F80 FPSO Flare Tip Replacement

Project at a glance

Client: Petrobras
Location: Búzios field, Brazil
Asset: F80 FPSO
Scope: Flare tip replacement engineering
Flare tips: 4
Heaviest flare tip: 2,700 kg
Main lifting equipment: 6 mT winch
Gantry height: 9.7 m
Maximum luffing distance: 7.7 m

Engineering a safe and practical handling methodology for future flare tip replacement

Conbit was involved in the engineering study for the future replacement of four flare tips on the F80 FPSO, located in the Búzios field offshore Brazil. The flare tips are positioned on a single flare tower top platform, creating a challenging lifting operation with limited space and significant height differences.

The study focused on developing a practical handling methodology that allows the flare tips to be removed and replaced during a future FPSO shutdown. The lifting and handling routes were predefined by the client, with all flare tips required to be transferred to the loading and unloading area on top of the pipe rack at EL. +60.202 m.

‍

Watch how we prepare and execute

Ilustration of top of flare tower with gantry being used to remove flare tip

The Challenge

The main challenge was creating sufficient clearance to move the flare tips from the top platform to the designated laydown area. The largest flare tip, LP01, weighs approximately 2,700 kg and needs to be lifted over the edge of the platform and its outriggers.

The available space also required careful consideration of the positioning of the lifting equipment. A deck extension was required to accommodate the main and service winches, while specific interfaces for the guidelines had to be identified and coordinated with the client.

Additional modifications to the top platform were required to facilitate installation of the lifting system. Special cut-outs in the grating and heat shielding allow the base frames to be installed directly onto the main structural steel.

‍

The Solution

Conbit engineered a dedicated gantry system to facilitate the replacement of all four flare tips. The system consists of a 9.7 m high gantry with a 6.9 m high strut and a maximum luffing distance of 7.7 m. This configuration provides the clearance required to lift the flare tips over the platform edge and outriggers.

A 6 mT winch was selected to handle the heaviest flare tip. The main and service winches are positioned in the designated laydown area, with guidelines used to control the load throughout the lifting and handling operation.

The resulting methodology provides the client with a defined approach for carrying out the future flare tip replacement during an FPSO shutdown, while taking into account the existing platform structure, available lifting routes and required equipment interfaces.

‍