Dana Petroleum PLC bought the assets of Petro Canada in 2010, which marked a significant increase in production. Since the acquisition, Dana has operated two platforms in the Dutch Continental Shelf: Hanze and De Ruyter.
Preparation and testing
Because flare tip replacement is critical during a shutdown, the Conbit team is always well-prepared. They made sure that they tested all the handling systems in advance.
Special lifting concepts characterize the flare tip handling method used by Conbit. The team assembled a temporary lifting configuration on the flare tip access platform to perform a challenging lift using lightweight modular equipment. At all times, the focus is on safety and efficiency. They thoroughly tested the lifting systems before installation.
In this case, the high-pressure flare tip (weighing 536 kg) was atop a vertical flare tower, 77 m above the main deck. The main equipment used for this project was a lifting winch (WLL=1MT), aluminum truss components, and a base frame.
The Conbit team executed the project within 13 days -- seven days before the shutdown for all preparations and six days during the shutdown.
Conbit’s team of IRATA rope access technicians has extensive experience in successful flare tip replacements. Before each project, a risk assessment is done, and a job safety analysis is documented. Daily toolbox meetings before starting the operation are also an essential part of the procedure.
Flare stack maintenance
The flare tip and some other parts of the flare stack had to be replaced. The scope of the work included relocating pilot gas lines, installing a new ignitor and thermocouple cables, and installing new conduit lines.
The major works of this operation consisted of the following parts
- Replacing the flare tip
- Replacing the flare front lines
- Relocate pilot gas lines
- Installing new ignitor and thermocouple cable
- The installation of new conduit lines