Drone Tank Inspections: Enhancing Safety, Cost Efficiency, and Performance in Oil Storage Tank Assessments

Pertamina, Indonesia's leading energy company, partnered with Halo Robotics to inspect a massive oil storage tank. The Elios 2 drone was deployed for the task, delivering results that surpassed all expectations.

Key Advantages at a Glance

Safety: Using the Elios 2 for internal inspections eliminated the need for manual entry via rope access or scaffolding, significantly enhancing worker safety during the process.

Cost Savings: The project reduced inefficiencies between asset owners and EPC contractors, resulting in lower costs and less downtime. Additionally, there was no need for expensive scaffolding setups.

Efficiency: The Elios 2 streamlined the inspection process, enabling systematic and repeatable assessments of aging infrastructure for long-term monitoring and data analysis.

Data Coverage: The drone provided access to previously unreachable areas, capturing high-quality visual and thermal data quickly and efficiently, offering more insights than traditional methods.

Introduction

Pertamina is Indonesia’s national energy company, and it has been continuously looking for ways to improve its maintenance procedures. To achieve this, they engaged Halo Robotics, a Jakarta-based drone technology firm, to assist with a major maintenance initiative at one of their refineries in Balongan, which has a capacity of 125,000 barrels per stream day.

The key asset in question was a large crude oil storage tank, designed in accordance with API 650 standards—making it a common structure across global refineries. This meant that the techniques used in the project could be applied to similar tanks worldwide.

A photo of the oil storage tank at the Balongan refinery

Revolutionizing Oil Tank Inspections

Pertamina needed to conduct a comprehensive inspection of a large crude oil storage tank at its Balongan refinery. The tank, built in 1972, had a capacity of up to 37,000 cubic meters and was in urgent need of maintenance.

The main objectives of the project included updating the original 1972 blueprints, conducting a detailed interior inspection to determine EPC requirements, reducing the risks associated with manual inspections, and improving the overall efficiency of the maintenance process.

A crucial requirement was that the collected data would be usable across all aspects of planning and execution for the tank, from engineering to construction.

To meet these goals, Pertamina divided the work into two key outputs:

⦁ Creating a Digital Twin through 3D scanning of the tank.

⦁ Conducting a Confined Space Inspection for a complete visual assessment of the tank’s interior.

The ultimate aim was to develop a replicable process that could be used across Pertamina’s operations nationwide.

Note: This case study focuses on the second output, the Confined Space Inspection. For details on the Digital Twin creation, refer to the full white paper on Halo Robotics’ website.

Inspectors working inside the oil storage tank

Implementing the Elios Drone for Tank Inspections

Halo Robotics was tasked with implementing new technologies to support both outputs of the project. For the confined space inspection, they chose Flyability’s Elios drone, citing several key features:

⦁ Collision-tolerant design – ideal for navigating tight spaces safely.

⦁ High-resolution imaging – 4K RGB and thermal cameras for detailed visual data.

⦁ Advanced lighting systems – 10,000 Lumen LED lights for clear visibility in dark environments.

⦁ Stabilization and distance control – ensures accurate and consistent data collection in GPS-denied areas.

⦁ Inspector software – streamlines data review and report generation for efficient analysis.

The Elios 2 in action during the drone tank inspection. The Elios 3 now offers LiDAR and close visual data capture capabilities.

Collecting Visual Data During the Inspection

The Elios 2 exceeded expectations during the confined space inspection of the oil storage tank. Compared to traditional methods that require human entry using scaffolding and rope access, the drone provided significant improvements in safety, time, and cost efficiency.

"The results from this drone technology have surpassed our expectations. These operations will greatly support preventive maintenance by helping us identify specific issues, apply the right type of repairs, and ultimately increase speed and accuracy," said Almuayat Librata, Oil and Gas Transportation Manager at Pertamina EP.

Details of the Drone Tank Inspection Mission

Halo Robotics created detailed flight plans to inspect various parts of the tank, including the shell, welds, rafters, girders, joints, and roof. Over five days, 20–22 flights were conducted daily using the Elios 2, resulting in 760 GB of video footage—both 4K RGB and thermal video.

This data was processed using Flyability’s Inspector software to generate a formal inspection report. The software allowed for efficient review, annotation, and comparison of thermal and visual data, producing a comprehensive final report within 14 days.

Examples of Point of Interest Reporting

Corrosion Identified—Tank Joint Left Side

Inspector comments:

⦁ 2x bolts counted

⦁ Shrinking thickness of steel plating and supports

⦁ Significant corrosion observed over a 67mm range

⦁ Distance measurement: 67mm +/- 5mm

Flaking and Oil Material Build-Up Observed—Tank Joint Right Side

Inspector comments:

⦁ 2x bolts counted

⦁ Significant flaking and oil buildup observed

⦁ Homogeneous deep corrosion detected

⦁ Deformation and exposure of raw metal to oxidation

⦁ Distance measurement: 67mm +/- 5mm

Example report generated by Flyability’s Inspector software

Future Prospects for Drone Tank Inspections

Pertamina found the use of the Elios drone for this large-scale maintenance project to be highly successful. The confined space inspection demonstrated that even the largest oil storage tanks can be systematically assessed by drones, meeting the standards of an API-certified inspector without the need for risky and costly manual entry.

"We believe that implementing such drone technology will significantly enhance tank inspections by reducing risks and costs while making the process safer and more efficient," said Erikson Nainggolan, Operation Planning Assistant Manager at Pertamina EP.

With this project completed successfully, Pertamina is now exploring how to expand the use of drone technology across other maintenance initiatives at its refineries throughout Indonesia.

ShenZhen Jakeconn Precision Technology Co., Ltd. , https://www.jakeconn.com