FalconScan: A hybrid UAV-crawler system for NDT inspection of elevated pipes in industrial plants

Periodic non-destructive testing (NDT) of pipes and tanks is vital in industrial plants, such as Oil & Gas facilities, to proactively detect defects and corrosion before leaks and forced shutdowns occur. This paper presents a hybrid system, consisting of a UAV and a crawler, which enables detailed contact-based inspection of elevated pipes, in pursuit of eliminating the need for dangerous scaffolding and manual inspection to improve safety and reduce cost. Similar to avian animals, the UAV autonomously perches on the pipe to conserve energy. A small inspection crawling robot is carried by the UAV, and is subsequently released onto the pipe’s surface to inspect its health. The crawler uses magnetic wheels for agile mobility and houses an ultrasonic testing (UT) sensor to thoroughly scan the pipe and detect wall thinning, which is a precursor for leaks. Finally, the crawler re-docks with the UAV, which in turn detaches from the pipe to fly back home or inspect another pipe. The multi-robot system is designed for and tested on pipe diameters as small as 8 in.