Acuren, a leading industrial inspection provider, deployed Voliro T’s advanced drone technology to conduct 26 stack inspections at a large-scale oil and gas refinery in Kansas. The use of traditional methods—crane and man-basket—would have resulted in excessive costs, long asset downtimes, and heightened safety risks. By leveraging Voliro T’s non-destructive testing (NDT) capabilities, Acuren completed the inspections in just 14 days, dramatically reducing labor and equipment costs while delivering highly accurate, risk-based inspection (RBI) data
Over $500k in immediate cost savings. By eliminating crane requirements and increasing inspection speed to 2-3 stacks per day—three times faster than conventional methods—while preventing costly shutdowns.
Millions in long-term savings by providing comprehensive UT data. At least four stacks exhibited significant wall loss, which, if left undetected, could have led to expensive emergency repairs and unplanned downtime.
Inspection workflow efficiency. By completing 26 heater and flare stack inspections in a record 14 days. With Voliro T, the refinery assessed critical assets that would have otherwise been overlooked, providing highly accurate risk-based inspection (RBI) data to support proactive maintenance strategies.
Refinery stacks play a crucial role in plant operations and require frequent monitoring to ensure structural integrity and compliance with safety regulations. However, traditional inspection methods present several challenges:
Expensive equipment and labor costs. Deploying large cranes for refinery inspections can be prohibitively expensive, with rental rates for heavy-lift or specialized cranes ranging from $20,000 to $50,000 per day. These costs include not only the base rental fee but also expenses for transportation, assembly, permits, and certified operators, making large-scale inspections a significant financial burden for oil and gas facilities.
Significant operational downtime and data gathering limitations. Manual inspections in refineries often necessitate shutting down stacks, resulting in substantial operational downtime and revenue loss. Moreover, traditional methods provide incomplete data, as they typically assess only one side of the stack—creating gaps that increase the risk of undetected corrosion. The high costs and extended timelines further limit inspection frequency, leaving many stacks unchecked and heightening the risk of catastrophic failures
Safety hazards: Workers using scaffolding or cranes face risks including fall hazards, toxic gas exposure, and extreme weather conditions.
To overcome these challenges, Acuren deployed Voliro T equipped with its high-temperature ultrasonic testing (UT) probe, enabling the refinery to detect corrosion risks early, prioritize maintenance, and reduce overall downtime—optimizing shutdowns for actual repairs rather than inspections. Designed for extreme conditions, Voliro T operates on surfaces up to 260°C (500°F), making it ideal for heater and flare stack inspections.
With Voliro T, Acuren’s inspection team achieved:
Asset integrity screening at scale. Collecting UT readings on assets that would have otherwise gone uninspected due to budget and logistical constraints.
Unparalleled access. Inspecting areas inaccessible to cranes, ensuring a comprehensive evaluation of asset integrity.
Proactive data collection. Delivering real-time thickness measurements, allowing for immediate risk assessments and proactive maintenance planning.
By completing 26 stack inspections in just 14 days—less than half the usual time—the refinery saved significantly by reallocating resources to critical repairs instead of costly inspections.
Safer operations. Keeping inspection teams on the ground and away from hazardous areas, reducing risks associated with working at heights.
Most of our customers have never seen a drone platform like the Voliro before that can perform UT thickness measurements. The ability to inspect assets while in-service was a game-changer, as it allowed us to assess structures that would otherwise be overlooked.” Omar Hasan, Drone Operations Manager at Acuren
Acuren’s deployment of Voliro T demonstrates how refineries can drastically cut maintenance costs, improve safety, and enhance data accuracy through drone-powered inspections. This shift away from costly, reactive maintenance toward predictive, risk-based inspections ensures better asset management and long-term savings.
By eliminating the need for expensive cranes, reducing downtime, and enabling full-scale integrity screening, Voliro T has set a new standard for refinery maintenance. As more facilities adopt this innovative approach, the industry is poised for a major transformation in how critical assets are monitored and maintained.
Acuren is a leading provider of non-destructive testing (NDT), inspection, and asset integrity solutions for industries such as oil & gas, power generation, and infrastructure. With a strong focus on safety, efficiency, and data-driven decision-making, Acuren leverages cutting-edge technologies—including advanced drone inspections—to help clients reduce costs, minimize downtime, and extend asset lifespan. Backed by a network of certified inspectors and engineers, Acuren delivers high-precision diagnostics and risk-based inspection (RBI) strategies to ensure the reliability and longevity of critical infrastructure.
Contact: https://www.acuren.com/contact-us/
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.
