Why Drones
Safety
Flares stacks can be incredibly tall structures, measuring above 160m even. Nevertheless, inspectors need to scale up the flare stack via rope or crane. At this height, the stakes are quite high, and it exposes the inspectors to tremendous risk.Better Data
Drones can capture data from all angles allowing the inspector to study the assets in detail Additionally, drones can also capture thermal data; this is especially helpful as temperature readings taken from nadir or laterally are more accurate than when taken from oblique.Lower Cost
The traditional method of inspecting is more expensive and labour intensive. A Drone-based inspection just requires a two-person team. The biggest cost savings are from decreased downtime; drones allow the plant to remain in production for longer.Reduced Downtime
Drone inspections take a fraction of the time required for traditional inspections. On average, a drone team can inspect 3-4 stacks in a day, whereas the traditional methods would take days or even weeks in some situations.Instant Reporting
Accurate and detailed data is made readily available in near real-time. Additionally, drone data can be easily integrated into any cloud infrastructure, making collaboration seamless.Inspect multiple assets
Inspecting Oil and Gas storage tanks is an equally slow and intense operation. Drones inspection can bring the same level of precision and efficiency and inspect other assets as well. Inspecting a flare stack the traditional way is slow, laborious and dangerous. Drones can transform this process and remove much of the danger and downtime while providing accurate and precise data.Inspecting One the World’s Tallest Flare Stacks in Just One Day
One of the tallest flare stacks in the world, measuring over 160m in height- Inspecting this enormous stack is a challenging operation that takes 3-5 weeks to complete. FEDS were brought on to test a drone-based flare stack inspection system and display the benefits of drones. Using their extensive fleet and experience, the FEDS team could make a 3-5 week-long inspection operation into just one day. Inspecting this flare stack the traditional way would be slow, dangerous, and a labour-intensive process. Even before the inspection can commence, the pre-inspection procedures would take more than a week; obtaining the necessary clearance and shutting and cooling down the stack. Once done, the actual inspection can take place. Inspectors would scale up the 160m tall stack via rope and inspect all the assets. For smaller stacks, you can use ground-based sensors to observe the flare tip, but only thermal sensors were viable since the distance rendered RGB sensors inaccurate. Even so, due to the distance, these systems would only play a role in monitoring the stack and cannot obtain conclusive data or conduct inspections. In the past, this left rope, scaffolding and helicopter were the only methods of inspection, and this resulted in excessive downtime, greater danger and higher cost. The FEDS team were confident that they could make this slow and tedious inspection into an efficient and effective process. They chose the DJI M-300 for the task. When paired with the H20T payload, the drone would become the perfect system for the job. Its robust transmission system enables you to fly high around the stack’s peak with confidence. The extended flight time of 55 minutes allowed the team to meticulously capture data of the assets from multiple angles, ensuring that they missed no detail out. Still, the more significant benefits came from the payload; the H20T can capture data using two sensors simultaneously. Using this payload, the team captured both RGB and Thermal data in just one flight, which cuts down the inspection time even further. The FEDS team proceeded to capture data from the flare tip, the nozzles, igniters and shield- taking note of the flow rates, flare functionality and more. In a quick 30 minutes, the M-300 had flown around and captured all the necessary data. This data was then processed once back in the office and submitted to the client as Visual Inspection Reports. Throughout the entire inspection, the flare continued burning with zero downtime. FEDS enabled the client to perform preventive maintenance during routine shutdowns, identify potential failure points, and ensure that the plant operates efficiently. In the Oil and Gas industry, one of the major priorities is managing assets with minimal downtime; FEDS can make this happen through intelligent drone inspection solutions. We reduce the risks, maximise uptime and keep your operations running at full capacity and provide you with reliable insights. If you’d like to find out how your Oil and Gas Fields can benefit from having drones, get in touch with us now.FAQs: Drone Flare Stack Inspection
A flare stack is a vital safety system used in Oil & Gas fields to safely burn off excess gases that could pose risks to people and the environment. It prevents hazardous build-ups by ensuring gases have a controlled release, mitigating the risk of explosions or plant shutdowns, which can result in significant financial losses.
Drones transform flare stack inspections by providing a safer, faster, and more cost-effective method to gather precise data without needing to shut down operations. They enable inspectors to assess the condition of flare stacks from a safe distance, capturing detailed visual and thermal data, which facilitates a more preventive maintenance approach and reduces downtime.
The benefits of using drones include improved safety by eliminating the need for inspectors to physically scale the structures, lower costs due to reduced need for scaffolding or helicopters, decreased downtime as drones can inspect multiple stacks in a day, and instant reporting with accurate, detailed data available in near real-time.
Yes, one of the significant advantages of using drones is their ability to inspect flare stacks while they are operational. This capability means that plants do not have to shut down or cool off the flares, allowing for continuous production and significantly reducing inspection-related downtime.
Drones equipped with advanced sensors can capture high-resolution visual (RGB) images, thermal data, and even 3D models of flare stacks. This data provides insights into the stack’s condition, including detecting cracks, monitoring temperature variations, and assessing the structural integrity, all of which are crucial for planning maintenance and ensuring safety and efficiency in operations.