Remotely-Piloted-Aircraft-System-(RPAS)-inspection-solutions-for-elevated-flare-infrastructure

Supporting safer, smarter flare inspections across industry

Elevated flare stacks are among the most challenging assets to inspect. Operating at height, exposed to extreme temperatures and mechanical stress, and governed by strict regulatory requirements, flare systems demand inspection methods that minimise risk while still delivering reliable, actionable data.

Traditionally, flare inspections have relied on scaffolding, rope access or elevated work platforms. These approaches inherently present safety risk, require extended shutdowns and carry significant inspection costs. As industry seeks safer and more efficient alternatives, RPAS-based inspection has emerged as a proven solution.

The Applus+ RPAS inspection approach

Applus+ in Australia provides end-to-end RPAS inspection services purpose-built for high-risk and hard-to-access assets such as elevated flares. Our approach integrates technical inspection expertise with compliant aviation operations, ensuring inspection programs deliver both safety and engineering value.

Key elements of the Applus+ solution include:

• CASA-compliant RPAS operations conducted by qualified and experienced RPA operators
• High-resolution photography and 4K video capture to support detailed visual assessment
• Targeted inspection objectives, including structural condition, thermal exposure effects and mechanical damage
• Integrated reporting aligned with regulatory, safety and integrity management requirements

This capability is supported by Applus+ broader asset integrity and inspection expertise across Australia’s energy, oil & gas and industrial sectors.

Delivering measurable safety and improved inspection quality

RPAS inspection significantly reduces exposure to working at height hazards by removing personnel from high-risk environments, while still delivering comprehensive inspection coverage.
Key industry benefits include:

• Improved safety outcomes through the removal of manual access to elevated assets
• Consistent, high quality inspection records to support ongoing integrity programs
• Reliable inspection data aligned with regulatory and audit requirements

These benefits align directly with industry objectives around safety leadership, inspection quality, and regulatory compliance.

Eliminating downtime while reducing cost

One of the key advantages of RPAS based flare inspection is the ability to complete inspections without interrupting operations. By removing the need for scaffolding or elevated access equipment, Applus+ enables operators to maintain production continuity while inspections are carried out.

Key operational and cost benefits include:

• Zero production downtime during inspection activities
• Immediate access to critical inspection data following capture
• Reduced inspection schedules from weeks to days
• Lower inspection costs through the elimination of temporary access systems
• Simplified inspection planning with reduced logistical complexity

High quality visual data allows integrity engineers to identify early signs of degradation, assess damage mechanisms, and prioritise maintenance activities, supporting more informed asset management decisions.

Part of a broader asset integrity offering

RPAS flare inspection forms part of Applus+ in Australia’s comprehensive asset integrity and inspection portfolio. By integrating aerial inspection data with complementary services such as non-destructive testing (NDT), advanced inspection and integrity engineering, Applus+ supports the full asset lifecycle—from baseline assessment through to ongoing condition monitoring.
 

Advancing inspection standards for the energy and industrial sectors

As asset owners continue to seek safer, smarter and more sustainable inspection solutions, RPAS technology is becoming a preferred tool for critical infrastructure assessment. Applus+ in Australia remains at the forefront of this shift, combining technical depth, regulatory expertise and proven delivery to help industry inspect with confidence,without compromising safety or operations.