NDT inspection with Flyability Elios 3 – non-destructive testing in a boiler house

NDT Inspection with Flyability Elios 3 – Non-Destructive Testing in Confined Spaces

The Flyability Elios 3 is a flying NDT platform: visual testing (VT), LiDAR 3D surveying and thermography (IRT) in a single flight – without scaffolding, without human entry into confined spaces. UT payload for wall thickness measurement is in development.

Visual Testing (VT) – 4K camera with 16,000 lumen LED illumination
LiDAR 3D surveying – Ouster OS0-128, deformation analysis and measurement
Thermography (IRT) – optional thermal camera for hotspots, CUI, insulation damage
UT payload in development – contact-based ultrasound wall thickness measurement

Free NDT consultation for your plant: Request a consultation

What Is NDT / NDE?

Non-Destructive Testing (NDT) – also referred to as Non-Destructive Evaluation (NDE) or in German as Zerstörungsfreie Prüfung (ZfP) – examines the condition of components and plants without damaging them. In confined spaces this was previously only possible with laborious scaffolding and human entry. The Flyability Elios 3 brings NDT methods directly into the confined space – without risk to people.

NDT Method	Description	ELIOS 3	Status
Visual Testing (VT)	Visual surface inspection	✓	Available (4K + 16,000 lumen)
Ultrasound (UT)	Wall thickness, internal flaws	⚠	In development (UT payload)
Radiography (RT)	X-ray testing	✗	Not possible (radiation source)
Magnetic Particle (MT)	Near-surface cracks	✗	Contact method
Penetrant Testing (PT)	Surface-breaking cracks	✗	Contact method
Thermography (IRT)	Thermal imaging, CUI, hotspots	✓	Available (optional payload)
LiDAR (3D)	Geometry, deformation	✓	Available (Ouster OS0-128)

Occupational SafetyPrevention of accidents through non-contact testing methods

Plant AvailabilityPrevention of unplanned outages through early detection

Legal RequirementsMeeting BetrSichV (German Plant Safety Ordinance) and DGUV requirements

Insurance CoverEvidence of proper maintenance and testing

NDT inspection at a waste-to-energy boiler

Elios 3: NDT Platform for Confined Spaces

The Flyability Elios 3 is not just an inspection drone – it is a flying NDT platform that combines multiple testing methods.

The combination of VT + LiDAR + thermography in a single flight makes the ELIOS 3 the most comprehensive NDT platform for confined spaces.

Visual Testing (VT)4K camera with 16,000 lumen LED illumination. High-resolution photos and videos for detection of cracks, corrosion and surface defects.

LiDAR 3D SurveyingOuster OS0-128 LiDAR with 1.31 million points/sec. Precise 3D point clouds for deformation analysis, surveying, CAD comparison and repeatable measurements.

Thermography (IRT)Optional thermal camera for detection of hotspots, moisture, insulation defects and temperature mapping.

Ultrasound (UT) – In DevelopmentFlyability is developing a UT payload for the Elios 3: wall thickness measurement and subsurface corrosion detection. Not yet available – we will keep you informed of the current status.

Benefits of Drone NDT Inspection

No Human EntryConfined spaces are inspected without human entry. No DGUV confined space procedures, no rescue chains, no risk.

Multiple NDT Methods SimultaneouslyVT, LiDAR and optional thermography in a single run. Saves time and cost compared to separate inspections.

Access to Hard-to-Reach AreasThe Elios 3 reaches areas that are inaccessible for humans – without scaffolding, without abseiling.

Minimal DowntimeInspections often possible at reduced operation. Drastically reduced shutdown times compared to conventional methods.

Repeatable MeasurementsThanks to LiDAR, exactly the same positions can be re-measured at follow-up inspections.

Complete DocumentationAll data is stored: 4K video, photos, 3D point clouds, thermography. Seamless documentation for authorities and inspectors.

LiDAR 3D scan of boiler burner – NDT data

UT Payload: The Future of Wall Thickness Measurement

Ultrasonic wall thickness measurement by drone

Flyability is working on a UT payload (Ultrasonic Testing) for the Elios 3. Goal: wall thickness measurement directly by drone in confined spaces – without scaffolding, without personnel. Until then we combine the drone pre-assessment (VT + thermography + LiDAR) with targeted conventional UT testing at identified locations.

Tanks and Pressure VesselsWall thickness measurement without scaffolding

PipeworkCUI detection under insulation

BoilersCorrosion monitoring in fireboxes

Steel StructuresCondition recording at hard-to-reach locations

The combination of VT + UT + LiDAR makes the Elios 3 the most comprehensive NDT platform for confined spaces.

Typical NDT Applications with Elios 3

Power Plant BoilersVT + thermography for the firebox, flue gas passes and superheaters. LiDAR for deformation analysis.

Chemical ReactorsVT for corrosion and coating condition; in future UT for wall thickness measurement.

Tanks and VesselsVT + LiDAR for internal condition; in future UT for wall thickness without human entry.

PipeworkVT for welds, thermography for CUI; in future UT for wall thickness measurement.

ChimneysVT + LiDAR for lining and structure, thermography for hotspots.

Bridges and Steel StructuresVT for cracks and corrosion, LiDAR for deformations and surveying.

Your Contact

Christian Engelke
Founder & Drone Pilot / Confined Spaces since 2017
“NDT and drone – a perfect match. VT, thermography and LiDAR deliver more data in a single flight than a conventional visual inspection with scaffolding. And when the UT payload arrives, the Elios 3 will become the most complete NDT platform for confined spaces.”

Flyability ELIOS 3 – The collision-safe NDT platform with 4K, LiDAR, thermography and UT payload
Industrial Inspection – Non-destructive testing in industrial plants with state-of-the-art drone technology
Confined Spaces Inspection – NDT testing in confined spaces without human entry
Tank Inspection – Tanks tested non-destructively by VT, thermography and LiDAR
Boiler Inspection – Boilers and steam generators inspected by drone using NDT methods
Chimney Inspection – Chimneys tested non-destructively from inside – VT, thermography and LiDAR

Frequently Asked Questions: NDT Drone Inspection

Which NDT methods can the Elios 3 currently perform?: Currently available: Visual Testing (VT) with 4K camera and 16,000 lumen LED, LiDAR 3D surveying (Ouster OS0-128) for deformation analysis and measurement, optional thermography (IRT) for hotspots, CUI detection and insulation damage. In development: UT payload for wall thickness measurement. Not possible: contact methods such as MT, PT and RT.
Does the drone replace conventional NDT methods such as UT or MT?: No – the drone does not replace all NDT methods but supplements them. Contact methods (UT, MT, PT) still require physical access. The advantage: the drone delivers a fast pre-assessment via VT and thermography. Only at suspect locations is conventional testing carried out – this is the hybrid approach.
Are the results standards-compliant?: Visual testing (VT) with the Elios 3 is aligned with the requirements of DIN EN ISO 17637. LiDAR surveys are reproducible and CAD/BIM-compatible. Inspection reports are aligned with BetrSichV and DGUV requirements. Recognition by TÜV/DEKRA is decided on a case-by-case basis – our experience shows increasing acceptance.
Which plants are suitable for NDT by drone?: All confined spaces with openings from 50×50 cm: power plant boilers (firebox, superheater, economiser), tanks and pressure vessels, chemical reactors and columns, chimneys and flue gas passes, pipework (from approx. 50 cm diameter), silos and shafts. For exterior inspections the DJI M30T with zoom and thermography complements the ELIOS 3.