Elevated Flare Stack Winching System

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Elevated Flare Stack – Winching System

Due to client confidentiality, it would be inappropriate to name this elevated flare stack winching system project site.

The Flare System, comprising of three independent flare risers fitted with flare tips, and the refractory lining to the flare tips had deteriorated, plus the nitrogen filled ‘O’ rings on the steam jackets had failed, prompting immediate tip replacement.

There were problems associated with the defects to the flare tips; due to the absence of refractory lining, the tips had distorted back in the direction of the support structure, causing major concern that the flare tips may fall on the support structure on their descent. Therefore, precise measurements had to be obtained at high level to confirm that the flare tips would not strike the rest of the structure. The investigation could not categorically confirm either way, therefore a contingency plan was put into place whereby, during the flare tip descents, high level operatives would have to be positioned to monitor and report until the tips had passed the critical area.

The method of lowering the flare tips down to ground level was with the aid of one large split drum winch, for the main lift, with the capability of 110tonnes when reeled through an intricate double block system, with a second auxiliary winch to lower the riser sections from the vertical to the horizontal.

The main winch wires, equipped with trunions, were bolted to the riser section. The riser and ancillary lines were supported, the auxiliary winch secured to the base riser. The main winch then lifted and separated the flanges, holding in suspension, while the auxiliary winch lowered the base riser down from the vertical to the horizontal to be put into storage. The main winch lowered the complete riser sections and flare tip down; this was repeated until all the sections were removed and the flare tip was horizontal at ground level.

Upon completion of the refurbishment to the riser sections and when the flare tip had been replaced, the individual flare systems were re-erected.

The project was completed to the satisfaction of all concerned, and fortunately the flare tips passed the support structure.

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Crown Services Project
Article Name
Elevated Flare Stack - Winching System
Description
The Flare System, comprising of three independent flare risers fitted with flare tips, and the refractory lining to the flare tips had deteriorated, plus the nitrogen filled ‘O’ rings on the steam jackets had failed, prompting immediate tip replacement.
Author
  • Client: Client confidential
  • Date: January, 2011
  • Services: Elevated Flare Stack, Winching system, Chimney Maintenance
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