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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
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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.
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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
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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
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Flare Tip Replacement
Flare tip replacement without using 200/300 ton crane
Successive stages in flare tip replacement
Final ground approach
Erection of flare structures without the use of heavy cranes
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
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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.
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 
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Maintenance Services & Spare parts Management
Preventive Maintenance Program
On-site Spare Part Inventory Management
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Specialized Engineering Services
To further support site operation, we offer specialized services including
Critical Device Proof Testing
Gas and Liquid Custody Transfer Validation Testing
- 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
SYSTEMS
| SCHEDULED SERVICES | UNSCHEDULED SERVICES | TECHNICAL ASSISTANCE |
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