Scope Overview

Flare systems on offshore oil and gas facilities are critical safety components, but their height, configuration, and live status make them extremely challenging to inspect. Traditional methods such as rope access or scaffolding often introduce safety risk, require production shutdowns, and provide limited image quality and coverage.

The aim was to complete a detailed visual inspection of two live flare systems without interrupting production, supporting Repsol’s integrity assessment and maintenance planning ahead of a scheduled turnaround (TAR) campaign.

The Challenge

Repsol required a proven inspection solution capable of:

• Capturing detailed visual and thermal imagery of flare tips, pilot lines, and associated structures while the systems remained live.

• Reducing safety exposure by avoiding scaffolding and work at height.

• Delivering consistent, high-quality data for condition assessment.

• Operating safely and effectively in a harsh offshore environment.

The Solution

Innovair deployed a two-person inspection team, each qualified as both inspection engineer and drone pilot. Using the DJI Matrice 300 RTK platform equipped with high-resolution visual and thermal payloads, the team carried out the full scope from the platform top deck with clear line of sight and RTK positional control.

The system provided:

• RTK-enabled accuracy and repeatable flight paths

• Safe operations on live flare systems

• Structural imaging of flare tips, booms, chords, braces and pipework

• High-resolution visual and 4K thermal imagery

• Reliable stability and image quality in offshore weather conditions

The Results

• Full flare system coverage achieved with no shutdown required

• Structural and thermal defects identified and reported immediately

• Thousands of high-resolution images and detailed 4K video captured

• Comprehensive engineer-verified reports issued with actionable insights

Want more information?

Download the full case study to learn how Innovair’s offshore drone operations delivered safe, efficient, and high-quality inspection results while reducing risk and supporting proactive maintenance planning.