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

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 risks, require extended shutdowns, and carry significant inspection costs. As the industry seeks safer and more efficient alternatives, UAV-based inspection has emerged as a proven solution.
 

End-to-end RPAS inspection capability for high-risk Infrastructure

Applus+ provides end-to-end RPAS inspection services purpose-built for high-risk and hard-to-access assets such as bridges, dams, pipelines, transmission structures, communication towers and industrial infrastructure, including flare stacks. Our approach integrates technical inspection expertise with compliant aviation operations, ensuring inspection programs deliver both safety and engineering value.

• Our CASA-compliant RPAS operations are conducted by qualified and experienced RPA operators
• We use high-resolution photography and 4K video capture to support detailed visual assessment

• We perform targeted inspection, including structural condition, thermal exposure effects and mechanical damage
• We provide Integrated reporting aligned with regulatory, safety and integrity management requirements

Delivering improved inspection quality while eliminating downtime and reducing cost

RPAS inspection significantly reduces exposure to working at height hazards by removing personnel from high-risk environments, while still delivering comprehensive inspection coverage aligned with regulatory and audit requirements.

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. We also provide immediate access to critical data following capture. The RPAS approach reduces inspection schedules from weeks to days, simplifying logistical complexity and lowering costs.

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

Comprehensive integrity management services to support the full asset lifecycle

RPAS flare inspection forms part of Applus+ 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.

Applus+ combines technical depth, regulatory expertise, and proven delivery to help industry inspect with confidence, without compromising safety or operations.