Flare Line Cleaned “ON-LINE!” avoids Refinery Crash within a Dutch refinery
No downtime during on-line, flare line clean
Summary
Following a previous on-line flare line cleaning success, Tube Tech provided a rapid mobilisation over the Christmas holiday season to one of the world’s largest oil refineries to remove ammonium bi-sulphate deposits from within a severely restricted flare line. The risk of a complete refinery crash was at stake, hence a proven safe and effective ‘on-line’ solution was essential. This critical path contract was successfully completed thanks to a fantastic all round team effort with Tube Tech, from both client and other supporting companies.
Challenge
- A 9m long section of a 30” x 5km long flare line was severely restricted.
- Deposits were expected to be very soft but in reality were rock hard.
- Deposit was potentially pyrophoric.
- Due to the presence of explosive volatile hydrocarbons within the flare line, no oxygen was allowed to enter the system and no gases were allowed to escape during cleaning.
- So critical was the nature of this contract the entire refinery were on high alert and as a result safe working practice and procedures were of paramount importance.
- The flare line had to be cleaned on-line otherwise the entire refinery would have to shut down – costing a substantial 7 figure sum per day.
- Arctic European weather conditions made working conditions and maintenance of equipment challenging.
Solution
- Survey within 48 hours and ready to mobilise within 5 days.
- As client request Tube Tech was to develop an innovative ‘dry’ and wet cleaning system.
- Tube Tech provided 2 additional back up systems to cover worst case scenario
- Access to the flare line was made available via pre-negotiated hot taps. Waste was contained and guided to a controlled waste disposal system installed and operated by Altena Group.
- Taking extreme weather conditions into account, risk assessments were regularly re-assessed and decisions made upon the best system
- Tube Tech also inspected before and after cleaning of the flare line using explosion proof inspection equipment
Tube Tech comment
Martin Byford, Operations Director: “The client reported that immediately after cleaning, a substantial volume of gas was bypassed to the flare with recorded no significant back pressure, indicating that the cleaning process had been a complete success. This contract was a great achievement for Tube Tech and a huge relief for the client.”
Clients can be contacted via Tube Tech for references.
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