Shell transforms refinery inspection with BVLOS drone-in-a-box operations

• Case study showcasing how Shell Petroleum benefits from 1,000+ remote drone-in-a-box flights a month;

• Permanently-located on-site Docks are deployed round-the-clock at two refineries in Rotterdam harbour;

• BVLOS operations have brought enhanced efficiency, safety, and consistency;

• The flights are conducted remotely by Skeye Netherlands;

• The workflow is assisted by a support chain involving heliguy™ and Vortex.  

Global energy giant Shell Petroleum has transformed critical infrastructure inspections with large-scale, automated BVLOS drone-in-a-box operations.

To deliver this programme, Skeye Netherlands — a leading international drone services provider — conducts more than 1,000 remote DJI Dock flights each month at two major refineries in Rotterdam Harbour, spanning approximately 30 kilometres.

Permanently located on-site, the Docks are deployed round-the-clock —  significantly increasing safety, efficiency, and situational awareness in high-risk industrial environments.

The drone data is processed using machine vision models, enabling rapid anomaly detection and supporting a shift toward proactive, evidence-based asset management.

This end-to-end workflow is powered by a unique collaboration between drone specialist heliguy™, robotics expert Vortex, Skeye, and Shell, combining enterprise-grade supply, specialist Dock and software training, technical maintenance, rapid part supply, and operational expertise.

Key takeaways

• Client: Shell Petroleum.

• Partner: Skeye (supported by heliguy™ and Vortex).

• EASA LUC: Skeye self-authorises BVLOS flights across Shell’s refineries, storage tanks, pipe racks, and jetties.

• Scale: 1,000+ autonomous BVLOS Dock flights every month — with this figure set to rise.

• Technology: A total of 8 docking systems operating 24/7.

• Data: Automated capture of RGB, thermal, video and emissions data, streamed securely to Shell’s workflows.

• Cyber Security: Skeye stores data on flight control software, adhering to strict security protocols.

• Machine learning: Anomalies are immediately seen by the pilot or detected by Shell’s machine vision models.

• Outcome: ‘Rounds by exception’ achieved. Automated drone-driven insights improve efficiency and safety.

• Supply Chain: heliguy™'s accredited DJI Dock team provides specialist DJI Dock supply, technical services, and training to Vortex → As an integrator, Netherlands-based Vortex leverages heliguy™’s support to offer rapid localised supply, assistance, and maintenance to power Skeye’s Dock operations and minimise downtime → Skeye utilises its expertise to deliver remote and automated operations for Shell → Shell benefits from continuous data.

Expert insight

“The BVLOS Dock programme shows the power of automated drone technology. It has become an essential part of Shell’s inspection ecosystem, delivering consistent data and freeing personnel from repetitive, high-risk tasks. This shift in workflow has had a major impact on Shell’s operations, and it is powered by a multi-level collaboration between heliguy™, Vortex, and Skeye.”

— Pieter Franken, QHSE and Compliance Manager at Skeye Netherlands.

Before drones: Operational challenges at Shell’s Rotterdam facilities

Before the integration of remote and automated drone flights, Shell’s Rotterdam refineries and tank farms presented a range of operational challenges that made traditional inspections costly, time-consuming, and potentially hazardous.

• High-Risk Environments: Routine checks required personnel to enter hazardous zones around tanks, pipe racks, and processing facilities—creating safety risks and slowing operations.

• Manual, Labour-Heavy Rounds: Twice-weekly floating roof inspections and other mandatory checks consumed valuable technician hours that could be better spent on diagnostics and maintenance.

• Regulatory Constraints: The sites sit within dense industrial infrastructure and near controlled airspace, requiring strict compliance and multiple permissions for any drone activity.

• ATEX No-Fly Zones: Explosion-proof areas demanded precise flight planning and robust fail-safe systems to ensure drones could never enter restricted zones, even during emergencies.

How automated BVLOS operations redefine industrial inspection

Utilising a total of eight docking systems, Skeye delivers fully automated, 24/7 Beyond Visual Line of Sight (BVLOS) drone operations from its Remote Flight Centre in Rotterdam.

Missions are flown remotely in three shifts, seven days a week.

Tackling critical industrial challenges, these drone-in-a-box solutions have become foundational to Shell’s digital transformation across its refineries, pipelines, processing facilities and jetties.

Pieter said: “Shell has become dependent on this technology. Shell believes in a round by exception.”

From two flights a week to 1,000+ BVLOS missions per month

Before reaching full BVLOS capability, Skeye began conservatively with two VLOS flights per week and an on-site observer.

This helped the company prove the concept, build a robust safety record, and develop operational workflows to enable the jump to BVLOS operations.

Today, under its EASA Light UAS Operator Certificate (LUC), Skeye safely self-authorises more than 1,000 BVLOS Dock flights every month — a number increasing as Shell continues to scale.

Missions include:

• Floating roof tank inspections.

• Monitoring critical gauges on processing units.

• Thermal monitoring of key assets.

• Visual pipe rack inspections.

• Emergency response imaging.

• Gas and emissions measurement, including Sniffer4D-equipped VLOS flights.

• Ad hoc requests, often triggered by system alerts or operator needs.

“The drone-in-a-box solution has had extremely little downtime — weather, technical, or regulatory,” said Pieter.

This has brought Shell the following benefits:

• Efficiency: Large areas are quickly covered and enable rapid re-tasking when priorities change.

• Safety: Fewer exposure hours at height or in restricted zones.

• Redeploying people to other tasks: Shell technicians can focus on diagnostics and remediation instead of routine patrols.

• Consistency: Repeatable quality and auditable records across 24/7 operations.

Data capture, AI, and secure workflows

Dock missions collect a range of data, including RGB imagery, thermal insights, and live video.

This data is transferred securely using:

• End-to-end encryption.

• VPN-protected links.

• On-premises versions of flight control software, complying with Shell’s stringent cybersecurity requirements.

Once captured:

• Detections are timestamped and logged.

• Data is integrated into Shell’s maintenance and security workflows.

• Machine vision models perform anomaly detection.

• Skeye supplies the underlying imagery and raises timely alerts.

• Operators in the control room make decisions based on yes/no model outputs and supporting visuals.

Pieter said: “This closes the loop between automated inspection, anomaly identification, and actionable intelligence.”

The heliguy™ → Vortex → Skeye support chain

heliguy™

8+ DJI Dock team, consisting of solutions engineers, regulatory specialists, DJI-accredited Dock engineers and DJI-certified FlightHub 2 On-premises technicians.

heliguy™ is an experienced Dock supplier, with a track record of supporting organisations, integrators, and service providers, including CyberHawk and Uali.  

This team provides Vortex with:

• DJI Dock systems, meeting on-demand supply.

• Specialist DJI-accredited Dock maintenance, operations, and FlightHub 2 training.

• Technical support, forensics, and spare part logistics - ideal for rapid swap-outs and repairs to minimise DJI Dock downtime.

Vortex

• Integration specialists in the energy/utilities sector.

• Based close to Skeye Netherlands - Vortex utilises heliguy™’s Dock knowledge/support to provide localised supply to Skeye.

• This includes Dock hardware, hands-on assistance, and on-location maintenance - designed to provide operational continuity.

• Equips Skeye with the knowledge needed for smooth, continuous Dock operations.

Skeye

• Executes the BVLOS operations for Shell.

• Manages flight scheduling, remote oversight, and data delivery.

• Uses its LUC to self-authorise complex industrial BVLOS missions.

This three-tier structure ensures reliable scaling, rapid issue resolution, and long-term operational sustainability.

Expert insight

“Delivering more than 1,000 automated flights a month doesn’t happen by accident. It takes robust training, reliable hardware, and a trusted support chain. Automated drone-in-a-box operations are only as resilient as the supply and support infrastructure, so this leading-edge, bespoke supply chain helps fuel a leading-edge drone programme and meet bespoke demands. We’re proud to enable partners like Vortex and Skeye as they help major organisations such as Shell turn automated and remote drone operations into everyday reality. The success of Shell’s drone-in-a-box programme demonstrates how automated BVLOS operations are moving from concept to critical infrastructure tool.”

— Ruairi Hardman, Business Development Manager, at heliguy™

Global Expansion: Next Stop, the Bahamas 

With the Rotterdam Harbour programme now a proven model, Skeye is preparing to expand its remote Dock operations, including a major upcoming deployment in the Bahamas.

As a LUC-certified operator, Skeye can replicate its BVLOS workflows efficiently, making DJI Dock systems a scalable solution across global industrial markets.

Summary

Shell has adopted an advanced automated drone inspection network — harnessing more than 1,000 BVLOS Dock missions every month across one of Europe’s most complex industrial landscapes.

Shell’s Rounds by Exception methodology, backed by machine vision, secure data pipelines, and resilient Dock hardware, has made routine inspections more efficient, enhanced safety, enabled earlier detection of issues, and freed skilled personnel for higher-value tasks.

This case study also demonstrates how the heliguy™ → Vortex → Skeye ecosystem has helped a major industrial operator modernise its workflows through drone automation.

Contact us for details on how heliguy™ can start and scale your drone-in-a-box operations.