Kopterflug inspects flares and flare stacks with the DJI Matrice 30T: 200x zoom and radiometric thermography from a safe distance – at full operation, without scaffolding, without shutdown. Refineries, chemical parks, oil & gas – nationwide.
Flare stack inspection with the DJI M30T – 200x zoom delivers close-up detail from a safe distance.
Flares and flare stacks are safety-critical components in refineries, chemical parks and oil & gas facilities. They are exposed to extreme loads: heat, corrosion, wind and thermal cycles. Classical inspections require scaffolding on 50–100 m structures – typically only possible during a turnaround.
At Kopterflug, we inspect flares and flare stacks with the DJI Matrice 30T: 200x hybrid zoom for visual close-ups and radiometric thermography for burner performance and temperature distribution – all from a safe distance during live operation.
This is a purely external inspection. The ELIOS 3 is not used for flares – the temperatures and heights require an outdoor drone with powerful zoom and thermography from a safe distance.
We fly the DJI M30T at a safe distance around your flare installation and systematically document all safety-relevant areas:
| Area | What we check | Why it matters |
|---|---|---|
| Flare Tip (Burner) | Condition of burner nozzles, wear, deformation, material loss, flame holders, pilot light | A damaged tip causes incomplete combustion, increased emissions and potential flame flashback |
| Refractory Lining & Heat Protection | Condition of refractory lining, cracks, delaminations, missing sections | Damaged lining leads to overheating of the steel structure and accelerated corrosion |
| Flare Tower & Support Structure | Corrosion on the shaft, welds, platforms, ladders, flanges, coating damage | Structural weakening of a 50–100 m flare is a significant safety risk |
| Guy Wires, Wind Shields & Steam Injection | Condition of guy wires, wind shields, steam/water injection nozzles | Defective guy wires endanger stability; blocked steam nozzles increase visible emissions |
| Base, Inlet & Piping | Corrosion and mechanical damage at foot ring, foundation anchors, flanges, process lines | Corrosion in ground-level areas and at flanges often invisible from ground level |
At the end we deliver a detailed inspection report with 4K footage of the entire flare installation, thermography maps with temperature distribution, damage classification and action recommendations.
The DJI M30T – primary system for flare head and flame zone inspection during live operation.
We also inspect horizontal/inclined flares and offshore/boom-mounted flares – the latter on request and after individual coordination due to increased logistics effort.
| Aspect | Classical | Drone |
|---|---|---|
| Shutdown required | Mandatory | Inspection during live operation |
| Access | Scaffolding on flare tower (50–100 m) | Flyover, no scaffolding |
| Time | 4–8 weeks | 1–2 days |
| Thermography | From below, telephoto lens | Close-up at the flare head |
| Documentation | Photos + sketches | 4K + thermography + LiDAR |
We analyse your flare installation: type, height, operating status, wind conditions, flight restrictions. We assess feasibility and advise you at no charge.
You receive a transparent quote. Together we plan the deployment – coordinated with your plant operations. No shutdown required, but wind conditions are taken into account.
Our pilot and assistant fly systematically around your flare installation – from foundation to burner tip. 200x zoom for visual details, thermography for temperature distribution. If required, with your experts on site.
You receive a detailed report with 4K footage, thermography maps, damage classification and action recommendations. A solid basis for your maintenance planning.
Christian Engelke and Dipl.-Ing. Karsten Lehrke – your direct contacts for flare inspection projects.
Christian
Founder & Drone Pilot
Karsten
Founder & Managing Director
Philipp
Founder, Mission Planning & Logistics
Juliana
Drone Pilot
Stephan
Mission Planning & Logistics
Since 2017, we have been inspecting industrial installations with drones. For flares we deploy the DJI Matrice 30T – 200x zoom and radiometric thermography from a safe distance to the active flame. We deliver the data, your maintenance team makes the decisions.
Classical: scaffolding (weeks, six-figure costs), shutdown, hot-work permit, industrial climbers. By drone: arrival, flight, documentation in one day – without scaffolding, without shutdown, without risk at height. The drone also delivers thermography data that is often not captured by the classical method.
We deploy the DJI Matrice 30T – with 200x hybrid zoom and radiometric thermography. The M30T is an outdoor drone with IP55 weather protection that delivers close-up detail of the flare tip from a safe distance. The Flyability ELIOS 3 is not used for flares – the extreme temperatures and heights require a powerful outdoor drone.
We systematically document: burner tip (wear, deformation, material loss), refractory lining (cracks, delaminations), pilot light (function), flare tower (corrosion, welds, coating), wind shields and steam injection nozzles, guy wires and foundations.
Yes – this is one of the greatest advantages of drone inspection. The M30T inspects from a safe distance to the active flame. No shutdown is required, no hot-work permit for the inspection and no turnaround window. Thermography even delivers more meaningful data during live operation, as the temperature distribution at the burner can be analysed.
The deployment is carried out with a defined safety distance from the flame and coordinated mission planning. We take into account wind and turbulence conditions, thermal updrafts and your plant's operating requirements. In unfavourable conditions we fly in sections or adjust the flight route – if in doubt, the deployment is rescheduled.
The systems deployed are not ATEX-certified. Flight therefore takes place outside critical Ex zones – in close coordination with your HSE team. In many cases the flare structure itself is inspectable from outside without entering the Ex zone. The exact demarcation is clarified in advance.
The M30T always maintains a safe distance from the active flame. The 200x hybrid zoom enables close-up footage from a great distance – it is not necessary to approach the flame or radiant heat. The exact flight distance is determined before each deployment based on flare type, wind direction and operating status.
Thermography makes visible what is invisible visually: overheating, uneven combustion, anomalies at insulation and refractory, as well as thermal anomalies at steam and air injection systems. Problems are detected before they become visible externally or lead to failures.
Typically up to approximately 100 m height, depending on weather conditions also beyond. Zoom and thermal sensors enable close-up footage from a safe distance – the drone does not need to fly all the way to the flare tip to fully capture the relevant areas.
No – the drone delivers an external inspection. Wall thickness measurements, internal lining inspection and concealed damage under insulation are not possible. For these questions, supplementary methods such as UT measurements or walk-throughs during turnarounds are required.
We inspect elevated flares, ground flares, enclosed ground flares, steam- and air-assisted systems, and horizontal/inclined flares. Offshore and boom-mounted flares are possible in principle but are only carried out on request and after individual coordination due to increased logistics effort.
Yes – guyed flares (guy-wire flares) are a typical use case. The M30T documents both the flare structure and the condition of the guy wires, turnbuckles and anchorages. Defects in the guy wires are safety-critical and are systematically captured during every inspection.
Industry practice: visual inspections every 1–3 years and a comprehensive inspection during the turnaround (every 3–5 years). Drone inspections make more frequent intervals economically viable – annual or semi-annual checks are achievable without scaffolding costs and shutdown.
We deliver 4K footage of the entire flare installation (foundation to tip), radiometric thermography maps with temperature values and marked anomalies, damage classification with position data and a summary inspection report with action recommendations for your maintenance planning.
The key international standard for flare systems is API 537 (Flare Details for General Refinery and Petrochemical Service). In practice, drone inspections are increasingly accepted normatively – particularly for condition assessment and maintenance planning between turnarounds. They do not in every case replace classical inspection methods or assessment by experts.
After a brief discussion of installation, flare type, height and location you receive a feasibility assessment and a quote. We coordinate scheduling, safety clearances and coordination with your plant operations – the effort on your side is minimal.
A drone inspection of the flare typically costs 70–90% less than the classical method with scaffolding or crane. Scaffolding alone generates six-figure costs just for erection and dismantling – plus production losses from the required shutdown and weeks of lead time. The drone inspection is usually completed in a single day, without shutdown and without construction measures. → More at Drone inspection costs.
Yes – the drone inspection can be carried out both during live operation and during a planned turnaround. Before the turnaround it delivers a current condition assessment, on the basis of which repair scopes and material orders can be planned precisely. During the turnaround it supplements the ground-based inspection, for example for hard-to-reach sections at the flare head. This way turnaround durations are shortened and unplanned extensions are avoided.
The DJI Matrice 30T is designed for deployment in challenging conditions but has no special heat protection certification. The flight is therefore planned so that the drone always operates outside the critical radiation zone. The 200x hybrid zoom makes it possible to capture close-up footage in high resolution even from a great distance. Wind direction and thermal updrafts are systematically taken into account during flight planning.
Via zoom and thermography we detect: material loss and deformation of the burner tip, cracks and delaminations of the refractory lining, blocked or damaged steam injection nozzles, corrosion at the wind shield, and thermal anomalies indicating uneven combustion or internal damage. Many of these findings are not visible from the ground with the naked eye.
In principle yes – offshore flares on platforms and FPSOs can be inspected by drone. However, the deployment requires additional coordination regarding logistics, safety clearances, helicopter operations and weather windows. We carry out offshore flare inspections on request and after individual feasibility assessment – contact us early so we can plan the deployment properly.
Thermography reveals temperature differences on the exterior that indicate damage to the internal refractory lining – such as missing or detached segments, cracks or moisture ingress. Areas with noticeably elevated surface temperature suggest reduced insulation performance. These findings are documented in the inspection report with position data and action recommendations, so that targeted repairs can be scheduled for the next turnaround.
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