MISTRAS provides unmanned robotic inspections for assets at-height in the energy sector. After adopting the Voliro T system from Swiss-based aerial robotics provider Voliro, aerial inspections are performed much faster and without having to close down a facility.

MISTRAS is a "one-source" global provider of technology-enabled asset protection solutions for evaluating the structural integrity of critical energy, industrial and public infrastructure. The company’s world headquarters is in Princeton Junction, New Jersey, and it has local offices in Europe, South America and Asia.

The company deploys various methods to access and service assets in hard-to-reach areas, including Confined Space Entry (CSE), diving, fall protection and rope access. Drone technology now complements manned inspections, particularly for at-height inspection and maintenance services for assets deemed difficult or unsafe to access. These include cooling towers, elevated pipe trays, and live flare stacks.

Without timely inspections, undetected damages can worsen and place facilities, personnel, and the environment in danger over time. The reason they’re often not inspected and repaired as frequently as they should be is because of the costs and risks associated with accessing them. New drone technology makes such inspections possible, speeding up workflows without closing down a facility. 

Voliro strategic partnership
In 2023, MISTRAS partnered with Voliro, a Swiss-based aerial robotics provider for non-destructive testing (NDT) inspections. The partnership enabled MISTRAS to enhance its service offerings, deliver results to its clients quicker and reduce operational costs. Mistras uses the Voliro T, Voliro’s flagship product featuring a unique 360° drone design that enables inspections on flat, curved and sloped surfaces.

Voliro originated from a research project at ETH Zurich, Switzerland, to develop an omnidirectional flying inspection robot. Over time, a proprietary tiltable rotor system was developed and made commercially available, which elevates conventional drones into advanced robotic platforms that are designed to excel in accurate close-to-structure work. MISTRAS’ adoption of the drone and payload coincided with Voliro’s system reaching General Availability (GA).

The term “non-destructive testing” refers to quality assurance and material examination techniques that preserve the integrity of inspected materials, components, and assets. Such inspections are a compliance requirement in many industries, and identify defects, flaws, irregularities, or wear and tear in structures to ensure safety and robustness.

Drones complement conventional inspection methods
MISTRAS now complements their conventional inspection methods with aerial NDT capabilities using the Voliro T. MISTRAS and its customers now benefit from more inspection work in less time, NDT measurements at live assets without shutdown, and multiple sensor payloads for various surface conditions.

MISTRAS provides many ultrasonic thickness measurements for inspection work for different customers in the energy sector. The Voliro T enables MISTRAS to perform ultrasonic testing at height and increase the amount of work in a short period. Ultrasonic testing (UT) is an NDT method that uses high-frequency sound waves to examine objects’ material characteristics and take dimensional measurements.

Fig 2. Drone technology now complements manned inspections at MISTRAS, particularly for at-height inspection and maintenance services for assets deemed difficult or unsafe to access. These include cooling towers, elevated pipe trays, and live flare stacks.

Ryan Marcantel, Chief UAS Operator at MISTRAS, explains in an online video how using drones changed inspection workflows of assets at height. While MISTRAS’ conventional inspection methods still have people working at heights with different instrumentation, a drone enables a UT technician on the ground to see the live data captured by the drone. 

The drone complements conventional inspection methods and has the added benefit of UT information being gathered from assets that are still live and in service without having to shut them down. Voliro also offers multiple payloads like the EMAT, a newer transducer generation that lets inspectors perform tests without direct surface contact. This allows Mistras to get additional data, such as readings from assets with a high corrosion buildup.

In addition to NTD inspections, MISTRAS’ UAV inspection services are used for mapping and surveying services. In addition to the non-destructive testing (NDT) inspection tools, such as ultrasonic (UT), infrared (IR), and gas detection sensors, the drone payload includes high-resolution video/imaging tools, and different cameras (multispectral/hyperspectral). Mistras’ website mentions different project deliverables captured with these payloads, including a tank farm volumetric mapping survey of 96 acres at two separate tank farm sites, and a complete assessment of at-height refinery assets.