Thermal Flare Stack Inspection by Drone

Getting Results - Why Use Drones to Conduct Flare Stack Inspections?

thermal stack inspection by drone

Safety: Flare stacks are often tall structures, and inspecting them traditionally requires personnel to climb ladders or use scaffolding, which can be hazardous. By using drones, inspections can be conducted remotely, eliminating the need for workers to physically access elevated and potentially dangerous areas. This significantly reduces the risk of falls, injuries, or other accidents associated with working at heights.

Accessibility: Flare stacks are typically located in industrial facilities with complex infrastructure, making certain areas difficult to access. Drones can maneuver around obstacles and provide close-up views of the flare stack from various angles. They can easily reach areas that are challenging for human inspectors, such as the top of the stack or areas hidden behind equipment or structures.

drone thermal equipment inspection

Cost and Time Efficiency: Drone inspections can be completed more quickly compared to traditional methods, reducing the overall inspection time. Drones equipped with high-resolution cameras or thermal imaging sensors can capture detailed visual data and identify potential issues. The data collected can be analyzed remotely, allowing for swift assessment and decision-making. This efficiency translates into cost savings for companies by minimizing inspection downtime and reducing the labor required for traditional inspection methods.

Detailed Data Capture: Drones equipped with advanced RGB and thermal imaging technology can capture high-resolution images and videos of flare stacks. These images provide detailed information about the condition of the structure, including corrosion, cracks, or other forms of damage. Thermal imaging sensors can detect temperature variations that may indicate insulation or combustion problems. The data collected by drones enables inspectors to conduct thorough assessments and make informed decisions regarding maintenance or repairs.

inspecting flare stacks by drone

Documentation and Comparison: Drone inspections generate visual data that can be stored and used for future reference or comparison. This historical documentation allows inspectors to track changes over time, monitor the progression of issues, and assess the effectiveness of maintenance or repair interventions. It also facilitates communication and collaboration among different stakeholders, such as maintenance teams, engineers, or regulatory authorities, who can remotely review the inspection findings.

Thermal flare stack inspection by drone improves safety, accessibility, efficiency, data quality, and documentation. It enables timely detection of issues, reduces operational disruptions, and enhances the overall integrity and performance of flare stacks in industrial facilities.

What Is a Flare Stack?

A flare stack, also known as a flare tower, is a tall vertical structure used in industrial facilities, such as refineries, chemical plants, and oil and gas production sites. It is designed to safely burn off excess flammable gases that cannot be efficiently processed or stored.

A typical flare stack consists of a tall vertical pipe with multiple burners at the top. The excess gases are directed to the flare stack through a network of pipes and are ignited at the burners. The gases burn with a flame at the top of the stack, visible as a bright flame. Flare stacks are designed to withstand high temperatures and to ensure the safe combustion of the gases.

infrared-stack-inspection-using-drone-RGB infrared-stack-inspection-using-drone-THERMAL
how-to-conduct-infrared-inspection-using-a-drone-rgb how-to-conduct-infrared-inspection-using-a-drone-thema

Why are Flare Stacks Used?

Safety: Flaring is used as a safety measure to prevent the release of potentially dangerous gases into the atmosphere. In situations where excess gases are produced due to equipment malfunctions, maintenance activities, or emergency shutdowns, flaring helps prevent the buildup of pressure that could lead to explosions or other hazardous situations.

Environmental Protection: Flare stacks are an essential component in the management of hydrocarbon waste gases. Instead of releasing the gases directly into the atmosphere, which could contribute to air pollution and the emission of greenhouse gases, these gases are burned off in the flare stack. Although flaring still releases carbon dioxide (CO2), it is considered a better alternative to releasing unburned gases with higher environmental impacts.

Process Control: Flaring can also be used as a means of process control in industrial facilities. During normal operations, some gases might need to be removed from the system to maintain safe operating conditions. Flare stacks provide a controlled outlet for these gases, allowing the facility to maintain proper pressure levels and avoid potential operational issues.

Why are Flare Stack Inspections Important

Safety: Flare stacks handle potentially hazardous materials and operate at high temperatures. Regular thermal flare stack inspection by drone help identify any structural damage, corrosion, or leaks that could compromise the integrity of the flare stack. Detecting and addressing these issues promptly can prevent accidents, such as fires, explosions, or gas releases, which could endanger personnel and nearby communities.

Compliance: Industrial facilities are subject to various safety and environmental regulations. Flare stack inspections help ensure compliance with these regulations, which often include requirements for routine inspections, maintenance, and emissions monitoring. By conducting regular inspections, companies can demonstrate their commitment to adhering to regulatory standards and avoiding potential penalties or legal consequences. 

Environmental Impact: Flare stacks are used to burn off excess gases, but inefficient or poorly maintained systems can contribute to air pollution and the release of greenhouse gases. Inspections can identify operational inefficiencies, such as excessive flaring or incomplete combustion, which can lead to higher emissions. By identifying and addressing these issues, facilities can minimize their environmental footprint and improve air quality.

Equipment Performance: Flare stacks are critical components of industrial operations, and their proper functioning is important for the overall performance of the facility. Inspections help assess the condition of the flare stack and its associated equipment, such as ignition systems and flame detectors. By identifying maintenance needs or performance issues early on, companies can prevent costly equipment failures, production interruptions, or unplanned shutdowns.

Preventive Maintenance: Regular inspections in accordance with the ASME STS-1 or other industry specific standards provide an opportunity to perform preventive maintenance on the flare stack. This can involve activities such as cleaning, lubrication, and the replacement of worn or damaged components. By proactively addressing potential issues, facilities can extend the lifespan of their flare stack, optimize its performance, and minimize downtime.

Flare stack inspections are crucial for ensuring safety, regulatory compliance, environmental responsibility, equipment performance, and preventive maintenance. By conducting routine inspections, industrial facilities can identify and address potential issues before they escalate, reducing risks and improving overall operations.

Drone Flare Stack Inspections Sample Images

Drone Flare Stack Inspections Sample Images

Please select the link below to download DJI-based flare stack analysis reports. These basic reports are created using radiometric JPG images. 

Radiometric images refer to images that capture and represent the intensity of electromagnetic radiation within different wavelengths or bands. Unlike standard images that are typically used for visual perception, radiometric images are used to quantify and analyze the energy emitted or reflected by objects in a scene.

Radiometric images are often captured using specialized sensors or instruments that can measure the intensity of radiation across specific wavelength ranges. These sensors can be designed for various applications such as thermal imaging, remote sensing, medical imaging, or scientific research.

In thermal imaging, for example, radiometric images capture the thermal radiation emitted by objects. These images can be used to measure temperature variations, identify hotspots, or analyze heat distribution in various fields like building inspections, industrial monitoring, or medical diagnostics.

In remote sensing, radiometric images can provide valuable information about the Earth’s surface, atmosphere, and vegetation. By capturing radiation in different spectral bands, remote sensing satellites can collect data on land use, vegetation health, ocean temperature, and much more.

Radiometric images are typically stored and processed using formats that preserve the raw or calibrated radiometric data. Common formats for radiometric images include formats like TIFF (Tagged Image File Format) or ENVI (Environment for Visualizing Images). These formats retain the pixel values and calibration information, allowing for further analysis and processing of the radiometric data.

Overall, radiometric images are essential in many scientific, industrial, and environmental applications where quantitative analysis of electromagnetic radiation is required.