Case Studies: Successful Flare Stack Inspections Using Drones

Flare stacks are critical components in the oil and gas industry, used to safely burn off excess gases during production. However, inspecting these towering structures has traditionally been a challenging and risky task. The height, locations and active status of most flare stacks make them difficult to access and inspect using traditional methods. Incorporating drone inspection services and using unmanned aircraft allows companies to safely inspect flare stacks, ensuring they are functioning properly or if any maintenance is required.

The Challenge of Traditional Flare Stack Inspections

Traditional flare stack inspections involve considerable risks and challenges. Inspections often require the use of scaffolding, rope access or helicopters, exposing workers to extreme heights, harsh environmental conditions and hazardous emissions. For more thorough inspections, businesses often need to shut down the flare stack, leading to costly downtime and disrupted operations.

Manned flare stack inspections pose a significant risk to workers. The elevated nature of the flare stacks means additional equipment such as scaffolding and ropes are required and working at height naturally comes with an increased risk. The International Safety Equipment Association reports that injuries and fatalities from falls and dropped objects cost over $20 billion in lost wages and medical expenses per year. Research such as this shows the genuine need for an alternative solution to manned flare stack inspections, and drones provide this solution.

Drone Flare Stack Inspection

Drones have changed the way flare stack inspections are conducted.  Equipped with high-resolution cameras, thermal imaging sensors, and LiDAR technology, drones can capture detailed images and data of each flare stack from various angles without the need for human intervention in hazardous areas.

Drone inspections also allow full visibility and data collection without the need to shut down operations. They provide both a safer alternative to manned inspections and a cost-effective solution as there is no operational downtime while the inspection takes place.

Environmental Benefits of Drone Flare Stack Inspections

In addition to improving safety and efficiency, drone inspections of flare stacks also offer environmental and regulatory advantages. The oil and gas industry is under increasing scrutiny to minimise its environmental impact, and drone technology can help companies meet these demands.

One of the key environmental benefits of drone inspections is the reduction in emissions. Traditional methods require a shutdown which leads to increased flaring activity when restarting production, releasing pollutants into the atmosphere. By allowing inspections to be conducted while flare stacks remain operational, drones help reduce unnecessary emissions, contributing to a reduced  carbon footprint.

Case Study: Inspecting One of the World’s Tallest Flare Stacks

One of the tallest flare stacks in the world, standing at over 160m in height usually requires 3-5 weeks of manual labour for a thorough inspection using traditional methods. However, Our  team demonstrated the efficiency of drone inspections by completing the process in just one day. Traditionally, the inspection involves extensive pre-inspection procedures, including clearance acquisition and cooling down the stack, followed by inspectors scaling the stack manually, a process which is both extremely hazardous and time-consuming.

Our team employed a DJI M-300 drone equipped with an H20T payload to speed up this process. The drone’s transmission system and extended 55-minute flight time allowed it to efficiently capture high-quality RGB and thermal data from multiple angles, in a single flight. This approach eliminated the need for manual scaling and extensive ground-based sensor setups and allowed the flare stack to continue burning throughout the inspection, with no downtime. We were able to collect data on flare tip, nozzles, igniters and shields, reducing the time, cost, and risks associated with traditional inspection methods. The data was quickly processed into Visual Inspection Reports, enabling the client to conduct preventive maintenance during routine shutdowns and maintain efficient operations.

Advanced Technologies Enhancing Drone Inspections

The success of our drone inspections is largely due to the use of industry-leading drone technologies. high-resolution cameras with extensive zoom capabilities provide clear, detailed imagery that enable inspectors to identify even the smallest cracks or defects in the flare stack’s structure. thermal imaging sensor detects variations in temperature, pinpointing areas of concern that require further analysis.

A drone’s ability to capture data from various angles and heights provide a comprehensive view of the flare stack, something that is difficult, if not impossible, with traditional inspection methods. The integration of these technologies allows for a thorough and precise assessment of the flare stack’s condition, enabling maintenance teams to make informed decisions about repairs or preventive maintenance.

Integrating Drone Technology into Gas and Oil Operations

By allowing drones to handle flare stack inspection, companies can avoid prolonged shutdown, and the genuine hazards related to traditional inspection methods. Partnering with a recognised drone company with access to the most suitable technologies and industry expertise ensures smooth and efficient inspections with minimal human risk and quicker operations.

Get in touch with us to know more about how you can incorporate drones into your oil and gas operations and make flare stack inspections safer and more efficient.