Power Plant Drone Inspection – NO Scaffolding, NO Human Entry, Inside & Outside

Kopterflug inspects power plants with the Flyability ELIOS 3 – boilers (Kessel), chimneys (Schornsteine), heat-recovery steam generators (Abhitzekessel), flue-gas ducts and cooling towers. No scaffolding, no confined-space entry: inspection in hours instead of weeks. LiDAR + 4K + Thermography, aligned with EN 12952, BetrSichV and the 1. BImSchV (German emission-control regulation).

• No scaffolding – drone enters through existing access openings (from DN 600)
• No human entry – no confined-space entry per DGUV Rule 113-004, no rescue chain
• 4K + Thermography + LiDAR in a single flight
• Documentation aligned with EN 12952, BetrSichV and 1. BImSchV

Power Plant Inspection by Drone: Fast Data, Short Downtimes

The Flyability ELIOS 3 with its collision-safe carbon cage – designed for complex boiler and flue-gas geometries.

In power plants, every hour of downtime counts. At the same time, boiler passes (Kesselzüge), chimneys, heat exchangers and flue-gas ducts are typically only reachable via scaffolding, rope access or human entry – methods that are not only expensive but needlessly extend maintenance windows. With the Flyability ELIOS 3, most safety-critical interior spaces can be inspected in a fraction of the time.

The collision-safe drone navigates GPS-independently through boiler passes, steam drums, chimneys and flue-gas ducts, delivering 4K video, radiometric thermography and optionally centimetre-accurate LiDAR data – without scaffolding, without human entry, after the installation has cooled to below 50 °C. For interior spaces with complex geometry or long vertical runs we deploy the Tether Power Unit, enabling unlimited flight time via ground power supply.

Typical findings in power plants that we inspect for: erosion and high-temperature corrosion on evaporator tubes (Verdampferrohre) and superheaters (Überhitzer), cracks and spalling in refractory linings (feuerfeste Auskleidungen) after thermal cycling, sulphurous attack (Versottung) and material damage in chimneys, and deposits in flue-gas passes and economisers (Economizer). Thermographic measurements complement visual documentation for hotspot analysis and insulation damage.

All technical assessment and safety decisions rest with your boiler experts, TÜV inspectors and DEKRA certifiers – we deliver the data foundation: structured 4K documentation, thermography reports and LiDAR point clouds that integrate into your existing maintenance documentation.

What We Inspect in Power Plants

Power plants have highly complex assets that require regular inspection. We inspect all safety-critical components – without scaffolding, without human entry:

Water-Tube Boilers (Wasserrohrkessel)Evaporator tubes, superheaters, economisers, refractory linings – without scaffolding, with 4K + Thermography + LiDAR. Documentation as basis for certified inspectors per EN 12952.

Chimneys & Flue-Gas Ducts (Schornsteine & Abgaskanäle)Interior and exterior inspection – without climbers, without scaffolding. Document masonry, liner pipes and sulphurous attack. Visual basis for operator duties per 1. BImSchV.

Tanks & VesselsFire-water tanks, process vessels, storage tanks – without human entry, without scaffolding. Document corrosion and coating damage.

Flue-Gas Passes & Inter-Heating-Surface SpacesAreas between heating surfaces, bends and behind tube bundles – the classic blind spots that are almost never fully checked in conventional inspections.

Combustion Chambers & Furnace Ceiling AreasTargeted inspection of ceiling areas, suspension systems and refractory zones in the furnace – the classic overhead blind area reached without scaffolding.

Coal & Biomass Silos / BunkersBunkers, internals and discharge systems – detect bridging and spontaneous-combustion risks early. LiDAR documents fill levels and wall conditions.

DeNOx Plants / SCR ReactorsCatalyst blocks and flow guidance in SCR plants – document blockages, deposits and damaged catalysts without human entry.

Fans – Interior HousingLarge induced-draft and forced-draft fan housings – detect deposits, blade damage and wear before imbalance causes mechanical damage.

Ash Hoppers & Bottom-Ash SystemsBelow the boiler in an extremely abrasive environment. Detect deposits, blockages and wear without human entry into the hot substructures.

Pipe Bridges & Media Runs (Interior Areas)Under platforms and inside installations – capture CUI (Corrosion Under Insulation), leaks and loose fittings that are not visible from outside.

The Challenges in Power Plants

Boilers, chimneys, combustion chambers – hot, dark, hard to access. Human entry requires DGUV measures, weeks of scaffolding and enormous downtime. The ELIOS 3 inspects in hours – without human entry, with 4K + Thermography + LiDAR.

High Safety Risk for Human EntryHot surfaces, toxic gases, confined shafts. Human entry into boilers requires extensive safety measures. ELIOS 3 flies in – your team stays outside.

Downtime = Hundreds of Thousands of Euros per DayScaffolding erection takes weeks. Every hour of standstill costs money. The drone inspects in hours instead of weeks – minimal production loss.

Deposits & Slag Remain Undetected for a Long TimeSlag, ash and encrustation form in boilers and combustion chambers – often in hard-to-see locations. ELIOS 3 makes deposits visible before they become a problem.

Visual Inspection Is Often Only PartialIn conventional crawl-through inspections only selected areas are checked. The drone systematically captures the entire interior – no zone remains unchecked.

Documentation Often Incomplete or Not ComparableHand-held photos are rarely reproducible. Comparisons over years are barely possible. ELIOS 3 delivers structured, repeatable data including a 3D model.

Unplanned Damage Discovered Only During ShutdownClassically, damage is often only found once the scaffolding is up – then it becomes expensive. Inspect by drone in advance – detect damage early, make shutdown plannable.

Access Only via Critical AreasLadders, narrow shafts, unstable internals – all massively increase the risk of entry. ELIOS 3 flies directly to the target – without loading structures or endangering personnel.

Complex Geometries Barely Fully CapturableTube registers, internals, bends – many areas are not fully visible from outside or from scaffolding. The drone navigates through tight and covered areas, capturing every corner.

Difficult Lighting Conditions & GlareReflective surfaces, dust or darkness make conventional visual inspections difficult. ELIOS 3 brings its own lighting and a stable camera – consistently high image quality.

Preparation Costs & Coordination ExplodeScaffolding, safety concepts, permits, coordination of multiple trades – enormous organisational effort. Drone deployment massively reduces complexity and accelerates approval processes.

Technology in Use for Power Plant Inspections

Depending on the task, we deploy the Flyability ELIOS 3, DJI M30T or handheld LiDAR – for complete inspection from boilers to cooling towers.

ELIOS 3 in Water-Tube Boilers (Wasserrohrkessel)Inspect evaporator tubes (Verdampferrohre), superheaters (Überhitzer) and economisers (Economizer) without scaffolding and without human entry – GPS-free navigation in confined boiler spaces.

ELIOS 3 in Chimneys (Schornsteine)GPS-independent ascent to the full chimney height – masonry (Mauerwerk), liner pipe (Futterrohr) and sulphurous-attack damage (Versottung) fully documented.

DJI M30T for Cooling Towers & Flue-Gas Ducts200× optical zoom and thermography for cooling tower outer surfaces, flue-gas ducts and CUI (Corrosion Under Insulation) detection at pipe bridges during live operation.

LiDAR: As-Built and Geometry Deviations3D point cloud of the boiler for as-built documentation and precise detection of tube deformations and geometry deviations per EN 12952.

Thermography: Hotspots and Insulation DamageThermal analysis identifies hotspots in boilers, insulation damage at steam lines and thermal bridges – without plant shutdown.

Minimal DowntimeNo scaffolding, no crawl-through training, no personnel airlock – inspection-ready in a few hours instead of days.

The ELIOS 3 in the interior of a power plant – GPS-free navigation, 4K and thermography in one flight.

What We Document in Power Plant Inspections

We fly the ELIOS 3 into your boiler installation and systematically document all safety-relevant areas. Technical assessment is carried out by your boiler experts and inspection engineers – we deliver the data:

Boilers, Boiler Passes & Furnace Spaces

What we check: Erosion and corrosion on evaporator tubes (Verdampferrohre), condition of refractory linings, superheaters (Überhitzer) and reheaters (Zwischenerhitzer), weld seams and tube connections.

Why it matters: Boiler interiors are the most safety-critical areas – tube-wall thinning, lining damage and weld defects must be documented before every re-commissioning. Conventional inspection via scaffolding takes weeks.

How we do it: ELIOS 3 flies systematically through boilers and passes – 4K camera from close range, thermography for hotspots and insulation damage, LiDAR for geometry deviations at tube walls.

Chimneys & Flue-Gas Ducts (Schornsteine & Abgaskanäle)

What we check: Wall corrosion, sulphurous attack (Versottung), cracks in liner pipes (Futterrohr), lining damage, condition of expansion joints and internals.

Why it matters: Chimneys are subject to the 1. BImSchV and must be regularly checked for load-bearing capacity and leak-tightness. Conventional internal inspection via rope access is complex and expensive at 50–300 m height.

How we do it: ELIOS 3 with Tether Power Unit for unlimited flight time – LiDAR documents plumb deviations and wall geometry, colourisation visualises corrosion areas.

Heat Exchangers, Air Pre-Heaters & Economisers

What we check: Ash and soot deposits, corrosion on tube bundles, dew-point corrosion (Taupunktkorrosion), leaks at seals and connections.

Why it matters: Deposits and corrosion in heat exchangers significantly reduce efficiency. Dew-point corrosion at the economiser is one of the most common wear causes in power plants.

How we do it: Thermography identifies hotspots and areas with reduced heat transfer – 4K documentation of tube bundles and dividing walls from close range.

Tanks, Vessels & Water-Side Spaces

What we check: Corrosion, sediment deposits, coating integrity, condition of internals and nozzles in boiler feed-water tanks, condensate tanks and cooling towers.

Why it matters: Feed-water and condensate vessels are pressure equipment per BetrSichV – corrosion and wall thinning must be regularly documented to ensure re-commissioning approval.

How we do it: ELIOS 3 inspects drained vessels completely – thermography complements visual documentation for moist wall areas and insulation damage.

Cooling Tower Areas & Hard-to-Access Interior Structures

What we check: Condition of packing fills (Füllkörper), water distributors, load-bearing structures and basin floors; corrosion and biological growth.

Why it matters: Cooling towers are indispensable for power plant operation – damage to packing fills and load-bearing structures is classically only documentable with high scaffolding effort. The drone captures even high-level areas without climbing equipment.

How we do it: ELIOS 3 navigates into the cooling tower interior – high-capacity battery for extended flights; LiDAR documents structural deformations and geometric deviations.

Steel Structures, Platforms & Elevated Plant Components

What we check: Corrosion, cracks and deformations on steel structures, walkways, support frames and pipe supports.

Why it matters: Elevated steel components are barely reachable during live operation – corrosion and fatigue cracks are often only discovered at the next revision when damage is already advanced.

How we do it: DJI M30T (exterior) and ELIOS 3 (tight interior areas) together – thermography documents hotspots at bearing and connection points; LiDAR captures structural geometry.

At the end we hand over a detailed inspection report with 4K images, thermography evaluation and optionally LiDAR point clouds – documented per EN 12952 (water-tube boilers), 1. BImSchV (chimneys) and BetrSichV requirements. Your boiler experts and inspectors assess the findings and decide on measures.

Typical Inspections in Power Plants

With the Flyability ELIOS 3 we inspect safety-critical assets – precisely, safely and with minimal downtime. Downtime costs thousands of euros per hour – we reduce inspections from days/weeks to hours. Up to approx. 80% cost savings:

Inspection Videos

ELIOS 3 Inspection of Burners in a Coal-Fired Power Plant

ELIOS 3 Inspection of an Absorber in an FGD Plant (REA)

ELIOS 3 Inspection of an Economiser in a Power Plant

ELIOS 3 Inspection of a Cold Condensate Tank (KAKO)

ELIOS 3 Inspection of a Condenser in a Coal-Fired Power Plant

ELIOS 3 Inspection of a Cooling Tower

LiDAR 3D point cloud of a power plant boiler house – centimetre-accurate geometry data for documentation and digital twins.

Your Benefits as a Power Plant Operator

• No human entry: No DGUV confined-space entry (Befahrung) required. No safety watch, no breathing apparatus, no rescue chain. Drastically reduced risk.
• Non-contact inspection – no secondary damage: Every crawl-through risks worsening existing damage – loose parts, brittle linings. The drone works without contact – no additional loading on the installation.
• Thermography: hotspots & insulation damage reliably detected: Insulation damage, leaks, overheated areas – visible with the thermal camera. 4K + LiDAR deliver a 3D twin for precise planning.
• Shared decision basis for all stakeholders: Unclear images and subjective assessments often lead to disputes between operator, certifier and maintenance. 4K video and 3D model create a shared, objective decision basis.
• No scaffolding: Scaffolding for boiler or chimney inspection is completely eliminated. Save weeks of lead time and substantial costs.
• Minimal downtime: Inspection in a few hours instead of weeks. Maintenance windows are optimally used – more time for real maintenance.
• Precise documentation: 3D models, thermal maps, 4K video – no more subjective crawl-through reports. Sound decision basis for maintenance planning.
• Cost savings of up to 80%: Compared with conventional inspection methods (scaffolding, climbers, crawl-through entry), you save up to 80% of total costs.
• DGUV-compliant: Our inspections fulfil DGUV requirements for confined spaces. No human entry = no risk.

How an 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 quotation. 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.

Major Power Plant Operators

Beyond the major operators there is a large number of other energy companies, municipal utilities (Stadtwerke) and wind and solar operators that make a substantial contribution to energy supply. Our inspections are deployed in many different types of installation – from boilers, chimneys and pipelines to water-bearing systems and ancillary installations. We work independently of any manufacturer or operator and adapt our inspection procedures individually to each installation.

RWEOne of the largest energy suppliers in Europe with extensive power plant capacities in lignite, gas and renewables.

LEAG (Lausitz Energie AG)Operator of large lignite-fired power plants in the Lausitz region and a key player in conventional electricity generation.

EnBWBroadly positioned energy supplier with power plants, hydroelectric facilities and a strongly growing share of renewables.

VattenfallInternational energy supplier with power plant sites in Germany and a focus on transformation to renewable energy.

UniperSpecialist in power generation and trading with a focus on gas-fired power plants and flexible generating capacity.

Your Contacts for Power Plant Inspections

Years of experience in complex industrial environments. We understand the requirements of power plant operators – tight maintenance windows, the highest safety standards, precise documentation.

Christian Engelke and Dipl.-Ing. Karsten Lehrke – your direct contacts for power plant inspection projects.

Christian Engelke Founder & Drone Pilot

Karsten Lehrke Project Manager

Philipp Founder, Operations Planning & Logistics

Juliana Drone Pilot

Stephan Operations Planning & Logistics

Related Services

• Cooling Tower Inspection – Natural-draught and cell coolers by drone – M30T outside during operation, ELIOS 3 for internals.
• Boiler Inspection – Steam boilers, heat-recovery steam generators and combustion chambers – 4K + LiDAR without scaffolding.
• Chimney Inspection – Tall structures inspected from the inside – without scaffolding and without rope access.
• Confined Spaces Inspection – Tight spaces without human entry – ELIOS 3 for all confined-space objects.
• Flyability ELIOS 3 – The collision-safe indoor drone with 4K, LiDAR and thermography in detail.
• Industrial LiDAR Survey – 3D point clouds for BIM, digital twins and as-built documentation.

Frequently Asked Questions about Power Plant Inspections

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