Tank thickness measurement with drone at Crossbridge Energy Fredericia
In this case study, we explore how we performed thickness measurement of a tank at Crossbridge Energy Fredericia with our Elios 3 drone and its UT payload.
Key points from the case:
Simple and effective ultrasonic metal thickness measurement with drone.
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The importance of tracking the condition of a tank
At Crossbridge Energy Fredericia, efficiency and product quality are paramount. Like many manufacturing companies with large fixed assets, refinery operations require careful maintenance of equipment to ensure stable and safe production.
An important part of this maintenance is monitoring the condition of the tanks. Over time, tanks are subject to significant wear and tear – both from the materials they store and from external environmental influences. Metal walls can become thinner due to corrosion, erosion and stress cracking, which can reduce their strength and increase the risk of downtime or accidents.
That’s why Crossbridge Energy keeps a close eye on the wear and tear and residual life of their tanks so they can intervene in time to ensure safe and efficient operation.
Precise monitoring of tank condition
As a key part of the maintenance plan at Crossbridge Energy, various non-destructive testing (NDT) methods are used to monitor tank condition. One of the most effective methods is ultrasonic thickness measurement, which provides accurate data on the residual thickness of the metal wall.
This method can be performed either manually, where a technician uses an ultrasonic probe to measure the thickness at selected points, or automatically, using specially designed crawlers that climb the sides of the tank and scan large areas quickly and accurately.
By utilizing these advanced techniques, Crossbridge Energy can continuously assess wear and tear and make timely maintenance decisions to extend tank life and ensure stable and safe operation.
The problem we can solve with drones
The automatic crawler method that Crossbridge already uses today is both efficient and accurate. However, reaching all areas of a tank can be challenging, especially when it is equipped with reinforcement rings – structural rings that encircle the tank to increase its stability.
These rings create a physical barrier that makes it impossible for crawlers to pass, leaving areas that cannot be inspected with this method. This is where drones can offer a flexible solution that ensures a complete and accurate inspection of the entire tank surface.
Example of reinforcement rings on tank:
Our solution with Elios 3 and UT Payload at Crossbridge
At Crossbridge Energy, they faced a challenge: inspecting a tank with reinforcement rings where traditional crawlers could not reach all areas. To solve this problem, we used our Elios 3 drone equipped with a UTM payload (Ultrasonic Thickness Measurement payload) to perform precise thickness measurements, even on the hard-to-reach sections of the tank.
Our Elios 3 drone is an advanced inspection drone designed for confined and complex environments. With its protective grid, precise stabilization systems and our skilled drone operator, it was able to navigate close to the tank surface and take ultrasonic measurements behind the reinforcement ring – an area previously impossible to measure with crawlers.
But we did more than just measure the thickness. At the same time as the inspection, the drone’s LiDAR scanner built a detailed 3D model of the tank, accurately mapping all measured points. This allows Crossbridge to visualize the data directly on a digital model, providing a much better understanding of the condition of the tank.
Data delivery and benefits:
✅ 3D mapping – Thickness measurements are integrated directly into an interactive 3D model for a visual overview.
✅ CSV data export – We provide the measurements in a CSV format so that Crossbridge can use the data to calculate the remaining life of the tank and plan future maintenance.
✅ Fast and safe inspection – No need for scaffolding or crawlers, reducing time, costs and safety risks.
With this solution, Crossbridge Energy was able to gain full insight into their tank, even in areas previously impossible to inspect, ensuring a more data-driven and accurate maintenance strategy.
