Offshore Inspection Mobil
Minimizing risk and downtime through drone-powered inspections
Case Details
Clients: ExxonMobil Nigeria
Start Day: June 2020
Tags: Oil & Gas, Energy
Project Duration: On-Going
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The Challenge
ExxonMobil Nigeria required a safe and efficient method to inspect active flare stacks on its OSO and USARI production platforms. The primary objective was to assess structural integrity, thermal conditions, and component wear without interrupting production.
Traditional inspection methods involved scaffolding or rope access, often requiring flare shutdowns—leading to production downtime, increased safety risks, and substantial operational costs. The client needed a more advanced, non-intrusive approach that maintained safety and production continuity while delivering the same or greater data accuracy.
Our drone-based solution provided the means to achieve this, enabling real-time visual and thermal data collection while completely avoiding the risks and interruptions of conventional inspection methods.
Our Approach
Our team deployed the DJI M300 RTK drone, integrating Close Visual Inspection (CVI) and Thermal Surveytechniques to perform a comprehensive flare stack assessment.
The inspection was structured in multiple flight segments, systematically capturing detailed data from base to tip at varying altitudes and radial distances.
All operations were carried out under NCAA (Nigeria Civil Aviation Authority) approval for industrial drone use. A comprehensive on-site risk assessment was also completed to safeguard both equipment and personnel throughout the mission.
Our approach combined high-zoom optical imaging with thermal infrared sensing, enabling simultaneous structural and temperature analysis. Continuous collaboration between our UAV pilots and the client’s on-site engineers ensured focused inspection of critical components and efficient data validation in real time.
The Results
- Captured high-resolution visual imagery and 4K video recordings
- Producedthermal maps and annotated hotspot reports
- Delivered a detailedstructural condition assessment with recommended maintenance actions
- Achieved:
- ~85% reduction in inspection time
- ~60% reduction in operational costs
- Zero production downtime(inspection performed on active flare)
Impact
The aerial inspection enabled predictive maintenance by identifying thermal anomalies and early signs of corrosionbefore escalation into costly repairs.
It also eliminated the need for scaffolding or rope access, significantly improving safety standards and operational efficiency.
By leveraging UAV technology, the client successfully maintained production while obtaining precise, actionable insights that informed its maintenance planning and asset management strategies