Inspecting confined industrial environments has always been a technical, logistical, and above all human challenge. Locations such as boilers and tanks require strict safety measures and often involve high operational costs, production shutdowns, and exposure to hazards for workers. But what if inspections could be done without putting a single person at risk?
The answer came with the Elios 3, the industrial drone from Flyability, exclusively distributed in Brazil by XD4Solutions. In this case study, you’ll learn how this innovative solution is transforming the way industries conduct internal inspections eliminating risks while drastically reducing time and operational costs.
The Challenge of Inspecting Confined Spaces
Traditionally, inspecting the inside of a boiler or tank requires skilled workers to physically enter confined spaces, often using scaffolding, complex PPE, and pausing operations for days or even weeks.
These inspections, besides being risky, were often imprecise or limited by visibility. Small damages could go unnoticed, requiring future returns to the site, increasing costs, and compromising safety.
Elios 3: An Aerial Revolution in Inaccessible Locations
The Elios 3 was designed precisely for this: to go where humans can’t—or shouldn’t. Equipped with cutting-edge technology, it offers:
- 3D LiDAR for real-time mapping and digital modeling of the environment;
- 4K camera for detailed visual inspections;
- Thermal camera for detecting temperature variations and potential failures;
- Unmatched flight stability even in low-light, dusty, and GPS-denied environments;
- Protective spherical cage for collision resilience.
This drone is, quite literally, the perfect explorer for extreme environments.
Case Study: Boiler Inspection at a Thermal Power Plant
Recently, one of Brazil’s leading thermal power plants faced the challenge of inspecting one of its internal boilers without halting production. Instead of using conventional methods requiring days of downtime, the team opted for the Elios 3, operated by XD4Solutions specialists.
Before Elios 3:
- 4 to 5 days of shutdown;
- Internal scaffolding assembly;
- Risk of exposure to gases and residual heat;
- Limited reporting.
With Elios 3:
- Internal flight completed in 2 hours;
- No workers had to enter the space;
- High-resolution visual and thermal imagery collected;
- Real-time 3D point cloud generated for later analysis;
- Immediate detection of corrosion and cracks in internal piping.
The client resumed operations safely, without delays or additional structural costs.
Why Choose Elios 3?
Beyond the clear time and safety savings, Elios 3 also offers strategic benefits:
- Reduction in operational risk insurance;
- More frequent preventive inspections;
- Early detection of structural failures;
- Compliance with standards such as NR-33 and NR-35;
- Integrated digital documentation for comparative inspections.
All of this operated seamlessly by a trained team, with local support from XD4Solutions.
Elios 3 Applications Across Industries
Elios 3 is not just for boilers. Its applications span across industries such as:
- Petrochemical (storage tanks and reactors)
- Pulp & Paper (digesters and evaporators)
- Steelmaking (furnaces and ducts)
- Energy (hydro, thermal, wind)
- Mining (silos, chutes, tunnels)
- Food & Beverage (grain silos, CIP pipelines)
In all these scenarios, it eliminates the human and financial costs of manual inspections.
Swiss Technology, 100% Brazilian Support
Exclusively distributed by XD4Solutions, the Elios 3 comes with:
- Specialized technical support in Brazil;
- Official Flyability training;
- Certified maintenance and original parts;
- Prompt service for urgent demands.
Flyability is the global leader in robotics for inaccessible environments, and XD4Solutions bridges this advanced technology to the Brazilian operational reality.
Want to Cut Costs and Eliminate Risks?
Contact the XD4Solutions team today and discover how the Elios 3 can revolutionize industrial inspections in your company.
