Different methods of replacing flare tips onshore

Onshore Flare Tip Replacement: Methods and Considerations

Choosing the Right Method for Onshore Flare Tip Replacement

Replacing flare tips onshore involves a different set of logistical and operational considerations compared to offshore environments. The selection of the appropriate method depends on factors such as flare stack height, site accessibility, shutdown duration, and whether other risers in the system must remain operational.

The three main methods used are:

- Mechanical Handling

- Regular Crane

- Retractable System

Each method can be executed safely when properly engineered and prepared.

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Flare tip replacement with modular lifting system

Mechanical Handling

Mechanical handling is typically used for very tall flare structures where conventional cranes cannot reach. This method involves installing temporary or permanent lifting structures at the top of the flare stack. These are erected manually using general rigging equipment and are load tested before use. A winch located at ground level is reeved through the lifting system at the top, allowing controlled lifting and lowering of the flare tip. The operation usually requires a crew of 5 to 8 people, depending on the complexity of the replacement and any additional tasks. The shutdown duration is similar to offshore operations, typically 4 to 10 days.

Regular Crane

When the flare stack is within reach of a standard crane, this method is the most straightforward and cost-effective. A mobile crane is positioned near the stack and used to lift the flare tip directly. This method is ideal for mid-height flare stacks and can be executed quickly with minimal setup. The crew size is generally 3 to 5 people, and the shutdown duration is comparable to mechanical handling, around 4 to 10 days, depending on site conditions and scope.

Retractable System

Retractable flare systems are designed to lower the entire riser, including the flare tip, to ground level for maintenance. This method is often used when other risers in the same system must remain operational, allowing for isolated maintenance without affecting the entire flare system. Interestingly, even retractable systems are sometimes serviced using mechanical handling or crane methods, especially when only the flare tip needs replacement and the full system is shut down. This flexibility allows operators to choose the most efficient method based on the scope of work.