Applus+ in Saudi Arabia demonstrates integrated drone-based inspection with advanced NDT

The demonstration focused on elevated and difficult-to-access asset locations, including tank shell and roof areas, as well as an insulated line section, where conventional inspection methods would typically require scaffolding, rope access, or other temporary access solutions. The objective was to assess whether drone-enabled inspection could provide reliable access for validated NDT application while maintaining inspection quality, traceability, and safety.

For UT and DFT, measurements collected using the drone-mounted system were directly compared with readings obtained through conventional hands-on verification at the same locations. Following calibration alignment, the results showed close correlation, with all verified readings within acceptable tolerance and defined measurement uncertainty parameters.

Validation and technical oversight were provided by qualified NDT personnel, including Level 3 supervision, in accordance with applicable methodologies and internal quality controls.

PEC was also deployed to screen for potential wall loss through insulation and coatings without the need for surface preparation or insulation removal. This enabled efficient identification of areas requiring follow-up assessment and demonstrated the suitability of PEC for access-constrained or operationally sensitive assets.

A key aspect of the demonstration was the integration of multidisciplinary expertise. The activity was delivered as a coordinated inspection exercise involving drone pilots, NDT specialists, and technical oversight personnel operating within a single workflow. This ensured alignment across flight execution, probe placement, data validation, and reporting.

Within this model, the drone functions as a safe and efficient access tool, while inspection integrity remains dependent on the correct application of established NDT methods, equipment calibration, disciplined procedures, and specialist interpretation. The value of the approach therefore lies in its controlled integration into recognised inspection practices.

From an operational perspective, drone-enabled access reduced the need for temporary access systems and minimised personnel exposure to working at height, while enabling inspection in areas that would otherwise require more intrusive and time-intensive preparation. This supports safer planning, reduced operational disruption, and more efficient deployment of specialist resources.

Inspection data and visual records were captured and structured to support traceability, technical review, and reporting. The output can be integrated into integrity management workflows, supporting condition assessment, maintenance planning, and asset decision-making.

This demonstration confirms that drone-enabled inspection can be incorporated into established inspection frameworks when supported by appropriate validation, qualified personnel, and coordinated execution. The approach is particularly relevant for assets with access constraints, live operating conditions, or shutdown limitations.

It also represents a step in the continued development of Applus+ Remote Digital Visual Inspection (RDVI) solutions. By combining drone-enabled access, structured visual capture, validated NDT data, and disciplined data management, Applus+ continues to develop inspection workflows that support remote engineering review, condition monitoring, and more informed maintenance planning across complex industrial assets.