Flare Tip Replacement - Cakerawala Gas Field, Malaysia

Teamwork assured safe and on-time delivery

Carigali Hess contracted the flare specialists of Conbit to perform a major overhaul of the flare system at the Central Processing Platform at the Cakerawala Field.

For this project, they need to replace the following:

complete flare tip access platform
the permeate flare tip
two high-pressure flare tips
two headers of the flare tips
a manifold

Watch how we prepare and execute

Equipment

Conbit used a modular lifting system to perform lifts that regular cranes cannot reach. In this case of flare tip replacements, they erected the heavy lifting system on the flare tip access platform. The Conbit engineers needed to replace the flare tip access platform, so they had to find a different solution. They designed a unique base frame to connect to the side of the flare tower. The lifting system is operated by winches, which remain at deck level. They lifted the replaced items directly to and from a supply vessel.

The engineers also mobilized a record of six winches: two high-speed main lift winches, two luffing winches, and two service winches. The winches were powered by generators and power packs, ensuring a standalone operation. Although all Conbit equipment is in working condition, they still tested and certified everything before shipping to the project site. The client also asked if Conbit could include extra equipment to guarantee higher continuity in case (part of) the equipment fails. The team transported the container with the power pack via sea and the other equipment via air transport.

Operation

Before mobilization, the team conducted a full load test at the Conbit‘s head office in Eindhoven, The Netherlands. Conbit’s engineers prepared a complete engineering package to ensure smooth execution. They reviewed the equipment by going to the site and worked out a ‘redundancy-kit.’ This ensures that the most critical components are included and that a higher continuity can be guaranteed.

Conbit finished the complete flare replacement project successfully within a 10-day shutdown period. In that narrow window, an offshore crew of 20-30 colleagues with different skills delivered the project's scope. They installed and load-tested the heavy lifting system, replaced components with a combined weight exceeding 20t, and demobilized from the platform.