at top levels

Flare tip changeout procedure

Successive stages in flare tip replacement

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.