From day to day, Robots advance from testing in labs to operating in the outside world. The
industrial application of Robotic technologies continually increases, providing unique solutions for
different challenges. Flare System is an important and critical equipment required for continuous
safe operations for any petrochemical plant addressing proper burning of excess hydrocarbon
gases, unusable gases which cannot be recovered or recycled, and gas flaring protects against
the dangers of over-pressure. This paper discusses the different types of robotic inspection,
advantages, and limitations based on actual site demonstrations. As an innovative case, here to
introduce actual business case for close aerial inspection and surveying technique to avoid
polyethylene plant shutdown and providing a reliable inspection technique for on-stream integrity
evaluation for the flare tip. Drones, formally known as unmanned aerial vehicles (UAVs), are a
flying robot that can be remotely controlled, and offer an innovative inspection method launched
between 2006-2008 for Engineering professional aerial inspection and surveying using Remotely
Operated Aerial Vehicles (ROAVs). The visual inspection detection accuracy of (ROAV) offer
higher than the normal visual inspection and easily approach all the flare structure from four
directions. Drone inspection cost is competitive considering the cost of maintenance to dismantle
the flare tip. Drone inspection can be used to assess the elevated flare parts for any seriously
damage in order to define a clear maintenance scope ahead of shutdown.