Flare Stack Steam Line Repair and Servicing

Case Study

Petron Bataan Refinery Flare Stack Steam Line Repair and Servicing

The Petron Bataan Refinery flare stack stands at 130 meters in height and is equipped with 68-inch diameter hydrocarbon and 20-inch diameter acid gas lines, as well as multiple steam lines. Petron required an experienced and reliable contractor to restore the integrity of the flare stack and its associated systems during the planned turnaround.

Project Challenges

This flare stack project presented several challenges:

Corroded Ladders and Gantries: Existing infrastructure, such as ladders and gantries, had experienced corrosion and required restoration and repair to ensure safe access and the safety of workers and equipment.
Tight Schedule: The project had to be completed within a short turnaround period, making time management and efficient execution critical.
Working at Height: Much of the work took place at significant heights (130 meters), presenting safety challenges and requiring specialised equipment and expertise.

BEC's approach

BEC was awarded the contract to perform repairs and servicing on the Flare Stack, including the replacement of flare tips, sectional steam line piping, and maintenance of critical safety components. The scope also involved restoring corroded ladders and gantries, as well as conducting crack repairs to ensure the continued safe and efficient operation of the flare stack.
The full scope of work included:

Insulation and Cladding: BEC removed the existing insulation and cladding from steam lines to facilitate further repairs.
Flare Tips: The team removed and replaced the flare tips for both hydrocarbon and acid gas lines, ensuring proper functionality.
Steam Line Piping: BEC replaced sections of the steam line piping to restore operational capacity.
Steam Tracer Couplings: Leaking steam tracer couplings and tubes were repaired, and new bolts were installed.
Crack Restoration: Cracks in critical flare components were restored, and comprehensive inspections and testing were conducted to ensure structural integrity.
Pilot Tip Assembly: All eight pilot tip assemblies for both acid and hydrocarbon lines were repaired or replaced as necessary.

The BEC Advantage

BEC’s approach emphasised delivering high-quality results while adhering to stringent safety standards. The team efficiently managed the project timeline, ensuring that all tasks were completed within the scheduled turnaround period. As a result, all systems were restored to full operational capacity. The integrity of the flare stack was enhanced, and safety systems were fully operational. By addressing corrosion, leakage issues, and structural damage, BEC helped Petron Bataan Refinery Inc. maintain the reliability and safety of the refinery’s flare stack system, ensuring it operates efficiently in the long term.