Chevron flare stack
103m flare stack erected at refinery
Babcock was recently entrusted with dismantling an old flare stack and erecting a new flare stack at the Chevron Refinery in Cape Town. Chevron South Africa (Pty) Limited, is the country's third-largest crude oil refinery and produces petrol, diesel, jet fuel and liquefied gas for the Western Cape and for export to other African countries. Our engineering solutions business (Ntuthuko Generation) acted as principal contractor on both these projects and equipment hire was supplied via our plant hire services business.
Dismantling of the old 52 m flare stack was accomplished with a Liebherr LTM 1440 mobile crane and demolition was carried out in three sections with each section weighing approximately 18 tons each. The new flare stack, 103 m high and weighing in it at nearly 80 tons, was erected in four sections. The first section weighed approximately 24 tons and was lifted by means of a Liebherr LTM 1440 mobile crane, while the other three sections, weighing a combined 55 tons, were erected utilising a Liebherr LTM 1500 mobile crane.
The rigging team controlled and directed the crane operator to ensure correct placement by means of tackle, lifting gear and chains. The engineering crew was responsible for cutting and welding of the flare sections, while the project management team’s task was to oversee site activities and ensure safe operations at all times.
“After we secured the initial contract, the scope of work continued to increase over time, which called for careful planning and very accurate logistical coordination,” says Je-T’aime van Staden, Sales Manager - Plant, Babcock.
Rising to the challenge
The scope of work included lifting personnel in a man cage to a height of 103 m. Inclement weather posed a challenge to keeping the project on schedule. The projects were completed on schedule, making it possible for Chevron personnel to commission the new flare stack during the refinery’s shutdown from February 13 to March 31 2015.
Maintaining an excellent safety record is of utmost importance to us and the Chevron Refinery project was completed with zero incidents or accidents.
Trusted to deliver. Together.
These two contracts drew on the synergies between the two Babcock business units and their depth of experience in the South African industrial arena.
“The successful completion of these contracts has demonstrated the broad range of capabilities and resources the two business units in tandem can offer clients,” Conrad Geyer, Construction Manager – Ntuthuko Generation.