The Flyability ELIOS 3 with radiometric thermal camera detects CUI (Corrosion Under Insulation), hotspots and leakages inside tanks, boilers and pipelines – without scaffolding, without human entry. Three sensors in a single flight: 4K video, LiDAR and thermal imaging.
Thermography was long tied to handheld cameras. The problem: to find hotspots, leakages or insulation damage in a 30-metre high boiler, access had first to be created – via scaffolding, rope access or human entry.
The Flyability ELIOS 3 with radiometric thermal camera changes this: the drone flies through the boiler, tank or chimney and simultaneously captures 4K video, LiDAR 3D data and thermal images – without human entry.
The difference “radiometric”: The ELIOS 3 does not just deliver colourful heat images – it delivers absolute temperature values per pixel. This enables quantitative analysis: is this hotspot at 85°C or 185°C? That difference is critical for assessment.
The radiometric thermal camera of the ELIOS 3 detects a wide range of concealed and visible anomalies in industrial facilities:
Wet insulation has a different thermal profile than dry. The thermal camera detects temperature anomalies beneath insulation – one of the most common and costly damage types in process industry. German term: Korrosion unter Isolierung.
Overheated components in boilers, furnaces and reactors: hotspots indicate refractory damage (Ausmauerungsschäden), blocked cooling systems or insulation failures.
Escape of hot or cold media creates local temperature differences that become thermally visible – even with small volumes.
In tanks and vessels, the thermal camera shows the fill level of the medium as a clear temperature boundary – useful for inventory assessment and drainage control.
Overloaded cables, switching contacts or transformers in switchrooms and cable ducts become visible through their thermal signature.
The thermal camera of the ELIOS 3 is available as an optional payload and is used in addition to the 4K camera:
Practical note: The thermal camera delivers raw data (radiometric), which is evaluated in Flyability Cloud (Inspector 5) or compatible software. The thermal images can be overlaid on the LiDAR point cloud – showing exactly where in 3D space the hotspot is located.
Detection of refractory damage (Ausmauerungsschäden, German for lining damage) via hotspots on the inner wall. Previously only possible with scaffolding – with the drone in hours rather than weeks.
Thermal anomalies in the lining indicate wear, cracks or missing insulation. The drone captures the complete thermal profile from inside.
CUI detection on insulated tanks, level determination, leakage detection at connections and weld seams.
CUI screening on insulated pipelines, detection of blockages or flow problems through temperature differentials.
Turbine halls, steam generators, condensers – anywhere temperature differentials are critical.
Visual Inspection (VT / 4K camera) detects:
Thermography additionally detects:
Recommendation: Deploy both methods simultaneously. The ELIOS 3 captures VT + thermography + LiDAR in a single flight. That is the advantage over separate inspections.
| Finding | Visual Inspection (4K) | Thermography | LiDAR |
|---|---|---|---|
| Visible corrosion / rust | ✓ | – | – |
| Cracks / delaminations | ✓ | ⚠ | – |
| Deposits / build-up | ✓ | – | ✓ |
| Coating damage | ✓ | – | – |
| Mechanical deformation | ✓ | – | ✓ |
| CUI (corrosion under insulation) | ✗ | ✓ | – |
| Internal hotspots | ✗ | ✓ | – |
| Leakages (small) | ⚠ | ✓ | – |
| Insulation defects | ✗ | ✓ | – |
| Fill levels | ✗ | ✓ | – |
| 3D measurement / geometry | ✗ | ✗ | ✓ |
Honestly: drone thermography has limits that need to be understood:
320×256 px is sufficient for industrial finding assessment but not for detailed component-level analysis. For high-resolution thermography, stationary cameras are better suited.
Different surfaces (bare metal vs. coated metal vs. plastic) have different emissivity values that must be taken into account during evaluation. German term: Emissionsgrad.
In open areas or chimneys with strong draught, convective effects can distort measurements.
The ELIOS 3 is specified for max. 50°C. Deployment in actively fired furnaces or directly above burners is not possible.
Even with the thermal camera, the ELIOS 3 is not approved for use in potentially explosive atmospheres – gas measurement (Gasfreimessung) is always required. German: ATEX-Zertifizierung.
Thermography extends drone inspection from pure visual testing to multi-sensor condition assessment. In a single flight, the ELIOS 3 captures:
This trinity of data – optical, thermal, geometric – delivers a complete picture that no single method achieves alone.
Our recommendation: For every inspection assignment we assess whether thermography makes sense for your application. In many cases it is a standard module with no additional deployment effort.
Our team has been performing drone-based thermography inspections in industrial facilities since 2017.
Christian Engelke
Founder & Drone Pilot
Karsten Lehrke
Managing Director
Philipp
Drone Pilot
Max
Inspection Specialist
Benjamin
Drone PilotIt depends on the inspection scope. In many cases the thermal camera can be deployed as an additional payload during the same flight – the additional effort lies primarily in evaluation. We clarify this on a project-specific basis.
The ELIOS 3 can detect temperature anomalies indicating CUI (wet insulation, thermal bridges). A definitive CUI diagnosis often requires supplementary measures (e.g. opening insulation at suspect locations). The drone localises the suspect areas – this drastically reduces the effort of targeted follow-up inspections.
The radiometric camera has a sensitivity of <50 mK (NETD) and measures in the range −10°C to +400°C. Absolute accuracy depends on the emissivity of the surface and correct calibration – for industrial finding assessment (hotspot yes/no, temperature comparison) the accuracy is sufficient.
A non-radiometric thermal camera delivers only a visual colour image showing relative temperature differences. A radiometric camera stores the absolute temperature value for every single pixel – enabling later software analysis, temperature comparisons between inspections and quantitative assessment. The ELIOS 3 uses a radiometric camera.
No. Thermography detects thermal anomalies indicating wall thinning or CUI – but cannot measure the actual remaining wall thickness. For that, ultrasound testing (UT) is always required. The typical workflow: drone thermography localises suspect areas, UT inspector measures precisely at those specific points.
We will advise whether thermography is worthwhile for your inspection – and deliver results, not just images.
Kopterflug Inspection Services GmbH
Am Tabakquartier 62, 28197 Bremen, Germany
+49 421 408 937-0 ·
[email protected]
Source page: /en/knowledge-base/thermografie-industrieinspektion