Flare Tip Replacement

Offshore flare tip replacement on FPSO's and Oil/Gas platforms has proven to be an integral part of our success. Having all of the necessary skills in-house has proven to be advantageous for our clients as it means 'no multi-contractor interfaces'.

Zenith has pioneered the design of a purpose-built lifting davit to improve the process of replacing flare tips offshore. The davit is positioned directly below the termination point of the flare stack thereby negating the use of expensive helicopters and barge cranes. This has been designed to take the weight of the tip as it is lowered to grade and to lift the new replacement tip into position.

We operate worldwide and have successfully carried out numerous projects in the Far East, Central Asia, Africa, The Middle East and Europe for the world's leading oil and gas companies.


At the early stages of the contract, Zenith's Structural Engineering Department provides our clients with an initial Concept Design of the proposed method to replace the flare tip. Following the client's approval, a full design, complete with calculations, is provided to the client. An analysis is carried out on the existing support boom or support tower.


Health & Safety

Safety is our absolute priority. We have successfully worked with many of the world's leading oil and gas companies in the most demanding environments offshore. Zenith's dedicated Health & Safety Department provides all necessary documentation for a safe and successful project after careful consultation with the client. ISO 9901:2008, DNV SCC** & Achilles Reg.


Davit Fabrication

Following the design, the temporary lifting davit is fabricated allowing for:

> Davit designed and fabricated for offshore and ship dynamics

> Ship surge, sway and heave acceleration

> On-board lift dynamic

> Brackets for installation access support built into the gantry steelwork for quick and safe installation


Off Site F.A.T. Testing

Prior to transporting the temporary lifting davit to site, the F.A.T. test is third-party verified. In addition, an experienced installation crew is selected. This same crew is used to carry out F.A.T. test build, which is typically undertaken in our yard, to check fitting and constructability and therefore the selected team are completely competent to perform this demanding task.



The flare is typically the last to go offline and the first to go online. At the start of the shutdown, the temporary works are installed together with the temporary lifting davit and the davit is tested in-situ to its S.W.L. If temporary access is required, either due to no in-situ access platform or the poor condition of the access platform, it can be designed and installed.

Removal & Replacement

The old flare tip is released and lowered to the FPSO/Platform deck or to a service vessel as in the case of a boom arm. The new flare tip is then lifted and secured into position. Any service lines can be repaired/replaced at this stage. The temporary works, lifting davit and any temporary access are then removed, allowing the flare tip to go back online.

Congratulations and thank you for the successful flare tip replacement. The KIKEH shutdown campaign was featured in the SBM Newsletter.

Prema Balam, Package Manager

What your team has achieved, given the delays to date, is quite astounding - something they and Zenith should be proud of. Well done.

Craig. J. Chatburn, Late Life Assets Modifications Coordinator

Zenith is doing a fantastic job out here. The team is the best advertisement for your company and they do an outstanding job for your clients.

Jim Leishman, Shutdown Manager