With safety, precision, and operational efficiency at the forefront of the oil and gas industry’s priorities, drone technology is rapidly gaining traction as a transformative force. Swiss-based inspection technology firm Flyability is leading this shift, with its advanced drone, Elios 3, now being deployed for high-stakes industrial operations — including non-destructive testing (NDT) in complex, confined, and hazardous environments.
The Elios 3 recently earned recognition with the Safety Award at the 2025 Offshore Support Journal Conference in London. Designed specifically for indoor and confined space inspection, the drone is equipped with collision-tolerant architecture, real-time LiDAR mapping, ultrasonic thickness measurement (UTM) capabilities, and a gas sensor calibrated for over 14 explosive gases. This integration allows the drone to not only fly safely through hazardous zones but also to gather critical data in a single flight.
As it flies, Elios 3 generates a real-time 3D digital twin of the inspected area, localising all UT readings and visual points of interest, which engineers can later examine in a point cloud format for defect identification and maintenance planning.
This capability is more than theoretical—it has delivered substantial savings and operational efficiencies in the field. UK-based CyberHawk saved US$600,000 using the Elios 3 for cargo oil tank inspections, while Turner Specialty Services reported a 60% cost reduction and completed a 600-meter pipe rack inspection in just two days.
The success is bolstered by advancements in autonomy and AI integration. Elios 3 features Smart Return-to-Home, which autonomously calculates the fastest, safest route back to its starting point—enhancing mission safety and uptime. Flyability has also revealed upcoming features like "Resume Inspection", enabling the drone to return to the precise point of battery depletion and continue its mission uninterrupted after a battery change.
These innovations mark a turning point for the industry. Drones are no longer limited to outdoor visual surveys—they are actively replacing traditional, risk-heavy inspection methods within tanks, stacks, and other enclosed infrastructure.
With multiple class societies certifying the data collected through Elios 3’s UTM module and the drone already garnering global awards for safety and engineering excellence, industry observers agree: drone-based inspections in oil and gas are not just emerging—they are here to stay.
Reference: https://oilreviewmiddleeast.com/technical-focus/drones-for-enhanced-oil-and-gas-operations
