Texo Case Study: Inspection of Oil Tanks on an FPSO

TEXO leverages the power of Elios drones to enhance efficiency, safety, and data accuracy in oil tank inspections. Discover how this technology is transforming offshore operations.

Key Benefits at a Glance

Savings Traditional methods involve 4–5 rope access technicians who must wait until tanks are emptied and cleaned before starting the inspection. This process can take up to 7–10 days, resulting in high labor costs and significant production downtime. With Elios 3, only two people are needed for 2 days per tank, cutting both labor expenses and production loss.	Speed Using traditional techniques, one tank can take 7–10 days to inspect. With Elios 3, the same task takes just 2 days. The ability to prioritize vulnerable areas allows for quicker identification of issues and faster maintenance planning.
Safety Oil tank inspections using rope access pose serious risks, with workers exposed to heights for long periods. Elios 3 enables pilots to stay safely outside the tank, eliminating the need for dangerous in-tank work.	Operational Efficiency Drones require only two personnel, reducing the need for crew space compared to traditional rope access. For FPSOs with strict crew limits, this helps free up space for other critical tasks.

Introduction

Floating Production, Storage, and Offloading (FPSO) vessels are essential in offshore oil and gas operations. These massive structures process and store crude oil until it can be transported via tanker or pipeline. They offer flexibility, as they can be relocated to optimize production portfolios over time. FPSOs are costly to build but designed for long-term use, often outlasting individual oil fields if properly maintained. Most of the processing equipment is located above deck, while storage tanks are housed below in the double hull. A typical crew size ranges from 50 to 70 people, and regular inspections are required for safety and regulatory compliance.

Customer Needs

TEXO, an inspection expert, was tasked with inspecting oil tanks on an FPSO. While dry dock inspections are manageable with scaffolding and large teams, in-station inspections are far more complex. Tanks cannot all be emptied at once due to operational and safety constraints, limiting the number of tanks available for inspection at any given time. Preparing just two tanks for inspection can take weeks, and traditional methods require 4–5 rope access technicians, who may wait for extended periods. Once the tanks are ready, the inspection itself is time-consuming and risky. Scaffolding adds further complications, including damage to coatings and potential dropped objects. Beyond the cost, the production slowdown caused by tank unavailability is even more expensive. Inspections must identify defects like cracks, distortion, and buckling, especially in high-stress areas such as toe wells. Any late discoveries increase downtime and repair costs.

Solution

TEXO deployed the Elios 3 drone to inspect the oil tanks, completing the job in just one week after cleaning and emptying. The team used only two people, significantly reducing risk and improving efficiency. Four flights were conducted to map the tank, and a 3D point cloud was generated for detailed analysis. According to Xiang Wong from TEXO, “Elios requires only two people instead of five, and it provides reliable data that gives onshore surveyors confidence that every area has been inspected.” The flight path ensures no section is missed, and the video continuity allows multiple inspectors to review the same data, adding layers of expertise. The Elios 3 also improves maintenance planning. Critical areas, such as stress points or hotspots, can be inspected first, allowing engineers to address issues quickly. This approach minimizes downtime and reduces the need for last-minute repairs.

Steam heating coils, which are fragile and hard to inspect manually, are a perfect example of where Elios excels. By flying precise patterns and creating a point cloud, engineers can easily spot issues and plan repairs accurately. This data can be combined with topside information to create a full picture of the tank.

Results

TEXO delivered a highly accurate inspection with detailed point cloud data, something previously unavailable. The entire process took just four days—far less than the usual two weeks. The client was extremely satisfied and expressed interest in expanding the use of Elios for future FPSO inspections. The inspection was completed without any risk to personnel, and onshore surveyors had full confidence that the entire tank had been thoroughly checked.

Conclusion

TEXO has found immense value in using Elios drones for various oil and gas inspection projects. While Elios 2 offers many advantages over traditional methods, TEXO highlights the added benefits of location referencing and point cloud data provided by Elios 3. As Xiang Wong explains, “Elios 2 is great for inspections without issues, but Elios 3 is essential when problems arise.” Looking ahead, TEXO plans to explore new applications, such as inspections on semi-submersible vessels. “These structures are like mazes,” he says. “Elios 3 is the ideal tool for navigating them and eliminating the need for human entry into confined spaces.” TEXO Group is certified by DNV as an approved service provider for remote inspection techniques (UAVs) as an alternative to close-up surveys of ship structures and mobile offshore units.

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