Drone Tank Inspections: Enhancing Safety, Cost Efficiency, and Operational Performance

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

Key Benefits at a Glance

Safety: By using the Elios 2, Pertamina eliminated the need for human entry into the tank via rope access or scaffolding, significantly reducing risks and improving worker safety during the inspection process.

Cost Savings: Traditional methods often involved expensive scaffolding and lengthy downtime. With the Elios 2, these costs were reduced, and the project became more cost-effective due to faster data collection and analysis.

Efficiency: The Elios 2 streamlined the inspection process, enabling systematic and repeatable inspections of aging infrastructure. This allows for long-term monitoring and maintenance planning, enhancing operational efficiency.

Data Collection: The drone provided comprehensive visual and thermal data, capturing details that would have been difficult or impossible to obtain through manual methods. This level of detail supports more accurate assessments and informed decision-making.

Introduction

Pertamina is Indonesia’s national energy company, responsible for a wide range of oil and gas operations. As part of its ongoing efforts to modernize maintenance processes, Pertamina engaged Halo Robotics, a Jakarta-based drone technology firm, to assist in a major maintenance project at one of its refineries in Balongan.

The refinery has a capacity of 125 mbsd (thousand barrels per stream day), and the specific asset requiring attention was a large crude oil storage tank. This tank shares design characteristics with API 650 tanks, which are widely used globally for storing crude oil and gasoline. Therefore, the methods used in this project could be applied to similar facilities worldwide.

A photo of the oil storage tank at the Balongan refinery

Innovating Oil Storage Tank Inspections

The tank in question had a capacity of 37,000 cubic meters and was over 50 years old, built in 1972. Pertamina aimed to perform a thorough inspection to update its original drawings and assess the structural integrity of the tank.

The main objectives of the project included:

• Updating the 1972 blueprints with current as-built schematics.
• Conducting a systematic interior inspection to identify EPC requirements.
• Reducing the need for rope access and manned entry to improve safety.
• Improving the overall efficiency of EPC maintenance processes.

To achieve these goals, Pertamina focused on two key outputs:

• Creating a Digital Twin through 3D scanning of the tank.
• Performing a Confined Space Inspection using advanced drone technology.

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

Inspectors working inside the oil storage tank

Utilizing the Elios Drone for Tank Inspections

Halo Robotics selected Flyability’s Elios 2 drone for the confined space inspection due to its advanced features and reliability in challenging environments. Key advantages included:

• Collision-tolerant cage for safe indoor operations.
• High-resolution 4K RGB and thermal cameras for detailed data capture.
• Powerful LED lighting for clear visibility in dark spaces.
• Stabilization systems for stable flight in GPS-denied areas.
• Inspector software for efficient data review and report generation.

The Elios 2 performing an inspection inside the oil storage tank

Collecting Visual Data Through Drone Inspections

The Elios 2 exceeded expectations during the confined space inspection, offering significant improvements over traditional methods. It helped Pertamina save time, reduce costs, and enhance safety by eliminating the need for scaffolding and rope access.

"The results from this drone technology have surpassed our expectations. These operations will greatly support preventive maintenance, helping us identify defects more accurately and improve inspection speed and precision," said Almuayat Librata, Oil and Gas Transportation Manager at Pertamina EP.

Details of the Drone Tank Inspection Mission

Halo Robotics conducted inspections of critical parts of the tank, including the shell, welds, rafters, girders, joints, and roof. Over five days, 20–22 flights were completed daily, resulting in 760 GB of high-quality video footage, including 4K RGB and thermal recordings.

The collected data was processed using Flyability’s Inspector software to generate a formal inspection report. This allowed for easy review, annotation, and comparison of visual and thermal data, ensuring a comprehensive assessment of the tank’s condition.

The entire process took 14 days, including input from an API-certified inspector, to produce a detailed final report.

Examples of Point of Interest (POI) Reports

Corrosion Identified—Tank Joint Left Side

Inspector Comments:

• 2x bolts counted
• Shrinking thickness of steel plating and supports
• Significant corrosion observed from 0 mm to 67 mm from the joint
• Distance measurement: 67mm +/- 5mm

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

Inspector Comments:

• 2x bolts counted
• Significant flaking or oil material deposit observed, build-up in joint (67mm height)
• Homogeneous deep corrosion
• Deformation and exposure of raw metal to oxidation and galvanic reaction observed
• Distance measurement: 67mm +/- 5mm

Example report generated by Flyability’s Inspector software

Looking Ahead to Drone Tank Inspections

The use of the Elios 2 in this large-scale maintenance project was a resounding success for Pertamina. It demonstrated that even the largest oil storage tanks can be systematically inspected using drones, meeting the standards of an API-certified inspector without the need for risky and costly human 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 successful project behind them, Pertamina is now exploring how to expand the use of drone technology across other maintenance projects at its refineries throughout Indonesia.

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