• Difficult Industrial Access Maintenance

     
                

    We are a highly specialized company providing maintenance and inspection services for high and difficult access structures such as :
    Flare stacks
    Flare tips
    Storage tanks / sphere tanks
    Columns
    Reactors
    No Cranes and Scaffoldings are Required

    Inspection/maintenance at problematic accessible locations
    To reach the problematic accessible locations, Our personnel make use of the FG JIB, a device that's designed to descend only. The FG JIB is intended for daily use by one person, and will carry a weight up to a 1000 kg. It provides stability and safety for anyone working at problematic accessible locations.

    Column Inspection
    Without the need for scaffolding:
          Removing insulation cladding
          Removing rockwool
          Removing corrosion dirt from the wall
    All action on site can be followed in the inspection cabin on video
    The steel wall is inspected by video and U.S. measurement, all is recorded by a CAD system (where, how, what)
    Blasting of spots of the steel wall is possible by specialized dust free blasting equipment
    Fixing the rockwool and cladding back in to place, piece by piece
    Cold and hot towers and pipelines can be inspected on line
    Substantial savings due to
          No scaffolding required
          No interference with operaion
          Before a turn around it is known what the situation is
          All is recorded on tape, visual for each person at any time
          Short processing time

    Special techniques are used in order to execute inspections such as :
    Videotechnic inspection
    Endoscopic inspection
    Magnetic induction testing of steel cables
    Layer thickness measurements of coatings
    Ultrasound wall thickness measurement

  • Inspection & Maintenance

     
    Inspection/maintenance of flare stacks & flaring systems           
           

    Full inspection with video and data on:

    Main stack body
    Flare stack piping works
    Top parts incl. stairway
    Inspection of guy wires

      1. Main stack body
      To determine the actual status of the main pipe, the wall thickness is to be measured at 20 cm x 20 cm locations all around the pipe by U.S. thickness measurement.
      The coating layer and conditions are to be checked.
      Bolts and nuts are to be checked.
      The inside of the main pipe status is to be checked for any damage, especially the bottom of the pipe and the locations around the welding spots.
      The vertical position of the stack pipe is to be checked.


    2. Flare stack piping works
      Main piping status is to be checked for fitting and condition of :
            bolts and nuts
            insulation
            welding locations
            supports
            expansion slots
            flance joints

    Mainsteam pipe's thickness by U.S. measurements next to any joint at both sides of the joint, 360° check.
    Gaspipes and steampipes are to be checked for coating layer conditions.
    All fitted pipes have to be run parallel to the main stack pipe. Expansion parts should be checked for free movement capabilities.

      3. Top parts incl. stairway
      Tip body
      Pilots
      Ignitors
      Gangway around the tip is to be checked on corrosion and mechanical damage
      All piping, supports, bolts and nuts are to be checked for corrosion and mechanical damage
      Stairway is to be checked from bottom to top including supports. Coating layer condition is to be checked
      Thermo couple's wiring is to be checked
      Smoke detonator



    4. Inspection of guy wires
      Status of all equipment, parts and peripherals are to be checked. Damage is to be checked and reported combined with status of safety when in use.
      All original drawings are to be taken as "status to be", or as indicated otherwise.
      All situations regarded as not safe for operation within the next 4 years are to be reported immediately to the inspection department.
      Dead weights.
      Tentioners, turnbuckles, shackles and clamps
      Cable protection
      Corrosion at cable
      Prevention
      Earthing


      Maintenance:
      Replacing flare tip without a crane (winch hoist installation)
      Replacing guy wire/retentioning
      Replacing piping/wiring
      Recoating guy wire
      Recoating stack pipe


    Cost reduction:
      Project lead time very short
      All know how on site
      No cranes, scaffolding needed
      No cost due to weather delay
      All actions are video recorded

  • Flare Tip Replacement

     
     
    Flare tip replacement without using 200/300 ton crane
    flare tip replacement flare tip replacement flare tip replacement

    guy wired flare structure self supporting flare structure derrick type flare structure

    flare tip replacement flare tip replacement flare tip replacement flare tip replacement flare tip replacement flare tip replacement
    Successive stages in flare tip replacement

    flare tip replacement flare tip replacement flare tip replacement flare tip replacement
    Final ground approach

    Erection of flare structures without the use of heavy cranes
    installing lift arm at next level lifting next pipe part and place it at the top flare tip final part flare tip final part



    Different types of flare stacks
    Three types of flare stacks can be distinguished:
      The free standing guy wired flare stack with only one major pipe going up. The height of these flare stacks varies between 60 and 240 meters
      The derrick type flare structures, where a steal construction supports one or more flare pipes
      The free standing flare stack that does the job without being suspended or supported by any additional structure


    All structures have in common that they make use of a flare tip. This tip is located at the end of the pipe and takes care of igniting the combustible gases. Normally a significant amount of steam is injected in the flame to reduce soot and the building of large flames together with cooling the flame base. This means that a lot of steam has to be transported to the top of the flare. Flare structures need to be inspected and maintained on a regular basis according to the time in between the turn-around or stop intervals of the plant.
    Inspection and maintenance can only be done when the flare is turned off completely. This means that it needs a total shut down of all the facilities connected to this flare. The flare stack itself is like the exhaust system of a motor vehicle, which means that without the flare the plant cannot produce any products. Once the flare produces a problem you can only do something by shutting down the entire plant which results in a large loss of production and therefore a loss of money each day the plant is down due to flare failure.

    Maintenance aspect
    A flare tip is usually inspected every 2 years (if possible to tie in with shutdown) and a well operated tip can last from 6 to 10 years. During the inspection, the tip is inspected for the following:
      Shell thickness (internal and external)
      Refractory lining (if any)
      Ignitor
      Main and pilot nozzles
      Thermocouples
      Steam / air piping


  • Tank Inspection

     
     
    Conventional method: by scaffolding
    Conventionally, to inspect a sphere tank internally and externally, scaffolding has to be erected for access. Due to the curved surfaces, erection is both time consuming and very difficult. For a 20m-diameter tank, the scaffolding would normally take 10 days to erect and another 4 days to dismantle. Beside these, adjustments to the scaffolding during the course of inspection are also a frequent occurrence as the scaffold pole may stand directly on a weld seam that needs to be inspected. All in, a full inspection of a sphere tank will take about 30 to 35 days.

    The FG method
    We developed an innovative method for the inspection of a sphere tank. Access to the external surface is done by rope abseiling, internal access is realised by the FG Sphere Frame®. In no more than 2 days the FG Sphere Frame is erected, and is dismantled in just 1 day, thus saving 10 days on scaffolding erection. The FG Sphere Frame is a plane structure that can rotate inside the sphere about the vertical axis, thereby allowing all surfaces to be accessed. The inspector easily executes rotation inside the sphere by raising the structure 10mm by means of a block and tackle, after which he only needs to push his hands against the shell. On reaching the spot he wanted, he just lets the structure rest on its rollers by lowering it. A full inspection can be completed within 16 days. All gritblasting, inspection, painting and erection will be co-ordinated by trained personnel, so that minimal time is wasted on liaison between different parties. Not to mention the savings on scaffolding costs internally and externally.
    access via abseiling
    FG Sphere Frame®
    inside the sphere tank

    Tank Inspection without using scaffolding
    The main goal of inspection is to obtain relevant information about the present condition of steel, concrete, coating and other parts, as a result of weather conditions, fatigue of metals and other influences that effect the maintenance condition of the tank, and the expected developments in maintenance condition.

    We apply NDO-techniques for inspections, with video techniques as most important tool. Some examples of inspection techniques are endoscopic inspection, MPI, thickness measurement of coatings, concrete quality inspection and ultrasonic thickness measurements.

    After every inspection a written report will be made up, supported with video images and photographs.
    Sphere Tank inspection
    sphere tank
    sphere tank inspection (external)
  • Maintenance Services & Spare parts Management

    Preventive Maintenance Program
    On-site Spare Part Inventory Management

  • Specialized Engineering Services

    To further support site operation, we offer specialized services including
    Critical Device Proof Testing
    Gas and Liquid Custody Transfer Validation Testing

  • SYSTEMS

    SCHEDULED SERVICES UNSCHEDULED SERVICES TECHNICAL ASSISTANCE
    • System Diagnostic Evaluation
    • System Performance Evaluation
    • System Maintenance Activities
    • Field Device Maintenance Activities
    • Product Documentation Updates
    • Spare Parts Management
    • Technical Database
    • Commissioning Support
    • 24 Hours Response Services
    • Troubleshooting
    • Start Up Support Assistance
    • Logic Modification
    • Turnaround Support Assistance
    • Spare Parts Management
    • Technical Database
    • Commissioning Support
    • Timely assistance for resolution
      of problems on products and softwaresvia Telephone, E-mail
      or Fax
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