Drone inspection in the process industry: 10 specific use cases

Drones have become an indispensable tool in the process industry for safely and efficiently inspecting areas that are difficult to access. This article shows 10 practical use cases of how drones are revolutionising inspections in tanks, chimneys, pipelines and other facilities. With state-of-the-art technology such as 4K cameras, LiDAR and Thermography drones provide precise data, reduce downtime and increase safety. Find out how companies can not only reduce costs by using drones, but also take the maintenance of their systems to a new level.

Drone inspection in the process industry: efficiency meets precision

The process industry places high demands on safety, efficiency and precision - especially when inspecting systems that are often difficult to access or dangerous. Drones have proven to be a game changer in this area. They make it possible to carry out inspections without interrupting operations and at the same time provide detailed data for precise analyses. In this article, we show you 10 concrete use cases of how drones are revolutionising inspection in the process industry. From safely checking tanks and chimneys to accurately analysing pipelines, drones offer new ways to save time and money without compromising on quality.

1. inspection of tanks and containers

The Inspection of tanks and containers in the process industry is an indispensable step towards ensuring safety and efficiency. Even if the Tank If the interior and exterior walls have to be emptied for inspection, drones offer an innovative way to check the condition of interior and exterior walls precisely and efficiently without the effort and risks of conventional methods.

Challenges during the inspection	Traditional methods Manual inspections require tank emptying and access for inspectors. Increased risks for employees in confined and hazardous spaces. Complex and time-consuming damage localisation. Typical damage patterns Corrosion on interior and exterior walls. Cracks in coatings or weld seams. Sediment deposits and impurities.
Advantages of drone inspection	Efficiency Faster damage assessment after emptying the tank. Precise data recording without time-consuming manual checks. Security No physical access to the tank required. Minimised risk for employees during inspection. Precision High-resolution cameras and sensors for detailed results. Use of LiDAR and thermography for comprehensive analyses.
Application examples	Material testing Detection of corrosion and damage to interior walls. Inspection of coatings and weld seams. Cleaning requirements Identification of sediments or deposits in the tank. Long-term monitoring Documentation of the condition for historical analyses.
Results of the drone inspection	Improved maintenance Early identification and targeted repairs. More efficient planning of maintenance measures. Cost reduction Reduction of downtime through optimised inspection processes. Reporting High-quality documentation with image and video data.

2. inspection of chimneys

Chimneys and exhaust gas ducts in the process industry are often exposed to high temperatures, chemical loads and the effects of the weather. Their regular inspection is crucial in order to detect damage at an early stage and ensure operational safety. Drones enable precise and efficient inspections, even in areas that are difficult to access or dangerous.

Challenges during the inspection	Traditional methods Require scaffolding or the use of industrial climbers. High time and cost expenditure. Dangerous conditions due to high altitudes and pollutants. Typical damage patterns Cracks in masonry or coatings. Corrosion of metal rings and anchors. Deposits due to soot or chemical residues.
Advantages of drone inspection	Efficiency Quick implementation after the system is switched off. No scaffolding or long preparation times necessary. Security No danger from working at great heights. Minimisation of risks for employees. Precision High-resolution cameras for detecting even the smallest damage. Thermography to detect hotspots or leaks.
Application examples	Structural analysis Check the masonry for cracks and spalling. Detection of corrosion on metal components. Cleaning requirements Identification of soot deposits or chemical contamination. Thermal inspection Localisation of hotspots or insulation problems.
Results of the drone inspection	Improved maintenance Targeted repair of damage after precise damage analysis. Optimised planning of repairs and cleaning work. Cost reduction Avoidance of cost-intensive scaffolding and long downtimes. Reporting Detailed documentation with visual and thermal data.

3. inspection of pipelines, media lines and pipe bridges

Pipelines, media lines and pipe bridges are central infrastructures in the process industry that transport materials safely and efficiently. Regular inspections are crucial to prevent damage such as Corrosiondetect leaks or structural weaknesses at an early stage. Drones enable precise inspection of these areas, which are often difficult to access, without unnecessarily disrupting operations.

Challenges during the inspection	Traditional methods Require complex scaffolding or the use of industrial climbers. Hazardous working conditions, e.g. at great heights or in the vicinity of chemical substances. Manual inspections are time-consuming and often inefficient. Typical damage patterns Corrosion on pipe and bridge structures. Leaks due to material fatigue or pressure load. Deformations or weakening of beams and anchorages.
Advantages of drone inspection	Efficiency Quick inspection of long pipe sections and bridges. Less effort thanks to remote-controlled inspection flights. Security No use of climbers or scaffolding required. Minimised risk for inspectors in hazardous environments. Precision High-resolution cameras for detecting even the smallest damage. Thermography and LiDAR for comprehensive analyses.
Application examples	Corrosion testing Identification of rust and weakening on pipes and anchorages. Leakage detection Localisation of leaks using temperature or humidity data. Structural analysis Inspection of beams and supports on pipe bridges.
Results of the drone inspection	Improved maintenance Targeted repair measures through precise damage analyses. Early detection of vulnerabilities reduces risks. Cost reduction Less effort for access measures and downtimes. Reporting Detailed documentation with images, thermographs and analysis data.

4. inspection of columns and reactors

Columns and reactors in the process industry must be taken out of operation for inspection in order to avoid damage such as Material fatiguecorrosion or cracks. With the help of camera drones and specially developed Indoor drones like the Elios 3, even hard-to-reach or narrow areas can be examined precisely.

Challenges during the inspection	Traditional methods Require the use of scaffolding, rope access or specialised equipment. Long system downtimes increase costs. Danger to inspectors due to chemical residues or extreme conditions. Typical damage patterns Corrosion on interior and exterior walls. Cracks in refractory linings or protective coatings. Material fatigue due to cyclical loads and high temperatures.
Advantages of drone inspection	Efficiency Quick inspection after decommissioning the system. Reduction of downtimes through precise data acquisition. Security No need to physically enter hazardous areas. Reduced risk through the use of indoor drones such as the Elios 3. Precision High-resolution cameras for identifying the smallest damage. LiDAR and thermography for comprehensive analysis of surfaces and temperature curves.
Application examples	Structural analysis Checking the wall thickness and protective layers. Identification of corrosion, cracks and deformations. Thermal analysis Detection of hotspots or insulation problems using thermography. Narrow access Inspections in confined areas with the Elios 3 or other indoor drones.
Results of the drone inspection	Improved maintenance Targeted repairs based on precise analyses. Optimised maintenance planning thanks to precise condition reports. Cost reduction Reduction in downtimes and lower inspection costs. Reporting Comprehensive documentation with high-resolution images, thermographs and LiDAR data.

5. inspection of cooling towers

Cooling towers play a central role in the process industry, especially in power stations and large Industrial plants. Regular inspections are crucial in order to recognise structural weaknesses, corrosion or deposits at an early stage. Drones offer an efficient way of precisely analysing both the external and internal structure while minimising risks and costs.

Challenges during the inspection	Traditional methods Require elaborate scaffolding or industrial climbers. Danger to inspectors due to working at great heights and in confined spaces. High time and cost expenditure due to long preparation times. Typical damage patterns Cracks and spalling in concrete or steel structures. Corrosion on load-bearing elements or connection points. Deposits or blockages that impair the cooling process.
Advantages of drone inspection	Efficiency The inspection can be carried out quickly without a great deal of preparation. Reduced downtimes thanks to minimally invasive inspections. Security No use of scaffolding or climbers necessary. Minimised risk for employees thanks to remote-controlled drones. Precision High-resolution cameras and sensors for detecting the finest damage. Thermography for analysing temperature differences and hotspots.
Application examples	Structural analysis Detection of cracks and spalling in concrete or steel structures. Analysis of corrosion on load-bearing elements. Thermal analysis Identification of temperature deviations in the cooling process. Cleaning requirements Detection of blockages or deposits that impair the cooling capacity.
Results of the drone inspection	Improved maintenance Targeted repairs and maintenance measures based on precise data. Optimised maintenance planning thanks to precise condition reports. Cost reduction Avoidance of cost-intensive scaffolding and long downtimes. Reporting Comprehensive documentation with high-resolution images, thermographs and analysis data.

6. inspection of heat exchangers and condensers

Heat exchangers and condensers are essential components in the process industry that ensure efficient heat transfer. Regular inspections are necessary to detect contamination, deposits or structural damage at an early stage. Drones enable precise and fast inspections of these sensitive systems, both from the outside and in areas that are difficult to access.

Challenges during the inspection	Traditional methods Require partial disassembly of the system for a complete inspection. Danger to inspectors due to chemical residues or high temperatures. High time and cost expenditure due to complex access routes. Typical damage patterns Contamination and deposits in the heat transfer surfaces. Cracks or material fatigue at critical joints. Corrosion due to chemical or humid environments.
Advantages of drone inspection	Efficiency Fast and precise inspection without time-consuming disassembly. Minimisation of downtimes through flexible application options. Security No direct contact with hot or chemical areas necessary. Reduction of risks through remote inspections. Precision High-resolution cameras for detecting the finest damage and deposits. Thermography for analysing temperature distributions and hotspots.
Application examples	Cleaning requirements Detection of deposits or blockages that impair efficiency. Structural analysis Checking weld seams and joints for cracks and corrosion. Thermal analysis Identification of inefficient areas based on temperature deviations.
Results of the drone inspection	Improved maintenance Targeted cleaning and repair measures through precise analyses. Optimised maintenance planning thanks to precise condition reports. Cost reduction Reduction in downtimes and lower inspection costs. Reporting Comprehensive documentation with high-resolution images and thermographs.

7. inspection of warehouses and production halls

Warehouses and production halls often house complex systems and infrastructure that need to be inspected regularly to ensure safety and operational capability. Inspections of roofs, supporting structures and technical equipment can be carried out efficiently and precisely using drones, without significantly affecting operations.

Challenges during the inspection	Traditional methods Require lifting platforms, scaffolding or industrial climbers. Time-consuming access measures and possible business interruptions. Danger to inspectors from working at great heights or in confined spaces. Typical damage patterns Cracks and corrosion on supporting structures and connection points. Damage or deformation to roofs or crane runways. Accumulations of dust or other residues that pose safety risks.
Advantages of drone inspection	Efficiency Fast inspection of large areas without long preparation times. Minimisation of operational interruptions thanks to flexible deployment options. Security No need to physically enter hazardous areas. Reduced risk for employees through remote-controlled drone operations. Precision High-resolution cameras and LiDAR for detailed damage assessment. Thermography for analysing insulation problems or leaks.
Application examples	Structural analysis Inspection of beams, roofs and crane runways for cracks and deformations. Identification of corrosion or other material damage. Cleaning requirements Detection of accumulations such as dust, dirt or residues. Energy efficiency Analysing heat losses or insulation problems using thermography.
Results of the drone inspection	Improved maintenance Targeted repairs and cleaning measures thanks to precise data acquisition. Optimised maintenance planning thanks to precise condition reports. Cost reduction Reduction in operational interruptions and lower inspection costs. Reporting Detailed documentation with images, thermographs and LiDAR data.

8. inspection of conveyor systems and crane runways

Conveyor systems and crane runways are critical components in warehouses and production halls that are often exposed to high loads. Regular inspections are essential to avoid safety risks and failures. Drones offer an effective way to inspect these systems precisely and safely, even in areas that are difficult to access.

Challenges during the inspection	Traditional methods Require the use of lifting platforms, scaffolding or climbers. Time-consuming and often associated with business interruptions. Danger to inspectors due to working at great heights or moving parts. Typical damage patterns Corrosion and cracks in supporting structures and connection points. Damage to rollers, rails or drive components. Loosening or material fatigue on screw connections.
Advantages of drone inspection	Efficiency Quick inspection without time-consuming preparations. Minimisation of downtimes through flexible inspections. Security No physical access to hazardous areas required. Reducing risks through contactless drone missions. Precision High-resolution cameras and sensors for detecting even the smallest damage. Thermography to identify overheating on moving parts.
Application examples	Structural analysis Inspection of supporting structures, rails and rollers for cracks and corrosion. Checking screw connections and wearing parts. Thermal analysis Detection of hotspots on moving components such as bearings or drives. Long-term monitoring Regular inspections to avoid breakdowns and safety risks.
Results of the drone inspection	Improved maintenance Targeted repairs and maintenance measures based on precise data. Optimised planning of maintenance intervals thanks to precise reports. Cost reduction Less downtime and lower inspection costs. Reporting Detailed documentation with pictures, thermographs and analyses.

9. detection of thermal anomalies

Thermal anomalies such as hotspots or temperature losses can indicate problems such as leaks, insulation faults or overheating. In the process industry, their early detection is crucial in order to avoid failures and ensure the efficiency of the systems. Drones with thermographic cameras offer a precise and efficient solution for identifying these problems without interrupting operations.

Challenges during the inspection	Traditional methods Require complex access methods, e.g. lifting platforms or climbers. Often only manual measurements at individual points possible. Danger to inspectors due to heat or chemical residues. Typical problem areas Hotspots on electrical or mechanical components. Heat loss from poorly insulated pipes or systems. Temperature anomalies due to leaks or inefficient processes.
Advantages of drone inspection	Efficiency Comprehensive inspection without interrupting operation. Fast recording of temperature data for large areas. Security No direct exposure to hot or hazardous areas. Minimised risk for inspectors thanks to contactless measurements. Precision High-resolution thermographic cameras for detecting the smallest temperature differences. Precise localisation and analysis of anomalies.
Application examples	Leakage detection Localisation of leaks in pipes or tanks based on temperature changes. Energy efficiency Analysing heat losses from insulation or pipes. Hotspot identification Detection of overheating on mechanical or electrical components.
Results of the drone inspection	Improved maintenance Targeted repairs and optimisations through precise temperature analyses. Early detection of inefficiencies and safety risks. Cost reduction Avoidance of expensive breakdowns through timely repairs. Reporting Comprehensive documentation with thermographic data and precise analyses.

10. inspection of refractory linings

Refractory linings in Industrial ovensThe maintenance of the structure, reactors and other thermally stressed systems is crucial for the protection of the structure and safe operation. Regular inspections are required to detect cracks, Spalling or material fatigue at an early stage. Drones enable precise inspections of these areas, which are often difficult to access, even in complex geometries or confined spaces.

Challenges during the inspection	Traditional methods Require complex access with scaffolding or climbers. Danger to inspectors due to thermal residues or cramped conditions. Long system downtimes increase costs. Typical damage patterns Cracks and spalling in the refractory lining. Material fatigue due to thermal cycles and chemical influences. Cavities or detachments between the lining and the structure.
Advantages of drone inspection	Efficiency Fast inspections, even with complex geometries. Reduction of downtimes through flexible application options. Security Inspectors are not required to enter hazardous areas. Minimised risk with remote-controlled indoor drones such as the Elios 3. Precision High-resolution cameras for detecting the smallest cracks or flaking. LiDAR and thermography for detailed analyses and visualisations.
Application examples	Structural analysis Detection of cracks, cavities and detachments in the lining. Thermal testing Analysis of temperature deviations to localise weak points. Long-term monitoring Regular documentation to assess material ageing and wear.
Results of the drone inspection	Improved maintenance Targeted repair measures through precise analyses. Optimised planning of maintenance measures. Cost reduction Reduction of downtimes and lower inspection costs. Reporting Detailed documentation with high-resolution images, LiDAR and thermographic data.

Conclusion

Drohnen haben sich in der Prozessindustrie als unverzichtbares Werkzeug für Inspektionen etabliert. Sie ermöglichen eine präzise und effiziente Überprüfung von Anlagen wie Tanks, Schornsteinen, Rohrbrücken oder feuerfesten Auskleidungen – selbst in schwer zugänglichen und gefährlichen Bereichen. Die Kombination aus hochauflösenden Cameras, Thermografie und LiDAR-Technologie liefert detaillierte Daten, die nicht nur die Sicherheit erhöhen, sondern auch die Planung von Wartungs- und Reparaturmaßnahmen optimieren. Im Vergleich zu traditionellen Methoden reduzieren Drone inspections downtimes and costs considerably without compromising on quality. Whether for preventive Maintenanceacute damage analyses or the documentation of repair measures - drones offer the process industry a future-proof solution for increasing efficiency, safety and sustainability.

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Frequently asked questions

What are the advantages of drone inspections compared to conventional methods?

Drones enable fast, precise and safe inspection of hard-to-reach areas without the need for complex scaffolding or climbers. They reduce downtime and costs while providing high-resolution data for precise analyses.

Are drone inspections also possible in confined spaces?

Yes, specially developed indoor drones such as the Elios 3 are designed for inspections in confined or hazardous areas such as tanks, columns and reactors.

Does the system have to be taken out of operation for a drone inspection?

In many cases, as with the Inspection of chimneyscolumns or reactors, it is necessary to shut down the system to ensure safe and detailed results.

What technologies are used for drone inspections?

In addition to high-resolution cameras, drones often use LiDAR for three-dimensional scans, thermography for detecting thermal anomalies and ultrasonic sensors for wall thickness measurement.

How long does a drone inspection take?

The duration depends on the size and complexity of the system. However, drone inspections are usually much faster than conventional methods and can often be completed within a few hours.

What types of damage can drones detect?

Drones detect corrosion, cracks, deformations, material fatigue, deposits and thermal anomalies such as hotspots or heat loss.

How are the results of the drone inspection documented?

The inspections provide detailed reports with high-resolution photos, videos and, if used, LiDAR or thermographic data. These can be used for further analysis and repair planning.

Are drone inspections possible in potentially explosive areas?

No!

Which systems can be inspected with drones?

Drones can be used for a variety of installations, including tanks, chimneys, pipelines, pipe bridges, cooling towers, columns, reactors, crane runways and industrial furnaces.

How often should drone inspections be carried out?

The frequency depends on the legal requirements and the specific system. As a rule, inspections should be carried out annually or as part of maintenance intervals in order to detect damage at an early stage.