Flare Stack Welding Scope

Flare Stack Welding Scope

Challenge:

Bilfinger were asked by our client to complete a complex welding scope at the top of a 100ft flare stack on an FPSO. The client had been struggling to get this job, which involved installation of rain caps and insulation blocks, completed due to access requirements, challenging weather conditions and the close proximity of an exhaust turbine.   

Solution:

Traditionally a cradle system would have to be rigged and repositioned to work around the flare stack, but these are restrictive, time consuming, and degradation of steelwork meant this wasn't possible. 

Bilfinger's five-man rope access team worked from anchor points around the flare stack and installed new supporting steelwork. Using breathing apparatus (BA), they were then able weld new rain caps while working from ropes. Instead of tack welding pins, Bilfinger's technicians used a stud welding gun to install 250 new insulation blocks.

Outcome:

Our team overcame a number of unexpected challenges, and the use of a stud welding gun, and BA-trained rope access personnel meant Bilfinger reduced installation time, completing the work plus additional scope within TAR timelines.