90% Cost Savings in CUI Inspection Using Voliro T Drone-Based PEC Sensor

In a first-of-its-kind mission, Osprey Integrity—a leading industrial inspection services provider—successfully deployed a drone-based Pulse Eddy Current (PEC) inspection workflow for Suncor Energy. The goal: identify corrosion under insulation (CUI) on large insulated storage tanks without scaffolding, insulation removal, or asset downtime. The project marked Osprey’s first use of Voliro’s integrated PEC payload, in Canada or anywhere else. The result was a 90% reduction in inspection costs per location.

Summary of Key Outcomes

The Challenge: Expensive, Inefficient CUI Inspections

Corrosion under insulation (CUI) is one of the most costly and difficult inspection challenges in industrial asset management. Traditional methods require stripping insulation, erecting scaffolding, and performing manual ultrasonic testing (UT)—a process that is complex, labor-intensive, and disruptive to operations.

In Oil and Gas, where up to 80% of facility infrastructure is insulated, CUI is responsible for an estimated 40% of all corrosion-related damage. Inspections are critical—but so is minimizing downtime and cost.

This was the challenge facing Suncor at its Northern Alberta site, where several insulated storage tanks were approaching scheduled regulatory inspections. Seeking to improve its process, the company wanted to find new ways to perform CUI inspections.

The Solution: A Smarter CUI Workflow—Drone-Based Pulsed Eddy Current Inspection

To avoid the cost, disruption, and safety risks of traditional CUI inspections, Suncor partnered with Osprey Integrity to test a drone-based approach with the Voliro T. 

The test took place at a Suncor site in Northern Alberta. Several insulated storage tanks at the site were due for regulatory inspection, offering the ideal setting to evaluate this next-generation approach.

At the core of the new approach was the Voliro T drone, equipped with a Pulse Eddy Current (PEC) sensor developed by SIXPEC and fully integrated into Voliro’s platform. 
Unlike ultrasonic testing (UT), PEC can detect wall loss through up to 4 inches of insulation and a 1mm aluminum jacket, without contact-based testing or asset disassembly. Mounted on the Voliro T inspection drone, the PEC sensor can maintain precise surface contact, even on curved or angled tank walls.

Osprey Integrity’s Proprietary PEC Workflow

Osprey Integrity deployed a proprietary, field-tested PEC inspection workflow that combined thermal, visual, and PEC data to maximize accuracy and minimize false positives. 

Designed to work specifically with the Voliro T drone platform, the methodology allowed for precise targeting of likely corrosion zones while avoiding unnecessary insulation removal.

Here are the steps Osprey followed:

1. Captured day and night thermal imagery to detect subtle temperature anomalies.  
2. Conducted visual inspections to identify surface irregularities and physical clues.  
3. Applied optical gas imaging as needed in areas where emissions were a concern.

These steps produced a targeted “treasure map” of likely defect zones. 

After the screening phase, a certified thermographer reviewed the data to eliminate false positives caused by reflectivity, process heat, or environmental factors. Anomalies with a high risk of moisture ingress—a key driver of CUI—were prioritized for follow-up.

Pulsed Eddy Current is a screening tool. You use it where it makes sense—to validate suspicions, to save unnecessary work, and to zero in on actual issues. When combined with thermal and visual workflows, it becomes a powerful part of the toolkit.”

– Courtland Penk, President and Founder of Osprey Integrity

Only after all of this screening was the drone-based PEC sensor used. Using this structured workflow, the Osprey team isolated one particularly promising target for PEC measurement: a thermal hotspot with no visible surface damage. 

After identifying the target, the Osprey team flew the Voliro T across the anomaly in deliberate horizontal, vertical, and diagonal passes, collecting PEC data with the drone to rule out artifacts caused by strapping, geometry, or patch plates. The data was viewed in real time via Voliro’s inspector tablet interface and exported in standard formats (PDF, CSV, JSON) for reporting.

The entire process—from screening to PEC validation—was completed remotely, making it safer than traditional methods, and without the need for insulation removal or downtime.

The Results: Verified Wall Loss and Major Cost Savings

Osprey Integrity’s tests at the Suncor site proved that CUI inspections can be reliably performed with Voliro’s PEC-enabled workflow. 

The business case is strong. With the right conditions, we’re seeing 90% cost savings—and better insight.” – Courtland Penk, President and Founder of Osprey Integrity

In the area flagged by thermal and visual screening, the PEC sensor detected up to 12% relative wall loss—a significant result, especially with no external indicators visible. The finding validated the multi-step approach and showcased PEC sensor’s ability to detect hidden degradation through insulation and aluminum cladding.

The financial impact was just as strong. Using Voliro’s drone saved an estimated $18,000 CAD ($13,000 USD) per location compared to conventional methods involving scaffolding, stripping, and UT—a 90% reduction in cost, along with major time and labor savings.

Additional operational benefits included:

• No insulation removal, reducing restoration work and preserving system integrity.
• No scaffolding or rope access, minimizing safety risks and setup logistics.
• No asset downtime, allowing operations to continue uninterrupted.

For Suncor, the mission demonstrated more than just technical success — it offered a scalable, repeatable model for efficient CUI inspections across their asset base.

Conclusion: Looking Forward—A Blueprint for Smarter CUI Inspections

The success of the trial has laid the foundation for broader adoption.

“It looks very promising,” Penk said. “The business case is strong. With the right conditions, we’re seeing 90% cost savings—and better insight.”

For operators managing insulated assets, Osprey Integrity’s work with the Voliro T’s PEC sensor proves that effective CUI screening doesn’t have to be costly or disruptive. 

By combining aerial mobility, thermal imaging, and PEC technology, teams can detect risks earlier, focus inspections, and cut costs—all without sacrificing safety or uptime.

Voliro’s drone platform, paired with the SIXPEC-developed PEC sensor, marks a step forward in inspection strategy. For Suncor and Osprey Integrity, the mission delivered clear, actionable CUI inspection results—and a scalable model for future inspections.

Revolutionize Your CUI Inspections with Voliro’s Drone-Enabled Pulsed Eddy Current Screening Tool

Avoid costly downtime, enhance safety, and gain unparalleled inspection insights with drone-powered UT technology. Whether you’re an asset owner looking to optimize maintenance strategies or an inspection provider seeking cutting-edge solutions, Voliro T is the solution you need.