Case Study Roundup: Drones in Energy

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From monitoring remote pipelines to optimizing wind turbine maintenance, drones are proving to the energy industry that they’re more than just flying cameras—they're essential tools for efficiency, safety, and sustainability. Here, we explore the latest case studies where drones and UAVs have delivered measurable impact, showcasing their versatility and value across energy applications.

Phoenix Air Unmanned's Record-Breaking UAS Patrol

Phoenix Air Unmanned (PAU) recently demonstrated how UAVs are reshaping pipeline patrols by covering an impressive 320 miles in a single day. Partnering with Shell Pipeline Company, PAU exceeded their target of 300 miles in just 7.6 flight hours using a single unmanned aircraft system (UAS). PAU delivered real-time data to inspectors while ensuring a safe and streamlined operation.

This milestone was achieved under PAU’s nationwide beyond visual line of sight (BVLOS) waiver from the FAA, which eliminates the need for visual observers along the flight route. This capability opens the door for scalable UAS operations across pipelines, electric grids, and other infrastructure. Since 2019, PAU has inspected over 16,000 miles of infrastructure, and their latest efforts highlight a step forward in making BVLOS operations routine and reliable.

According to Will Wheeler, PAU’s director of operations, the milestone not only proves the business case for UAV inspections but also underscores their potential for meeting regulatory requirements more efficiently than traditional methods.

Cutting Costs and Boosting Safety With Piperack Inspections

From Flyability

Industrial piperacks are vital to keeping operations running smoothly, but inspecting them is often a time-consuming and risky task. Turner Industries faced this challenge head-on by using the Elios 3 drone to inspect 2,000 feet of elevated piperacks. The results? A 60% cost reduction and completion in just two days—a fraction of the time required by traditional methods.

The Elios 3 provided safe, efficient, and accurate access to inspect the elevated structures without the need for scaffolding, cherry pickers, or rope access. It eliminated the risks associated with working at heights while delivering detailed 4K images and LiDAR point clouds, enabling maintenance teams to precisely identify and address issues like corrosion and insulation damage. Benefits include:

  • Access and Safety: No more prolonged work at 50 feet above ground, reducing fall risks for personnel and eliminating drop hazards for those working below.

  • Speed: The inspection of 2,000 feet of pipe rack was completed in just 39 flights over two days, compared to the lengthy process of traditional inspections.

  • Efficiency: The drone's LiDAR and high-resolution imaging allowed for comprehensive analysis and streamlined maintenance planning, saving both time and resources.

Turner Industries' innovative use of the Elios 3 not only minimized operational disruptions but also set a new benchmark for piperack inspections. By embracing drone technology, they demonstrated how UAVs can revolutionize industrial asset management—delivering safer, faster, and more cost-effective solutions.

Driving Innovation in the Energy Sector

These case studies highlight the transformative power of drones in the energy industry, demonstrating their ability to overcome traditional inspection challenges with speed, safety, and efficiency.

As drone technology continues to evolve, its role in the energy sector will only grow. With advanced features like real-time video feeds, LiDAR, and robust flight capabilities, UAVs are paving the way for smarter, more sustainable operations. These innovations are more than technological breakthroughs—they’re proof of how the energy industry is embracing a future powered by efficiency, precision, and safety.

Drones aren’t just flying into the spotlight; they’re soaring into the future of energy.

Ready to explore multiple drone solutions, cutting-edge edge technology, real-world applications, live demos, and unparalleled networking opportunities? Join us at the Energy Drone & Robotics Summit from June 16–18, 2025. Want to showcase your company’s latest innovations to an audience of over 1,400 industry drone, robotics, energy and oil and gas professionals? Get involved now by securing your booth.