Flare Stack Drone Inspections
Project Overview
Engineering Design Services has completed multiple flare stack drone inspection projects for refineries and industrial facilities across Texas. These inspections leverage advanced unmanned aerial systems to safely evaluate critical flare infrastructure while minimizing operational disruption and eliminating the need for personnel to work at height.
Result & Impact
• Improved worker safety by eliminating the need for personnel to perform high-elevation inspections
• Reduced operational disruption by enabling inspections without shutdowns
• Delivered high-quality visual and diagnostic data for flare stack condition assessment
• Enhanced maintenance planning through accurate, real-time asset documentation
• Identified potential hot spots and structural concerns early
• Supported safer, more efficient inspection practices across refinery operations
Engineering Tools & Technologies
• DJI Matrice 300 RTK drone platform
• High-resolution optical zoom imaging (23x)
• Drone-based laser scanning (LiDAR)
• Thermal imaging systems
• Photogrammetry and 3D reconstruction
• Gas and leak detection monitoring tools
• High-definition aerial photography and video capture
• Industrial inspection and condition assessment workflows
Scope
• Perform drone-based inspections of flare stacks and associated infrastructure
• Conduct close-range visual assessments of flare tips and structural components
• Document flare system conditions without requiring operational shutdowns
• Capture high-resolution imagery & videography for engineering review and reporting
• Support maintenance planning and asset condition tracking across facilities
• Provide inspection services across refineries and industrial sites in Texas
Solution
Engineering Design Services utilizes the DJI Matrice 300 RTK platform equipped with high-resolution, 23x optical zoom imaging systems to conduct safe, detailed flare stack inspections. Drone-based data collection allows engineers to assess structural integrity, identify visible defects, and evaluate flare tip conditions from a safe distance. Depending on project requirements, additional sensing technologies are integrated to enhance diagnostic capability and deliver comprehensive asset insights.
