A flare tip changeout is the process of removing an existing flare tip from an offshore oil and gas facility and replacing it with a new one. Flare tips operate at the top of flare systems and can require replacement when they reach the end of their service life.

Unlike a conventional equipment replacement, an offshore flare tip changeout can involve significant height, restricted access, limited working space and complex lifting requirements. The flare tip must be safely disconnected, lifted from its position, lowered to a supply vessel or suitable deck area, and replaced with a new component. The new flare tip then needs to be lifted and accurately positioned for installation.

This makes flare tip replacement an engineered offshore lifting operation, where the lifting method is just as important as the replacement itself.

The process begins with understanding the flare structure, available space, access routes, component weights and required lifting path. Thunder Cranes can then develop a detailed lifting plan and method statement to determine how the operation can be performed safely and efficiently.

For flare tip changeouts, Thunder Cranes provides modular lifting technology such as the TC-MLS, a portable lifting system designed for flare tip handling. Its modular construction allows the system to be transported and assembled in restricted offshore environments, while winch-based operation provides controlled movement of the flare tip.

During a typical changeout, lifting equipment is transported to the offshore facility, positioned and assembled, and prepared for operation. The existing flare tip can then be disconnected and lowered from the flare deck to a supply vessel or designated area. The replacement flare tip follows the reverse process, being lifted into position and prepared for installation.

The objective is simple: remove the old flare tip and install the new one safely, efficiently and within the available shutdown window.

Offshore flare structures are not always designed with conventional crane access in mind. The flare tip may be positioned high above the platform with very limited space around it.

A modular lifting system provides another approach. Instead of asking, “How can we get a large crane to the flare tip?”, the engineering question becomes:

“How can we bring a suitable lifting system to the flare tip?”

This approach can reduce equipment requirements, simplify logistics and make lifting possible in areas where conventional crane access is difficult.

Every flare tip changeout begins with planning.

Assess → Engineer → Prepare → Install → Lift → Replace

Thunder Cranes combines lifting expertise, project-specific engineering and specialized equipment to support complex flare tip replacement operations.

In one documented offshore project in Malaysia, flare tips located approximately 52 metres above sea level required replacement within a six-day shutdown window. Thunder Cranes developed a customized lifting solution and supplied specialist personnel to support the removal and installation process. The changeout was completed within the allocated shutdown period.

For offshore operators, the goal is not simply to lift a flare tip.The goal is to complete the entire lifting operation with a controlled method that fits the structure, space, equipment and shutdown schedule.

That is where an engineered flare tip changeout solution can make the difference.