World record – largest flare tip replacement
Tight shutdown window
The main development in Kazakhstan’s Kashagan field is D-Island, a structure built on recovered land that typically outputs 340,000 barrels per day. Due to reaching the end of its service life, both its flare tips required replacement. This work was to be carried out during a tight shutdown window.
Ersai turned to flare tip replacement experts from ALE’s Conbit operation, whose lifting solutions can be tailored for extremes of height or reach and are also tested and certified before shutdown – providing peace of mind that maintenance will be on time and to schedule. At 10,000kg, D-Island’s high-pressure flare tip also set a world record for the largest ever replaced.
Conbit’s scope was to replace the facility’s high pressure and low-pressure flare tips, and also to install a new ignition cable. Prior to the start of the project, Conbit’s engineering team determined that a mechanical handling method was suitable, as the flare tip access platform had sufficient strong points to carry both the lifting system and flare tips.