Key Benefits at a Glance

Every five years, all ships must undergo a thorough inspection to ensure they are safe for operation. As ships age, these inspections become more frequent and intense. For vessels over 15 years old, major inspections occur every 30 months. These assessments involve ultrasonic thickness (UT) measurements and visual checks, especially in high-stress areas like the midship section. This is essential for identifying hidden structural issues that might not be visible to the naked eye.

Traditional UT Inspections on Ships

Historically, conducting UT inspections involved significant effort. Teams of up to 30 people would enter confined spaces, build scaffolding, and then climb to take measurements. This process was not only time-consuming but also risky. Scaffolding could lead to accidents, and any leftover parts could damage critical systems like pumps, requiring costly repairs.

These inspections often required the ship to be in dry dock, which adds to the expense. The cost of building scaffolding alone for a 15-year-old tanker could range from $300,000 to $700,000, with the ship out of service for 40–60 days. Dry dock fees could reach up to $4–6 million, making traditional methods very expensive.

Image: Scaffolding requires large teams and poses serious safety risks, especially when working at height.

C-Bird, a specialized inspection company, has been using the Elios 3 for UT inspections on older vessels. Their team finds that the Elios 3 is faster than traditional methods while still collecting the necessary UT and visual data. This improves safety and reduces costs, making the inspection process more efficient.

UT inspections often require entering confined spaces inside a ship's ballast tank.

How UT Drone Inspections Benefit the Maritime Industry

C-Bird was tasked with inspecting 12 oil tanks on a medium-sized vessel. Malcolm Connolly, C-Bird’s CEO, was responsible for gauging measurements and close-up inspections as part of the ship’s periodic survey. The tanks measured 38 x 28 x 20 meters, with complex internal structures including transverse web frames and bulkheads.

For this project, C-Bird used the Elios 3 equipped with its new UT payload. The drone provided detailed LiDAR mapping and visual inspections. The visual element was crucial, as inspectors needed to capture images at arm’s length from the surface being inspected. The Elios 3 allowed them to do this without climbing scaffolding or entering dangerous spaces. As a product advisor and beta-tester for the new UT payload, Malcolm saw this as an ideal opportunity to test the drone in a real-world NDT environment.

Conducting a Ship UT Inspection with the Elios 3

C-Bird used two Elios 3 drones equipped with the UT probe to inspect the 12 oil tanks. A class inspector guided the process, specifying what needed to be tested. This drone-based approach was much faster than traditional scaffolding methods. Once the equipment was onboard, the inspection could begin immediately, saving thousands of hours of setup time.

The team flew the Elios 3 around each tank, taking UT measurements at multiple locations as required. Both UT and visual inspections were completed within seven days. At the end of the flights, the pilots confirmed with the class inspector that all measurement points had been covered accurately.

A close-up view of the Elios 3 during a tank inspection.

The Elios 3 streamlined the visual inspection process. Pilots collected both visual and UT data during the flights, providing a clear view of the inspected areas. This allowed C-Bird to complete the work twice as fast, with one drone handling visuals and the other focusing on UT measurements.

An example of a point cloud with UT spot measurements from the Elios 3.

C-Bird compiled the data into the format required by the class society and submitted the results for review. This process was far quicker than traditional methods, as all data was collected in one go, without the need to move around scaffolding or use mobile elevation platforms.

Certified Results from Using the Elios 3 for UT Ship Inspections

After a two-year pilot program, C-Bird and the Elios 3 were certified by the American Bureau of Shipping, one of the world’s leading classification societies, as an approved supplier for ESP hull gauging. This recognition marked a milestone, showcasing the value of drone-based inspections in the maritime industry.

Watch how the Elios 3 uses live 3D modeling to guide the drone and perform a UT measurement.

The Elios 3 delivered five key benefits for C-Bird. First, it enabled precise localization of UT measurements within a 3D point cloud. Second, it allowed inspectors to access hard-to-reach areas safely, reducing risk exposure. Third, it produced reliable, class-certified results. Fourth, its versatility made it suitable for a wide range of environments with different payloads. Finally, it provided detailed, structured reports that met the requirements of the class society.

C-Bird plans to continue using the Elios 3 and its UT payload for inspections across multiple industries, including maritime, oil and gas, and asset management. By combining speed, safety, and high-quality data, the Elios 3 has set a new standard for UT inspections in challenging environments. With this technology, C-Bird is ready to tackle even more complex projects in the future.

Discover more about the Elios 3 and its UT payload

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