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RotoMag with UT module

Nexxis designed custom solution for internal visual and ultrasonic (UT) inspection of the Liquid Burning Flue stack.

Summary of key details of asset:

  • Liquid Burning Flue (Stack)
    • Bottom Up Inspection via crane assistance with access for magnetic crawler
      • Crane movement and support will not require fine crane movements. Crane to support umbilical and couplant weight as well as provide fall arrest for the crawler with expected movements of approx. 5 m at a time.
    • Material: Carbon Steel
    • Wall Thickness: 10mm
    • Height: 70m Inspection
    • Diameter: 6m at the bottom to 3m at the top
    • Surface Condition: Build up and scale expected, cleaning required for UT.
    • Coating: None internally.
    • Internals: No internal baffles or obstacles.
    • Coverage and Inspection Method: UT approx. every 200mm vertical at four cardinal circumferential angles

Spectrum SP90 Pan, Tilt and Zoom (PTZ) Integration

UT Extension; Current UT cables are 30m long. UT cables will be extended and tested for signal to noise ratio and electrical noise.

Couplant Deployment; To counter the head pressure of 70+m runs, Nexxis designed and implement a couplant delivery system.

Cleaning Attachment; Nexxis designed and implement a light scale cleaning head with associated mudguard to reduce ferromagnetic material build-up on the crawler magnets.

The design will also assist with UT data collection.


Encoder Extension

Existing encoder cables are 30m long. UT cables will be extended and tested for signal to noise ratio and electrical noise.

Schmitt Trigger to be designed and implemented for signal conditioning.


Contact us to find out more about the RotoMag with UT module or any of our custom robotic solutions.

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The Process

To solve complex assignments, a strategy that considers both purpose and potential is required. Our hybrid approach maximises the opportunity to solve virtually any design challenge, no matter the industry.  A cross-section of our development process reveals an agile method, which blends science, technology and business. The physical output of our process results in products that meet end-user goals, business objectives and utilise next-generation manufacturing.

Discovery & Opportunity Identification

We actively seek to uncover the most potent opportunity for your immediate position, while considering the most optimal finance, acquisition and support model to complement asset life-span.


With all planning and specifications defined, a complete electrical, mechanical and software prototype is produced and rigorously tested by our dedicated engineering team.

Recommendation & Validation

We collect high-level data from testing, to provide you with the best solution for your inspection, independent of hidden agendas. This ensures that the right technology is applied to the relevant project.

Deliver, Deploy & Support

Your system is delivered ready for deployment, complete with structured training and documentation to assist with immediate usage, backed by our 24/7 support team.

Need a custom solution?

Nexxis focuses on future outcomes, to try and achieve the best possible outcome for clients.