect all safety-critical assets – without human entry, without decontamination:

Reactors & Stirred VesselsProcess reactors, stirred tanks, pressure vessels – contaminated, toxic. Document linings, agitators, heating coils. Without entry.

Columns & Distillation UnitsDistillation columns, absorption columns, crackers – tight areas, tall columns. Inspect internals, trays, packings. Without human entry.

Tanks & Storage VesselsChemical tanks, storage tanks, buffer vessels – without human entry, without DGUV confined space entry. Document coatings, corrosion, linings.

Silos & Bulk StoragePowder silos, solid vessels, bulk material storage – without entry. Detect bridging, deposits, lining damage.

Tube Bundle Sections & Convection AreasTube bundles, deflection areas and flow zones in process furnaces and heaters – often extremely difficult to access. Document fouling, tube bowing and hotspots without human entry.

Cooling Towers & Process Cooling Systems (interior)Packing media, water distribution and supporting structures in wet cooling towers. Detect biofouling, blockages and corrosion without access.

Containment Basins & Safety PondsContainment structures for chemicals – systematically capture coating damage, cracks and leaks before they become a major incident.

Flanges & Valve ClustersDense fitting areas in difficult-to-reach zones – detect leaks, corrosion and damaged seals early with thermography and 4K.

Pre-Startup Inspection (Turnaround Check)Rapid visual inspection immediately after turnaround, before plant restart. Identify forgotten foreign objects, incorrectly installed internals and damage – under maximum time pressure.

What We Document During Chemical Plant Inspections

We fly the ELIOS 3 into your plant and systematically document all safety-relevant areas. Technical assessment is handled by your process engineers and inspectors – we deliver the data:

Reactors & Stirred Vessels

What we check: Wall corrosion, coating damage, cracks at internals and nozzles, condition of agitators and heating coils.

Why it matters: Reactors are pressure vessels per BetrSichV – wall thinning, pitting or coating failure can lead to uncontrolled releases. Early finding documentation secures continued operation.

How we do it: ELIOS 3 navigates through the manhole opening, systematically covering wall sections, internals and nozzles – 4K camera at close range, thermography for hotspots and coating delaminations.

Columns & Distillation Units

What we check: Packings, trays and internals for deposits, corrosion, deformation; condition of deflector plates and nozzles.

Why it matters: Blocked column internals directly impair process efficiency and can lead to pressure build-up. Damage to trays and packings is often only reachable by conventional access with extensive scaffolding.

How we do it: The ELIOS 3 flies column segments top to bottom – even tight areas between internals are fully captured with the 180° field of view of the 4K camera; high-capacity battery or tether for long columns.

Storage Tanks & Process Vessels

What we check: Floor corrosion, wall corrosion including the water-oil interface zone, coating integrity, sediment deposits, nozzles and manhole frames.

Why it matters: Process vessels with aggressive media are particularly corrosion-prone. Wall thinning and coating failure lead to leaks – often in locations unreachable without a drone.

How we do it: Full interior documentation after emptying – ELIOS 3 covers walls, floor and roof interior; thermography detects delaminations and moisture behind the coating.

Heat Exchangers & Pipelines

What we check: Pipe corrosion, hotspots and insulation damage along pipeline routes, condition of pipe bridges and supports.

Why it matters: CUI (Corrosion Under Insulation) and leaking pipeline connections are among the most frequent damage causes in chemical plants – often detected late because the affected areas are inaccessible.

How we do it: DJI M30T with thermography for outdoor pipelines; ELIOS 3 for duct shafts and walkable conduit spaces; thermography evaluation identifies hotspots along runs.

Chimneys, Exhaust Ducts & Flue Gas Systems

What we check: Wall corrosion, cracks and material damage in the interior; condition of internals and expansion joints.

Why it matters: Corroded exhaust ducts can allow pollutant release and are subject to regulatory monitoring obligations. Interior inspection by scaffolding or rope access is costly and time-consuming.

How we do it: ELIOS 3 inspects chimneys and ducts after cooling (<50°C) from the inside – tether power unit for unlimited flight time in long shafts; LiDAR documents geometric deviations.

Shafts, Channels & Underground Infrastructure

What we check: Corrosion, cracks, leaks and deposits in inspection shafts, cable ducts and drainage structures.

Why it matters: Underground shafts are hazardous areas (Confined Space) per DGUV Regel 113-004 – access requires extensive safety measures. The drone documents the condition without human entry.

How we do it: ELIOS 3 navigates autonomously through tight shafts – LiDAR creates cross-sectional profiles, 4K camera documents cracks, deposits and corrosion zones.

Challenges in the Chemical Industry

Reactors, columns, process vessels – toxic, corrosive, difficult to access. Decontamination + respiratory protection + rescue chain = weeks of lead time. ELIOS 3 inspects in hours – without human entry, with 4K + thermography + LiDAR.

Toxic Environments with High Safety OverheadChemical residues, corrosive gases, mandatory respiratory protection. Confined space entry = DGUV measures, decontamination, rescue team. ELIOS 3 flies in without risk.

Downtime = Six-Figure LossesPurging, inerting, gas-free measurement = days. Every hour = production loss. Drone minimises downtime to a few hours.

ATEX Zones & Explosion RiskSolvent vapours, gases, dusts – even tiny ignition sources are critical. The drone reduces personnel exposure to a minimum – no one in the hazardous area.

Extensive Decontamination Before EntryReactors must be purged, neutralised and gas-free measured – often multiple times. With the drone, inspection can often begin sooner – less cleaning effort required.

Product Losses from Emptying & PurgingEvery inspection often means: product out, purge, dispose. This causes direct costs and environmental burden. Drones reduce interventions to a minimum – less product loss.

Coating Damage Goes Undetected for LongEarly damage leads to undercutting, blistering or delamination – often in hard-to-reach areas. 4K + LiDAR makes even small defects visible early.

Corrosion Under Deposits & FoulingProduct residues, polymer deposits or encrustations obscure critical areas. The drone identifies problematic zones – even without complete cleaning.

Complex Internals & GeometriesAgitators, internals, trays, packings in columns – many areas are barely reachable. ELIOS 3 navigates through complex structures and delivers full visibility.

Documentation for Audits & AuthoritiesAuthorities, inspectors and internal audits demand traceable condition assessments. Structured image data + 3D model create a solid decision basis.

Typical Inspections in the Chemical Industry

With the Flyability ELIOS 3 we inspect process plants without human entry – safely, precisely and with minimal downtime. Deployment after shutdown, gas-free measurement and operational release. Exact localisation in the 3D model:

Technology in Use for Chemical Plant Inspections

Flyability ELIOS 3 and DJI M30T for contaminated reactors, columns and pipe bridges – without human entry, fully decontaminable.

• ELIOS 3 without human entry in reactors and columns: Contaminated reactors, distillation columns and absorbers are inspected completely without confined space entry permits.
• Fully decontaminable: The ELIOS 3 is decontaminated after each deployment in contaminated areas – no cross-contamination between plant sections.
• DJI M30T for pipe bridges and CUI detection: CUI (Corrosion Under Insulation) on outdoor pipelines and pipe bridges is detected by thermography – without removing insulation.
• LiDAR: internals and geometry in columns: 3D measurement captures packings, trays and geometric deviations in columns for maintenance planning.
• Thermography: hotspots and leaks: Thermal images reliably reveal hotspots, leaks and insulation damage on pressure vessels and process pipelines.
• GPS-free navigation in metallic structures: ELIOS 3 SLAM navigation functions in completely enclosed metal vessels without satellite signal – precise and safe.

Your Benefits as a Chemical Company

• No human entry: No DGUV confined space entry, no respiratory protection, no personnel decontamination. Risk to your employees is completely eliminated.
• Minimal downtime: Inspection in a few hours instead of days. No complex preparation for human entry – faster restart.
• Precise damage detection: Thermography reveals leaks and hotspots. LiDAR captures geometry and deformations. 4K video documents every centimetre.
• Cost savings up to 80%: Compared to conventional confined space entry with scaffolding, decontamination and safety overhead, you save up to 80% of costs.
• DGUV-compliant: Our inspections meet DGUV requirements for confined spaces. No human entry = no risk.
• Reproducible inspections: Stored flight paths enable comparison inspections over years. Damage progression becomes measurable and documentable.
• Precise documentation – 4K + Thermography + LiDAR: Coating damage, corrosion, cracks – precisely documented. Thermal camera shows hotspots, LiDAR provides 3D twin for planning.

How the Inspection Works

Step 1: Initial Consultation (free)

We analyse your requirements and advise you free of charge on all technical and organisational questions.

Step 2: Scheduling & Quotation

You receive a transparent quote. Together we plan the timing, access and safety concept.

Step 3: On-Site Inspection

We carry out the inspection with state-of-the-art drone technology – usually within a few hours.

Step 4: Evaluation & Inspection Report

You receive a detailed report with 4K footage, 3D models, thermography analyses and a systematic findings overview.

Standards & Compliance for the Chemical Industry

Our inspections meet the highest safety and documentation standards of the chemical industry:

• DGUV Confined Spaces (DGUV Regel 113-004): No human entry required – eliminating all risks and requirements for confined space entry per DGUV.
• BetrSichV (Industrial Safety Regulation): Our documentation is structured per BetrSichV for pressure vessels and technical plant equipment.
• IEC 61511: Functional safety for safety-instrumented systems in the process industry – our data supports your safety instrumented system documentation.
• Customer-specific safety concepts: Coordination with your HSE team. We comply with all site safety regulations and permit procedures.
• Decontamination protocol: After deployment in contaminated areas, proper decontamination is performed per your specifications.
• EU Drone Regulation: Liability insurance coverage of €5 million.

Your Contacts for Chemical Industry Inspections

Christian Engelke and Dipl.-Ing. Karsten Lehrke – your direct contacts for chemical plant inspections.

Since 2017, we have been inspecting complex industrial plants – numerous deployments in reactors, columns and process vessels, routinely without human entry into contaminated areas. Highest safety standards, precise documentation, minimal downtime.

Christian Engelke and Dipl.-Ing. Karsten Lehrke are your direct contacts for technical questions – deployment planning, safety concepts, coordination with your HSE team.

Related Services

• Oil & Gas Inspection – Pipelines, reactors and refineries – inspection in potentially explosive areas.
• Tank Inspection – Interior walls, floors and coatings in chemical tanks documented without confined space entry.
• Confined Spaces Inspection – Inspection of tight, hazardous or contaminated interior spaces without human entry.
• Pipe Bridge Inspection – Corrosion and damage on pipe bridges and pipeline systems in the process industry.
• Industrial LiDAR Survey – Precise 3D measurement of plants, columns and complex process structures.
• Nuclear & Power Plant Inspection – Drone inspection under the highest safety requirements in radiation-exposed areas.

Frequently Asked Questions about Chemical Plant Inspections

Get in Touch

Questions about drone inspection for chemical plants or need a quote? Fill out the form below and we will get back to you within 24 hours.