Replacing flare tips onshore and offshore without the use of cranes is a speciality of FG International Holland BV.

Different types of flare stacks such as:

1.  the free standing guy wired flare stack with only one major pipe going up. The

     height of these flare stacks varies between 60 and 240 metres.

2.  the derrick type flare structure, where a steel construction supports one or more

     flare pipes.

3.  the free standing flare stack that does the job without being suspended or

     supported by any additional structure.

All have in common that they make use of a flare tip, which is located at the end of the pipe and takes care of igniting the combustible gases.

Normally a significant amount of steam is injected into the flame to reduce soot and the building of large flames and to cool the flame base. This means that a lot of steam has to be transported to the top of the flare.

Flare structures need to be inspected and maintained on a regular basis according to the time in between the turn-around or stop intervals of the plant.

Flare tip changeout procedure with the FG LAF

Before commencement of the actual work, the flare platform structure is inspected for rigidity and status of maintenance. In case of a negative outcome, additional supports can be fitted to ensure safe working loads on the existing structure. This is carried out in cooperation with the principal.

The main winch and the assisting winch are being installed at the base of the structure.

The Lifting Arch Frame (LAF), weighing 300 kg, is hoisted up. Each piece of the frame structure weighs about 16 kg. It is made of an aluminium alloy that has a high strength to weight ratio. It is capable of lifting 5 tons load, and flare tips usually weigh about 1 ton to 3.5 tons.

The LAF is positioned against the flare tip and braced alongside the tip. Every single part that has to be fixed at the top, is secured against falling down from the top of the boom during the installation works. The LAF's forward and backward movements are executed by chains that secure the parallel position as well. The blocks, tackles and winch cables are fitted to the flare tip.

The bolts on the flare tip are loosened and lifted up just 50mm with some bolts still in, but with loosened nuts. This is a trial test which is usually required by the local authority as a safety procedure. If the tip is balanced, the remaining bolts are removed and the tip is lifted high enough to clear the platform while leaning forward out.

During heavy weather, guiding cables can be used to ensure that wind will not sway the tip in an uncontrolled manner while being lowered.

The winch is located about 30 metres away from the base of the stack so that no one is in the drop line of the load. The area below the stack will be secured, no other personnel may be permitted to enter without first notifying FG personnel.

When the tip is safely down, the new tip can take the place of the old one or the old one is being repaired and hoisted up in reverse sequence of this procedure.

Flare tip replacement with the FG LAF offshore

FG equipment is brought to the platform via a small barge and is hoisted onto the platform using the existing platform's crane (if any). If not available, FG can bring their own equipment up to the platform via a portable manual winch.

Assuming that the tip needs repair and this can be done on the platform itself, than it is advised to bring the tip to the platform.

• The FG Arch Frame is erected over the flare tip.
• Two guide wires are pulled to the main-platform.
• The flare tip is lifted up and hooked onto the 2 guide wires.
• The flare tip is brought to the platform via these two guide wires.
• Repair is carried out on the platform.