‍For critical oil and gas assets, a visual inspection only tells part of the story. To truly understand the integrity of storage tanks, pipelines, and energy infrastructure, engineers require physical measurements. Confirming physical measurements using Non-Destructive Testing (NDT) and Ultrasonic Thickness (UT) data adds crucial insights to assess the true condition of an asset.

Historically, capturing this data meant high-risk, expensive access via rope or Elevated Work Platforms (EWP). The result was often a collection of data points buried in static PDF reports, disconnected from the physical asset.

This is the gap a Structural Lifecycle Management System (SLMS) is designed to close. By integrating advanced aerial NDT data directly into a high-fidelity digital twin, engineers can move beyond visual assessment to a workflow grounded in continuous, auditable data.

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The new reality: physical data meets the digital twin

This is the gap Trendspek’s Structural Lifecycle Management (SLM) platform is built to close.

The rise of specialised aerial robotics, such as Voliro, is changing how physical measurements are gathered. These advanced UAVs are engineered to perform accurate, contact-based NDT on complex structures at height, eliminating the need for hazardous human access.

These platforms use an open, modular system to integrate various NDT sensors. This allows for physical contact with structures from the air, a capability that traditional, visual-only drones lack.

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Core NDT capabilities using Voliro T

Using an open, modular payload platform, tools like the Voliro T can be fitted with various NDT sensors to meet specific inspection needs:

• Ultrasonic Transducer (UT): Measures wall thickness and detects subsurface defects like cracks or corrosion. High-temperature probes can operate on assets up to 260°C, often removing the need for a costly shutdown during inspection.
• Electromagnetic Acoustic Transducer (EMAT): Ideal for rough, corroded, or dirty surfaces as it operates without a couplant (gel or oil).
• Dry Film Thickness (DFT): Specifically used to measure the thickness of protective coatings, such as epoxy or zinc, ensuring asset longevity.
• Pulsed Eddy Current (PEC): Designed for detecting corrosion under insulation (CUI) and fireproofing without requiring their removal.

By reducing the reliance on scaffolding or heavy machinery, this approach minimises operational disruptions and shortens project timeframes while providing a safer way to inspect hard-to-access locations.

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The integrated workflow: from capture to action

Drawing from our technical collaboration with Voliro and Osprey Integrity, the process of turning physical measurements into a system of record follows four key stages:

• Capture: Your team uses the Voliro T to take Ultrasonic Transducer (UT) and Corrosion Under Insulation (CUI) readings in areas that were previously inaccessible or high-risk.
• Model: Anchor geolocated A-scan data and physical locations onto your high-fidelity digital twin, adding specific notes on severity, materials, and condition.
• Analysis: Use the 3D environment to view qualitative versus quantitative data, including wall thickness, volume, capacity, and elevation.
• Action: Execute on evidence-based decisions to minimise downtime, reduce resource requirements, and address critical maintenance needs with confidence.

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Connecting NDT Evidence to 3D Context

The real value for an engineer moves beyond the data collection to the ability to review that data in context. When geolocated NDT data is brought into a digital twin platform like Trendspek, it is anchored to a 3D spatial record of the asset.

Trendspek converts NDT, photogrammetry, and spatial data into an engineering-grade system of record. Combining these data sets enables:

• Physical data in context: Contact-based data, such as A-scan data or thickness measurements, is mapped directly onto the exact point on the 3D model. This removes the guesswork of correlating a PDF data point to a physical location on-site.
• Layered insights: You can overlay physical data with visual reality capture, thermal layers, and historical inspections. This creates a centralised source of institutional memory for every stakeholder, from maintenance planners to facility managers.
• Defensible capital decisions: By visualising physical measurements within the digital twin over time, you gain the evidence needed to track degradation. This allows your team to justify CAPEX allocation and prioritise preventative maintenance over reactive repairs.

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