Robotic Water Wall Tube Inspection (ULTRA-Bot)
What Is It
Inspect Boiler First-Pass Water Wall Tubes Without Scaffolding
IRC Engineering’s ULTRA-Bot is a robotic inspection system designed for boiler first-pass water wall tubes.
It combines ultrasonic thickness mapping and visual imaging in a single automated inspection pass - without scaffolding or confined-space entry.
Key advantages include:
- Continuous UT thickness data
- Simultaneous visual capture
- Up to 15 probes at once
- Up to 4,000 metres of tube scanning per day
- Precise location-tagged measurements
Why ULTRA-Bot
Why Choose ULTRA-Bot?
ULTRA-Bot transforms boiler water wall inspection from limited spot-checking to continuous, data-driven coverage.
Full Coverage
Continuous thickness data across the tube surface instead of isolated spot checks.
Faster Inspection
Scans at an encoded speed of 3 metres per minute, reducing outage inspection time.
Safer Access
Operates with approximately 8 inches of clearance, eliminating the need for scaffolding or confined-space entry.
Better Decisions
Visual and thickness data are captured together for more accurate condition assessment.
How It Works
Our ULTRA-Bot Inspection Method
A continuous automated inspection process designed specifically for boiler first-pass water wall tubes.
System Setup
Position and secure ULTRA-Bot on the water wall tube bank.
Anchoring
Use the built-in anchoring provision for additional safety during inspection.
Robotic Scanning
ULTRA-Bot moves continuously across the tube bank while performing UT scanning and visual capture.
Data Capture
Thickness measurements and visual data are automatically recorded with precise location tagging.
Analysis & Reporting
Generate inspection data for condition assessment, targeted repairs, and long-term planning.
Our System
Our ULTRA-Bot Robotic Inspection System
15-Probe UT Scanning
Scan up to 15 probes simultaneously in single-line UT mode.
Visual + UT Inspection
Capture visual footage and thickness data during the same inspection pass.
High-Speed Coverage
Encoded scan speed of 3 metres/minute with up to 4 million thickness data points per day.
IDMS-Ready Data
Location-tagged inspection data can integrate with Inspection Data Management Systems.
A fully automated system designed to deliver continuous, traceable water wall tube inspection data.
Applications
Applications of ULTRA-Bot Inspection
Boiler First Pass
Inspect water wall tubes surrounding the furnace where thermal degradation is most severe.
Water Wall Tube Banks
Perform continuous UT thickness mapping across large tube sections.
Tube Wall-Loss Assessment
Identify developing wall loss using detailed thickness data.
Outage Inspections
Reduce inspection time without scaffolding or confined-space entry.
Targeted Repairs
Use precise location data to identify tube sections requiring repair or replacement.
Get full water wall coverage, not just a sample.
Why IRC
Why Choose IRC Engineering Services?
ULTRA-Bot was developed specifically by IRC for the demanding conditions of boiler water wall tube inspection.
Built for the First Pass
Designed specifically for tight-access boiler water wall inspection.
Continuous Inspection
Move beyond manual UT spot-checking with continuous thickness mapping.
Integrated Data
Visual and UT information captured together in a single inspection.
Faster Outages
Reduce inspection time by eliminating scaffolding and confined-space requirements.
Precise, location-tagged data supports repair decisions and long-term inspection planning.
Built for the First Pass. Proven in the Field.
ULTRA-Bot combines robotic mobility, ultrasonic thickness mapping, and visual inspection to deliver a more complete picture of boiler water wall condition.
Continuous data. Precise locations. Faster inspection. Safer access.
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