WHITE PAPER

EFFECTIVE
FLARE TIP
REPLACEMENT

THE POWER OF PREPARATION

INTRODUCTION
Flare tip replacement is a challenging operation which exerts pressures across the entire
project team. Extremely tight shutdown windows are necessary to minimise impact on
productivity, but present a level of complexity and risk that demands excellence in
engineering skill and safety standards.
This is why major offshore operators such as ExxonMobil trust Conbit to undertake flare tip
replacement work. This white paper combines decades of Conbit’s engineering expertise
and customer feedback to provide an overview of the flare tip replacement process,
selecting the right supplier and the benefits that mechanical handling can offer.

SAFETY

Safety is paramount with multiple aspects regarding personnel, equipment, infrastructure and the environment
to consider in delivering a safe project.
The flare tip is sited above the plant or above water and so the possibility of the unit itself or parts of the
handling equipment dropping presents a significant risk, as does the need for rope access work.
Time pressure, which is always present during shutdowns, increases the risk a hazardous situation occurring, and
that is why offshore operators frequently look to a specialist contractor to ensure the work is carried out safely.
The key criteria to consider when selecting a specialist contractor are:
• The power of preparation. Detailed method statements and 3D renderings of procedures allow all those
involved to have the best view of the planned work and can prove invaluable in identifying required
precautions during the Hazard Identification (HAZID) stage.

• The quality and condition of equipment. A supplier with their own inventory and strong equipment
management processes can be critical to project safety.

• The safety record of the supplier. Strong safety records provide assurance that you are working with a
conscious supplier who prioritises safety.

TIME CHALLENGE

Flare tip replacement can be on the critical path during maintenance shutdowns, which means delays or time
savings in the replacement work can have a direct impact on plant performance.
Operators of offshore assets require confidence that schedules will run to time, so selecting not just the right
supplier but also the best working methods is essential.

• Repetition and routine in flare tip replacement can make a major difference in the time required to safely
and accurately finish the work. Selecting a supplier with a strong track record in similar work is the best
way to achieve this.

• Communication lines should be kept as short as possible. The offshore team can make decisions
independently, which can save valuable time. The offshore team is able to determine the impact of their
decisions and can consider whether further consultation with the engineering team is required.

ENGINEERING CHALLENGE

There are three ways in which offshore flare tip replacements are more challenging than onshore lifting projects.

First, the job must be completed in a harsh, fast changing environment.

Second, the lifting is done high above the deck of the offshore asset, which makes
mobilisation challenging.
Third, the temporary lifting system has to be erected from below without any lifting aids above.

These challenges demand both strong engineering skills and well trained offshore teams to ensure a smooth
transfer from planning to implementation.
The combination of these facets is highly valued by many offshore operators, and Conbit has found the following
factors are often crucial when assessing engineering capabilities.
• Strong structural engineering and analysis experience. The dynamic factors of the lifting operation require
detailed structural analysis. Flare tip lifting to and from supply vessels are engineered without the use of
motion compensated systems. The use of high speed winches in combination with light weight lifting material
demands detailed feasibility analysis by qualified structural engineers.
• Offshore operators demand engineering that can be verified. The reporting style of Conbit allows for third party
checks, which is like a breath of fresh air for the project team of the client.
• In our operation, we have more and more interactions with third party Marine Warranty Surveyors. Offshore
operators feel confident that they are able to convince these parties of the feasibility of the engineered solution
with the engineering documents provided by Conbt. Often, our clients let Conbit take control of the MWS
process and be in direct contact, which increases the project’s efficiency.

FLARE TIP REPLACEMENT PROCEDURE

Shutdowns for flare tip maintenance and replacement are typically planned well in advance as they require
cessation of production at the facility. They are therefore kept to a minimum, limited to unavoidable repairs
and replacement. The flare is the last part of the plant that is shut off and the first to be turned on, which puts
pressure on the team completing the flare scope.

DIFFERENT METHODS ExxonMobil often chooses to replace their flare tips

with a mechanical handling method. This requires
There are a number of different methods to replace
a small team of 4 – 6 persons and only a few days
flare tips, which are laid out as follows. The selection
of shutdown. It allows for easy planning and
of the most appropriate solution depends on safety
preparation, and for the lifting to be done in a
requirements, budget, and the availability of crane
controlled manner with unnecessary risks mitigated
vessels or jack up barges and bed spaces.
during the preparation phase.
 CRANE OR JACK UP
HELICOPTER MECHANICAL
VESSEL

Safety at flare tip The flare tip access platform Standard riggers at the flare Crew is used to working at
access platform is small and there are no tip access platform. this altitude.
rapid escape possibilities if
the load starts to swing.

Exposure Limited in time. The Minimum exposure. Operation will take 3-5 days
operation will draw at the top of the flare.
attention.

Visibility on the load From the cockpit, the pilot Line of sight depends on Clear line of sight from
usually cannot see where the positioning of the jack winch to load.
the hook is – even with up vessel, which depends
plexiglass side-bubbles or on soil conditions and other
removable doors. The pilot jack-up barge activities.
must rely on the signaller’s
communication to
manoeuvre into position.

Load positioning Hovering with a load is a The long line of the crane The load can be controlled
difficult, fatiguing and might cause some swinging from within arm’s reach.
potentially dangerous of the load.
activity that requires a high
level of pilot concentration
and should therefore be
limited in time.

Flexibility Flexible. Needs to be Spot market availability. Just in time mobilisation.

booked well in advance.
Dedicated mobilisation

Standby Full spread rate applies. Full spread rates apply. Limited cost impact.

Associated services Different crew required to Additional lifting equipment Equipment can be used for
perform rigging below the required for lifting below the lifting below the flare tip
flare tip access platform, flare tip access platform. access platform. The same
and for mechanical works Additional crew required for crew can perform mechan-
mechanical works. ical works and repair and
modification services.

Duration Pre-S/D: 2 days Pre-S/D: 2 days Pre-S/D: 2 days

S/D: 1 day S/D: 1 day S/D: 3-4 days
Post-S/D: 1 day Post-S/D: 2 days Post-S/D: 2 days
No option for additional
works.

Persons on Board 4-5 3-4 5-6

Costs High – often outweighs any Depending on availability.. Moderate.

saving in duration.

In some flare structures, a davit or other permanent lifting structure is incorporated. Many offshore operators
integrate this permanent lifting solution into the design during the construction of the offshore facility, because
they feel that they need to take precautions for the future. The main disadvantage of permanently installed lifting
systems is that you need to inspect and test them before use. These activities need to take place within the
shutdown period. If the system does not pass the tests, you cannot complete the flare tip replacement as
planned. It will either jeopardise the shutdown duration and/or the budget, or the flare tip cannot be replaced.
MECHANICAL HANDLING –
THE MOST EFFECTIVE SOLUTION

Conbit advocates the use of handling flare tips with temporary lifting equipment. The lifting equipment is installed
at the flare tip access platform and is operated by winches, which remain at deck level.

WHY? Before the shutdown, Conbit’s crew unpacks the

container and starts preparing at deck level. For a
The mechanical flare tip handling method provides the
typical flare tip replacement project, the crew installs
maximum control of the load. Your lifting system is
two winches on deck level. These winches are used for
based on a fixed platform, so you can position the flare
setting up the flare tip handling system and they will
tip smoothly. Methods based on floating or helicopter
perform the actual lifting. The winches are connected to
crane capacity have the risk of bumping the flare tip
their power source and are then ready to commence
when positioning it.
the lifting operations.
Testing of the temporary lifting system can be done
When all flanges of the flare system are spaded and the
before mobilization. This advantage results in fewer
system is flushed, the works inside the flare structure
project risks during the operation. The last thing you
start. This part of the job is considered to be within the
want to happen during your shutdown is that you are
shutdown and is kept to a minimum. The first operative
unable to perform the lift, because the lifting system is
climbs up in the flare tower and brings a rope and a
not fit for purpose. Permanently installed davit systems
sheave, which is used to pull up one of the winch wires.
do not provide this advantage.
Once this winch wire is reeved through the sheave, all
The use of temporary lifting systems can be planned other components are lifted to the flare tip access
better. For other lifting methods (eg a helicopter or platform by the winch. At the flare tip access platform,
crane vessel) the operator depends on the availability the lifting configuration is assembled and load tested.
of expensive equipment. Although the operation might
Once load tested, the old flare tips are lifted overboard.
be shortened, the standby costs for contingencies are
They can either be lifted to a supply vessel or can be
very high. Temporary lifting systems can be mobilised
lowered and retrieved from the platform. The new flare
well in advance with lower costs.
tip is lifted and connected to its flange at the top.
METHOD After the flare tips are replaced, the lifting configuration
is disassembled and lowered to deck level. The
The flare tip replacement project starts with a period of
shutdown period can end after the flare tip access
engineering and project preparation, which results in a
platform is cleared, the flare tips are commissioned,
load tested system packed into an offshore container.
and all crew have safely departed the flare structure.
This container is transported to the offshore facility and
brought onboard. The crew soon follows and arrives at After the shutdown, the winches and all flare tip
the offshore facility a few days prior to the shutdown. handling equipment are packed into the container, and
demobilisation of crew and equipment commences.
THE POWER OF PREPARATION

FLARE TIP REPLACEMENT – MALAMPAYA

Shell Philippines contracted Conbit to replace the flare tip on their PROJECT
Malamaya offshore facility, in the West Philippine Sea.
ENGINEERING
The flare tip (weighing 4160 kg) was replaced during the 2017 shutdown. PROCUREMENT
Shell approached Conbit because of our specialized flare tip replacement INSTALLATION
service. Our highly experienced rope-access technicians and riggers have
proved themselves to be readily adaptable to changing situations and Client
weather conditions offshore. Shell Philippines Exploration BV

Project Name
Malampaya flare tip replacement

Photo: Execution of flare tip replacement

with temporary lifting equipment

PART OF THE ALE GROUP

FLARE TIP REPLACEMENT MALAMPAYA
01SD058-A

PREPARATION AND TESTING

Because flare tip replacement
issuch a critical activity during
a shutdown, the Conbit team is
always well prepared and the
handling systems are thoroughly
tested in advance.

SAFE AND RELIABLE

Conbit’s mechanical flare tip
replacement method has several
advantages over the helicopter
lifting method. The risks are better
controlled because Conbit’s method
consists of a series of small, easily
manageable steps. Furthermore,
Picture: Engineered flare tip replacement handling system. bringing in mechanical handling
Featuring Conbit’s adjustable modular equipment tools is relatively easy, and the
team required is smaller than is
the case with helicopter lifting.
In short, Conbit’s mechanical
flare tip replacement method is
safer, more reliable and less costly.

PERFORMANCE
The client’s management was
delighted with Conbit’s execution
of this project, because this highly
critical activity was completed on
time, within budget and safely.

The client complimented the Conbit

Photo: During lifting operation team not only on their excellent
safety measures and good safety
observations during the project, but
also on their thorough equipment
preparation at the Conbit warehouse
and the load test execution.

“TO MINIMIZE SHUTDOWN

TIME, CONBIT’S FLARE
TIP HANDLING SERVICES
ARE WELL PREPARED AND
SYSTEMS ARE THOROUGHLY
TESTED”

Photo: New flare tip Photo: Old flare tip

PART OF THE ALE GROUP

 tip replacement, Australia

PROJECT

ENGINEERING

INSTALLATION

Client

Project Name

Photo: Disconnecting the

Rigging line from the load that
is attached to the offshore lift
line.
 Flare tip replacement, Australia
01SD080A

The flare tip at the flare tip access platform (FTAP) required replacement THE POWER OF PREPERATION
during the shutdown. A base frame and lift boom were utilised to Conbit prepared for the manoeuvre
perform the mechanical handling in the removal of a pre-existing flare tip with a thorough engineering plan
and replacement with a new one weighing 442kg and measuring and ensured all operators were
3.747mm x 819mm. A supply vessel was used to move the existing and well-trained and were expertise in
new flare tip to and from the platform. flare-tip operations. Conbit
monitored the sea state and the
It was completed within four days. wind speed. The flare tip access
platform had a sufficient amount of
The Kingfish A (KFA), Kingfish B (KFB) and West Kingfish (WKF) strong points to carry the loads of
platforms are located within Production Area VIC/L07 approximately 72 the lifting system and the flare tip.
to 77 km off the Gippsland coast in approximately 77 to 78 m of water To assure all stakeholders involved,
depth. The KFA platform is connected to the KFB platform by the KFA- factory acceptance test (FAT) took
KFB400 pipeline; the KFB platform is connected to the Halibut (HLA) place during the engineering phase
platform by the KFB-HLA500 pipeline; and the WKF platform is connected at the Conbit warehouse, with the
to the KFA platform by the WKF-KFA300 pipeline. client witnessing it.

CHALLENGES
Conbit was required to mobilise
the equipment in a very short
timeframe, which tested the
logistics team’s ability. With expert
planning and shipping of
equipment, Conbit could negotiate
this challenge.

BAD WEATHER
Conbit monitored the weather prior
and during operations as bad
weather was anticipated which had
the potential to limit access to the
platform and disrupt the overall
operation. The staffing schedule
had to be adjusted to ensure that
the work would be completed
before the weather impacted on
the operation and had to dismantle
Photo: Dismantling lift boom Photo: Preparation for rotating the equipment after the weather
new flare tip. had passed, three days later.

“The handling method

is more favourable
alternative due to its
cost-effectiveness and
equipment’s flexibility.”
 PROJECT

ENGINEERING

INSTALLATION

Client

Project Name

Photo: Lifting new elbow part

Flare tip replacement, Australia
01SD079A

THE POWER OF PREPERATION

Conbit prepared for the
manoeuvre with a thorough
engineering plan. The flare tip
access platform had a sufficient
amount of strong points to carry
the loads of the lifting system and
the flare tip. To assure all
stakeholders involved, a load-test
took place at the engineering
phase at the Conbit warehouse,
with the client witnessing it. After
this, the primary lifting equipment
was sent via air cargo.

CHALLENGES
Conbit faced the unexpected
challenge of performing the
offshore lift to a supply vessel with
no dynamic positioning. This
impacted the timing and created
further challenges of keeping the
vessel level and finding the critical
moment for the touch-down. As a
Photo: Disconnecting the rigging line result, Conbit devised an action
from the load plan to minimise this impact.

Furthermore, Conbit was required

to mobilise the equipment in a
very short timeframe, which
tested the logistics team’s ability.
With expert planning and shipping
of equipment, Conbit could
negotiate this challenge.

ADDITIONAL SCOPE
Conbit were also tasked with
removing existing piping using
their lightweight rigging equipment
and changing out the elbow from
underneath the flare-tip, weighing
350kg. By remaining flexible and
adaptable, Conbit could easily take
on this additional scope for the
client.

Photo: Load ready for lifting to the

supply vessel
ABOUT CONBIT

We believe that in our business preparation is key. We prepare our projects so thoroughly that they
always run smoothly and efficiently. This is how we make a difference for our clients.
Our people are what make Conbit the leader in our field. For us, project preparation is all about
teamwork in an open and transparent atmosphere. We challenge ourselves to go beyond limiting
boundaries to find better and more creative solutions and to design, supply, install and maintain
projects perfectly, safely and on time. Our clients rely on us not only because of our strong team
that works with them in close consultation but also because we invest in the latest technologies and
equipment to meet their needs, so that they can excel in their industry.
With over 20 years of experience, we have a proven track record in special lifting and structural
engineering. Clients come to us for our full-service approach and our innovative customized
solutions. In preparing our projects so thoroughly we create a reliable, safe and sustainable base,
from which we have a powerful impact in our clients’ benefit.

Conbit
Steenoven 5, 5626 DK Eindhoven, The Netherlands, T: +31 40 711 45 05 E: [email protected]