Kopterflug inspects pipe racks with thermography, 4K documentation and 3D surveying – without scaffolding, without aerial work platforms, without rope access. CUI detection by thermography, corrosion monitoring, structural assessment. Nationwide across Germany.
The DJI Matrice 30T with 200x zoom and radiometric thermography – for systematic pipe rack inspection during live operation.
Pipe racks are the lifeblood of every process plant – they transport media, energy and resources across extensive industrial sites. At the same time, they are permanently exposed to weathering, thermal cycles and mechanical stress.
At Kopterflug, we inspect pipe racks using a hybrid approach: the DJI Matrice 30T with 200x zoom and radiometric thermography for exterior inspection, the Flyability ELIOS 3 for enclosed sections from the inside. No scaffolding, no aerial work platforms, no access restrictions – everything during live operation.
The radiometric thermography of the M30T is particularly valuable: it detects Corrosion Under Insulation (CUI) – the most common and costly damage type at pipe racks – without removing the insulation.
Typical damage patterns at pipe racks: CUI develops when moisture penetrates under the insulation and attacks the pipe surface – thermographically detectable as a temperature anomaly, long before the damage is visible from outside. On the supporting structure we check for corrosion at gusset plates, weld failures and deformations from overloading or wind loads. At flange connections, thermography detects leaks through temperature differences. On the pipelines themselves: external corrosion, wall thickness loss at bends and T-pieces, and support damage from vibration.
Our services for pipe racks:
We fly the DJI M30T along your pipe racks and systematically document all safety-relevant areas. For enclosed pipe tunnels, the ELIOS 3 is deployed:
What we check: 4K footage of corrosion, cracks, deformations, weld damage at steel columns and cross-beams.
Why it matters: Structural weakening of the supporting structure can cause the entire pipe rack to fail. Early detection prevents consequential damage.
How we do it: 4K zoom (200x) documents detail shots from safe distance, thermography shows moisture ingress at joints.
What we check: Thermography screening of the entire insulation for temperature anomalies – indication of Corrosion Under Insulation.
Why it matters: CUI is the most common and costly damage cause at insulated pipelines. Without thermography, CUI remains invisible until line failure.
How we do it: Radiometric infrared camera of the M30T captures temperature differences indicating moisture ingress and corrosion under insulation.
What we check: Condition of pipe clamps, sliding bearings, fixed points, expansion bends and hangers.
Why it matters: Defective supports lead to uncontrolled pipe movements, stress cracks and leaks. Every missing clamp is a risk.
How we do it: 4K detail shots of every support along the entire pipe rack – systematically documented.
What we check: Foundation settlements, cracks in concrete foundations, erosion, undermining, vegetation.
How we do it: Aerial shots identify settlements and displacements, 4K zoom documents concrete damage and cracks.
What we check: Visible deflection of individual pipe segments between supports, missing or broken clamps, displacements at sliding and fixed points.
How we do it: 4K footage from various angles makes deflections visible that are not recognisable from ground level – particularly for pipe racks at 10–30 m height.
What we check: Operating condition (open/closed), visible leaks, corrosion at valve housings, damage to actuating elements and drives.
How we do it: 200x zoom of the M30T captures fitting details from safe distance – position, leak indicators and corrosion grade are recorded in the report.
Pipe racks are among the most complex and least accessible plant components in industry. Conventional inspection methods are expensive, risky and often incomplete.
Kilometre-long pipe racks with hundreds of lines. CUI screening, column corrosion, supports – during live operation.
Media-carrying pipe racks in chemical plants. Aggressive media and atmosphere accelerate corrosion.
Steam, feedwater and cooling water lines on pipe racks in power plants. High thermal stress.
Closed pipe channels and enclosed line routes – ELIOS 3 flies through and documents the interior condition.
In large industrial plants, pipe racks often run over several levels. Restricted access to upper and lower levels and concealed areas between pipe bundles.
Independent supporting structures with large spans over traffic routes or waterways. Restricted access without traffic disruption and high safety requirements.
| Aspect | Conventional (scaffolding / aerial platform) | Drone |
|---|---|---|
| Access | Aerial platform/scaffolding, section by section | Overflight of entire route |
| Time | 3–6 weeks | 3–5 days |
| Operation | Closures, lockouts required | During live operation |
| CUI detection | Only by removing insulation | Thermography – non-destructive |
| Documentation | Photos per section | 4K + Thermography + LiDAR 3D |
We analyse your pipe rack: length, height, media, accessibility, flight restrictions. We check feasibility and advise you free of charge.
You receive a transparent quotation. Together we plan the deployment – coordinated with your plant operation and maintenance team.
Our pilot and assistant fly systematically along your pipe racks – M30T for exterior, ELIOS 3 for enclosed areas. On request with your inspectors on site.
You receive a detailed report with 4K footage, thermography maps for CUI suspect areas, damage classification and optional 3D models for your maintenance planning.
Christian Engelke and Dipl.-Ing. Karsten Lehrke – your direct contacts for pipe rack inspection projects.
Since 2017, we have been inspecting industrial plants with drones – experience from hundreds of pipe rack and pipeline inspections in refineries, chemical parks and power plants. Our hybrid approach combines the DJI M30T for exterior inspections with the ELIOS 3 for enclosed areas. We deliver the data, your maintenance teams make the decisions.
Christian
Founder & Drone Pilot
Karsten
Founder, Managing Director
Philipp
Founder, Operations & Logistics
Juliana
Drone Pilot
Stephan
Operations & Logistics
We check the condition of the entire pipe rack – including supporting structure, pipelines, insulation, supports and foundations. The aim is to detect corrosion, CUI, structural damage and support defects early, before they lead to leaks or failures.
For exterior inspections we use the DJI Matrice 30T – with 200x hybrid zoom, radiometric thermography and IP55 weather protection. For enclosed pipe tunnels and enclosed cable ducts, the Flyability ELIOS 3 is deployed – GPS-free, collision-safe, with LiDAR.
The pipe rack inspection is carried out systematically along the entire route. Even hard-to-access areas – undersides, tight pipe bundles, concealed supports – are covered without additional access equipment.
Typical process: 1. Overview flight for visual capture of the entire structure, 2. Thermography screening to identify anomalies (CUI, leaks, hot spots), 3. Detail documentation of conspicuous areas with 200x zoom, 4. LiDAR scan on request for deformation analysis and as-built documentation.
Yes. Corrosion, coating damage and rust pitting at columns, cross-beams and joints can be captured visually very well – even in hard-to-access areas that are typically skipped in conventional inspections.
Yes. Typical signs such as deflection, deformation and buckling are made visible by high-resolution shots from various angles – particularly well detectable at pipe racks in 10–30 m height.
Yes – with high-resolution zoom, many critical areas can be inspected in detail. Conspicuous spots can be specifically documented and flagged for further assessment by inspectors – very hard to achieve with conventional methods at height.
Partially yes. Thermography can provide indications of moisture or water ingress – particularly at joints, transitions and other critical points where temperature deviations make moisture visible.
The radiometric thermography of the M30T detects temperature anomalies under insulation indicating moisture ingress and corrosion. CUI suspect areas are marked in the report for further assessment – without removing a single piece of insulation.
Typical damage such as open or damaged cladding, missing bands or sheets and mechanical damage can be reliably documented – important indicators, since insulation damage is the entry point for CUI.
Yes. Thermography shows temperature distributions along the lines and makes anomalies visible – for example uneven media flow, possible leaks or unusual temperature gradients.
Yes. Particularly bends, flanges and transitions frequently show elevated corrosion and are systematically captured – areas that are often skipped in conventional inspections due to access situation.
Yes. Typical problems such as damaged or missing clamps, bent supports and corrosion at contact points between pipe and support are systematically documented along the entire pipe rack.
Yes. Sagging pipelines between supports are clearly visible and documented – a clear indication of defective or missing supports with consequential risk for weld cracks.
Partially yes. Misalignments, play in sliding bearings or unusual positions of lines can be visually detected and documented – relevant for assessing thermal expansion problems.
Indirectly yes. Thermography can show temperature anomalies at flange connections indicating leaks or tightness issues – often before deposits or visible traces appear.
Yes. We capture the condition of valves and flanges, visible corrosion at housings and drives, and mechanical damage – via 200x zoom also from safe distance. All fittings are systematically documented.
Yes. From the air, cracks, spalling, settlements and displacements at foundations can be detected – indicators of structural problems often better visible from above than from ground level.
Yes. Influences such as standing water, vegetation and contamination are documented alongside, as they promote damage in the long term – for example through moisture ingress into insulation or increased corrosion.
Partially yes. Video recordings allow unusual movements or vibrations to be made visible – particularly relevant for pipelines near pumps, compressors or other vibration sources.
No – exterior inspections by drone take place during live operation. No lines are blocked, no scaffolding is erected, no areas are cordoned off. Only for internal inspections of enclosed pipe tunnels is local coordination required.
Depends on length and complexity. Typical: a 500 m pipe rack inspected in half a day, including thermography screening. Kilometre-long pipe rack networks in refineries: typically 3–5 days for the complete route.
Yes – that is precisely the advantage of drone inspection. Crossing areas, overlaps, areas between closely spaced lines are often barely accessible for climbers. The M30T reaches these areas from the air – systematically and without additional access overhead.
The most common findings are CUI (Corrosion Under Insulation), surface corrosion at columns and cross-beams, defective pipe supports and clamps, insulation damage as entry points for moisture, and flange anomalies as potential leak indicators. In older plants, foundation settlements are also found.
We deliver 4K footage of the entire pipe rack, radiometric thermography maps with marked CUI suspect areas, damage classification with GPS-referenced damage points, and optionally 3D point clouds. The georeferenced damage points allow your maintenance planners to precisely locate every finding without a repeat inspection.
Depends on age, media and environmental conditions. Common practice: full inspection every 2–5 years, more frequently for CUI-susceptible lines. Drone inspections make annual screening economically feasible – a significant improvement over conventional methods that often only allow 5–10 year intervals.
Questions about drone inspection for pipe racks, or need a quote? Fill out the form and we will get back to you within 24 hours.