Resources / Case Study / Flying in One of the World’s Harshest Environments: MFE Supports Altomaxx in Elios 2 FPSO Tank Inspections

Case Study

Flying in One of the World’s Harshest Environments: MFE Supports Altomaxx in Elios 2 FPSO Tank Inspections

When an offshore operator in Labrador, Canada, needed a safer way to inspect FPSO cargo tanks in heavy seas, it turned to Altomaxx, one of the only maritime drone inspection providers certified by Lloyd’s Register, DNV, and ABS. With support from MFE, Altomaxx deployed Flyability’s Elios 2 in one of the world’s harshest environments, pairing industry-leading maritime drone credentials with expert drone piloting to deliver safer, faster FPSO tank inspections than traditional methods would allow.

Benefits

Reliable Inspections in Harsh Maritime Conditions

Altomaxx pilots flew the Elios 2 safely and consistently even as the FPSO rolled in heavy seas, capturing usable data despite the constant motion.

Improved Safety

Remote data collection with the Elios 2 eliminated the need for personnel to work at height or in confined spaces to collect data.

World-Class Inspection Expertise

Altomaxx is one of the only maritime drone inspection service providers in the world certified by Lloyd’s Register, DNV, and ABS.

Introduction

When an offshore operator in Labrador, Canada needed to inspect cargo tanks on an FPSO*, it turned to Altomaxx, the only drone service provider certified by the three biggest inspection entities in the world: Lloyd’s Register, DNV, and ABS.

Regular cargo tank inspections are essential on FPSOs to manage corrosion, verify coating condition, and ensure tanks remain fit for service in one of the harshest operating environments in the world.

Conditions on this FPSO were particularly challenging. Heavy seas caused constant movement inside the tanks, making manual data collection unsafe and impractical.

To complete the work without delaying operations or exposing crews to unnecessary hazards, the operator wanted to find a new approach that would reduce downtime and improve safety.

*Note: FPSO stands for Floating Production, Storage, and Offloading vessel. An FPSO is a ship-shaped offshore facility that processes hydrocarbons from subsea wells, stores the product onboard, and offloads it to shuttle tankers or pipelines.

→ Altomaxx’s Inspection Certifications Altomaxx is one of the only maritime drone inspection providers in the world certified by three major classification societies. It also serves as a global certification body for ISO’s unmanned-flight standards:

Lloyd’s Register. Certifies Altomaxx to perform drone-based inspections on maritime vessels and offshore assets.
DNV. Certifies Altomaxx to use drones for inspection work on maritime and offshore structures, including tanks and hulls.
ABS. Certifies Altomaxx to apply drone-based methods in support of class-related inspections on offshore units and vessels.
ISO 21384-3. Recognizes Altomaxx as the first global certification body for ISO 21384-3 Unmanned Flight: Standard Operating Procedures, enabling it to certify other operators and underpin its own drone inspection program.

The Challenge

Inspecting cargo tanks on an FPSO is demanding even in calm conditions. These tanks are confined spaces with limited entry points, complex internal structures, and beams and stiffeners positioned far above the tank floor. Traditional inspection methods require the use of time-consuming temporary structures, and expose personnel to significant hazards. But this FPSO was not operating in calm conditions—far from it. During standard inspections in the North Atlantic, huge swells rock and keel the FPSOs, and that motion translates directly into the tank environment where the Elios 2 has to fly. As the vessel rises and falls, the tank shifts with it, making precise maneuvering even more challenging. Conditions like these demand a high level of competency from the drone team, and Altomaxx has a tested training regimen it uses to get pilots ready for these inspections that includes developing expertise in the environment and on the Elios 2 platform.

“You’re dealing with huge volumes of steel and very little room to maneuver. You have a tight weather window and the expectation that you’ll come back with the data the client needs. If you miss a section, you may not get another chance before the vessel goes back online.” Steve Priestley, COO at Altomaxx

The Solution

Altomaxx chose Flyability’s Elios 2 for flying within the FPSO’s cargo tanks. MFE supported the project with equipment, best practices, and operational guidance. The drone’s protective cage, powerful lighting, and stability made it well suited for flying inside a space that was constantly in motion. Onsite, Altomaxx paired an Elios 2 pilot with an inspector and a support technician at each tank entry. The team planned short, focused flights, working in methodical passes from the manway to the farthest beams and stiffeners. Pilots timed their movements with the vessel’s motion, using the Elios 2’s collision tolerance to remain close to the steel walls and sections without compromising safety. Across the cargo tanks, the Elios 2 captured a comprehensive visual record of internal structures that would normally require significant access preparation.

→ About Altomaxx’s Offshore Experience Altomaxx operates in more than 20 countries across five continents, and the FPSO inspection in this case study is just one of hundreds it has completed over the last five years. Its pilots have deep experience inspecting FPSO assets—cargo tanks, ballast tanks, and hulls—and have logged more than 2,000 flight hours on offshore missions with the Elios 2 alone.

The Results

The drone-based workflow proved both safe and effective, even as the FPSO keeled with the sea’s swells.

Altomaxx completed the inspection on schedule, capturing stable visual data across the cargo tanks. After Altomaxx collected visual inspection data inside the tanks, the operator received a complete record of tank conditions to support its offshore integrity program.

Key results:

Stable inspections in a very harsh environment. Despite heavy vessel motion, the Elios 2 maintained stable flight and captured clear imagery throughout the inspection window, giving the operator dependable visual data from every required area inside the cargo tanks.
No scaffolding or rope access required. The drone removed the need for in-person data collection inside the tanks, eliminating work-at-height exposure and keeping crews out of confined spaces by allowing remote data collection for elevated beams, stiffeners, and other difficult locations.
Faster tank assessments. Visual coverage that would traditionally require a week or more of setup and manned entry can be completed in one to two shifts, keeping the project on schedule despite limited offshore weather windows.
High-quality visuals in complex tank geometry. The Elios 2’s lighting and camera system delivered crisp imagery without harsh shadows, revealing coating condition and structural details across wide, open spans that would be challenging to reach manually.
Reduced offshore downtime. The drone workflow allowed the operator to continue inspections during a period when traditional access methods were impractical or unsafe due to sea state, avoiding delays that would come from waiting for calmer conditions.
Maritime-ready inspection credentials. Altomaxx’s certifications from Lloyd’s Register, DNV, and for remote inspection techniques (RIT) on maritime vessels and floating platforms supported a compliant inspection workflow, ensuring the data met the operator’s offshore and maritime integrity requirements.

“In confined space environments, the only drones we want to fly are an Elios 2 or 3. Even with swells causing so much motion in the tanks, we are able to get the coverage we need and check every area the inspector has on the list.”
Jared Seufert, Senior Manager of Strategic Initiatives at Altomaxx

Conclusion: A New Standard for Offshore Tank Inspections

By proving that drone-based FPSO tank inspections can be completed safely and reliably even in huge swells, Altomaxx has demonstrated an approach that offshore operators can trust—not just for one inspection, but for future inspections across similar assets globally. Altomaxx’s inspection expertise, combined with certifications from Lloyd’s Register, DNV, and ABS, helped ensure the workflow aligned with the operator’s offshore integrity requirements. The result was a complete record of the FPSO’s cargo tanks delivered within a tight operational window. For operators seeking safer, more compliant ways to inspect critical maritime assets, Altomaxx is leading the way.