Flare Replacement Method for replacement When replacing flare tips, we use the "long line" flying techniques (often referred to as "Vertical Reference"). The great advantage with this method is that it allows the pilot to fly while looking down, using a bubble window in the helicopter. He always has a vertical view directly to the the platform and the load he his carrying. The technique involves the use of a 20 meter long lifting strop ensuring the helicopter is operating well above any danger area, and the helicopter downwash is minimized.

Another important factor when doing these operations is the use of customized guide systems. These guides have locking devices and are installed on the riser flange prior to removal of the existing flare tip. All bolts are removed, locks are released and the flare tip is lifted off.

 When installing the new flare tip, the guides are steering the load directly onto the flange and automatically lock the flare tip flange when it is in position. Typical duration of a flare tip replacement operation will be from 6-10 hours, depending on the type and number of flare tips. This means the time from the installers enter the flare boom until all replacement work is completed.

Preparation The actual replacement work represents an important, but still a small part of a total flare tip replacement project. Prior to all operations, a detailed operations manual for the work is prepared. Every aspect of the work is here described in detail. This means such as a step by step description of all activities to take place, organisation of the project, schedules, risk assessments and tool lists.

When entering the flare boom, the Vertech crew shall be confident that all tools and equipment needed for the work is in their tool boxes. The preparations and packing of these tool boxes are essential for the success of the work.

Personnel The main key to our success offshore has been the experience of our personnel and the continuously improvement of equipment and techniques. Our offshore organisation is small, but contains a group of highly qualified personnel. Some of the installers involved have been involved in our offshore work from the early beginning. Their experience with these operations is invaluable.

Other personnel in our team are project managers, engineering personnel and a helicopter pilot. All mentioned personnel have been involved in offshore maintenance and construction work in general for many years. The helicopter pilot employed with Vertech is an experienced long line pilot. His responsibility is to quality assure all aerial work that Vertech Offshore is involved in. He will also normally act as the Offshore Supervisor when doing the work.

Personnel involved in the offshore operation is normally:

• 1 Operations Supervisor (Vertech helicopter pilot)
• 3-4 Mechanical Installers
• 2 helicopter pilots (1 long line pilot / 1 pilot in command)
• 1 helicopter technician
• 1 load master
The 2 pilots, the technician and the load master are all part of the helicopter crew. Operation Supervisor and installers are part of the Vertech offshore team.

Tools and equipment All special tools and equipment required for the operation is provided by Vertech. This includes such as specialized guide equipment, lifting accessories and all kind of hand tools needed for the work up in the flare boom. Tools and equipment are normally brought offshore in 2-3 small aluminium tool boxes, weighing approximately 300 kg each.

Safety When carrying out all types of helicopter lifting operations like this, safety has highest priority. Safe Job Analysis is an essential task where every aspect of the work is scrutinized. A separate SJA is prepared for the helicopter work. All lifting equipment and manufactured tooling shall of course be certified according to local requirements.

Eltel normally subcontract a helicopter operator for the work. Before subcontracting a helicopter, both the company and the actual pilots shall be quality assured and approved by ES’s helicopter co-ordinator. Prior to any operation, the long line pilot shall have demonstrated his skills. In ES we have developed our own quality system for approval of pilots. Any helicopter pilot doing work for ES shall be approved according to this system.

Over the 13 years of operating offshore, we have never been involved in any accidents or personnel injuries at all. The combination of experienced personnel in all positions, the specialized equipment and good planning make this method the safest, fastest and most cost effective method of replacing flare tips.

Helicopter Normally a Super Puma helicopter is used for this kind of work. The Super Puma is a twin engine helicopter and has a lifting capacity between 3.0 and 4.0 tonns depending on the model available. Super Pumas are operated in many areas in the world, also in Australia. Even if the companies operating these helicopters do not have a pilot with the required skills, Vertch can provide a prequalified long line pilot from Norway, UK or Canada.

If the flare tip to be replaced exceeds the limit for a Super Puma, this can be solved in different ways.