FlareSafe™: Innovative flare tip inspection, repair, and replacement

The challenges of oil and gas flare systems

Flare systems in the oil and gas industry are essential safety mechanisms used to burn off excess gases that cannot be processed or sold. These systems are critical for preventing the release of potentially hazardous gases into the atmosphere and for maintaining the safety and environmental compliance of industrial operations. 

The key challenges of flare systems are: 

  • Rapid Deterioration: Flare systems deteriorate quickly, especially as gas pressures and flow rates reduce due to environmental flaring targets. Excessive heat damages flare tips, associated structures, and equipment. 
  • Operational Constraints: Remedial work can only be carried out during shutdowns, bringing the risk of unplanned production loss if not executed efficiently. Time is critical once a shutdown starts. 
  • FPSO-Specific Challenges: Flare tip replacement on Floating Production Storage and Offloading (FPSO) units presents unique difficulties. Ship movement is amplified at the top of the flare tower, making conventional replacements challenging. 
  • Weather Dependency: Traditional methods of flare tip replacement, especially those involving helicopters, are highly dependent on favourable weather conditions, leading to potential delays and increased costs. 
  • Safety Risks: Working at height and in confined spaces during flare system maintenance carries significant safety risks, especially in offshore environments. Transportation and
  • Storage: Safely transporting and storing new flare tips can be challenging, particularly in offshore settings. 
  • Cost and Efficiency: The need for specialised equipment and personnel, combined with the time-sensitive nature of the work, can lead to high costs and efficiency challenges.  

Flare Tip Replacement and Inspection

The solution: FlareSafe ™ for flare tip inspection, repair, and replacement

EM&I have developed FlareSafe™ a system designed for floating installations which reduces shutdown time, safety risk and weather dependency. The system is designed to address the challenges associated with flare tip replacement and maintenance on offshore structures.

Key features and benefits of this innovative system

  1. Reduced Downtime: Minimises shutdown periods, enhancing operational efficiency. 
  2. Reduced Personnel on Board (POB): The system allows for fewer people to be present on the offshore installation during operations. 
  3. Enhanced Safety: Lowers health, safety, and environmental concerns during operations associated with flare tip replacement and maintenance.  
  4. Weather-Independent: Enables operations in challenging weather conditions, reducing delays. 
  5. Innovative Cradle Design: Stabilises flare tips during the entire process, protects flare tips during transportation, installation, and removal, and allows cost-effective shipping in standard containers. 
  6. Versatile Application: Compatible with helicopter lifts and cradle-based installations, and adaptable to various weather conditions using double A-Frames 
  7. Global Availability: Worldwide service through strategically located operations centres, backed by in-depth engineering and laboratory support 

A complete package

The FlareSafe ™ system includes: 

  • Project Management 
  • Planning (engineering, health & safety and quality plans, project plans, rigging plans, CTRs and work packs) 
  • Site pre-visits and preparation 
  • Procurement 
  • Inspection, Repair & Maintenance 
  • Reinstatement of flare systems 
  • Close Out & Compliance Reporting 

This scope can be applied to flare tips, pipework, structures, mechanical, electrical and instrumentation. The services are delivered through strategically located operations centres, with further in-depth engineering and laboratory support.  

In which asset types can FlareSafe™ be used?

FlareSafe is specifically designed for floating installations, especially for FPSOs (Floating Production Storage and Offloading vessels).  The system addresses the specific challenges of flare tip replacement on FPSOs, which face amplified movement at the top of flare towers due to sea conditions. 

Patents

The FlareSafe™ System Integrity Services have a UK Patent No: GB2529610. 

Please go to Patents and Trademarks section for further information. 

FlareSafe Leaflet

FlareSafe Video

FlareSafe Cradle
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  • Tullow Ghana

    We have been largely impressed with the professionalism that characterised the overall delivery of the scope by EM&I and its local partner Stark Energy. The high safety standard exhibited from the onset, with no incident recorded, is highly commendable. The team’s desire to overcome every challenge was remarkable since this was a heavily weather-dependent scope.

  • Vestigo

    I would like to further extend our appreciation to EM&I on the success of FPSO Berantai hull repair works in December 2023, through the application of CLAM technology. This advanced technology application along with the highest level of resources’ expertise and teamwork shown throughout the activity, have resulted in a safe and successful outcome.

  • Shell

    I would like to pay special recognition to the EM&I boys for the pace at which they worked..... all this completed whilst working to the safety standards we demand and in a tank which was physically demanding due to the temperature of surrounding tanks

  • Repsol Sinopec

    This has been a big win from the point of view of safety with NO confined space entry and NO working at heights as well as the added benefit that
    four tanks were completed in just over two days!

  • MODEC

    I would like to thank EM&I for all their work in creating and negotiating the alternative UWILD plan. This is the first MODEC asset globally to have been granted an alternative to the traditional diver driven inspection work.

  • Ocean Rig

    Congratulations with your job well done and safely. It’s been a pleasure having you guys on board. I have to report that I really appreciate working with your team here on board, their positive and professional attitude was greatly appreciated

  • BW Offshore

    The approach taken by EM&I towards Health and Safety has been excellent and they proactively advise on improvements that could be made in this area. Having a trusted expert in this field who could highlight any areas of concern and make the required recommendations was of immense value to the operations. All in all it has been a productive visit and I have no hesitation in having the EM&I team back on board in the future.

  • Vantage

    Your excellent professional organization and great work results in the successful completion of this scope with the minimum down-time for the rig. Overall I was very impressed and couldn’t recommend your company highly enough to anybody who would ask.

  • ExxonMobil

    EM&I have been able to provide skilled, specialist personnel during every mobilisation, and in all cases, they have been outstanding. The work has been professionally done and the reporting of the highest quality. I would like to pass on my appreciation to everyone in EM&I involved in the job for their hard work and making the job very successful.

  • SBM Offshore

    This Project required exceptional vigilance in keeping personnel safe, EM&I did a very good job in a safe manner. They maintained high safety awareness and gave full cooperation among the ASOM team. This Project can be summarised in 4 words … preparation, verification, execution, documentation. EM&I scored top marks in all categories.

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