Home / Case Studies / Shell Pearl GTL, Qatar

TCO, Kazakhstan


Shell’s Pearl GTL (gas-to-liquids) is the world’s largest plant to turn natural gas into cleaner-burning fuels and lubricants.

Zenith Structural Access Solutions Limited was awarded the contract by Shell Pearl GTL Qatar in 2015 to replace three flare tips on their main flare riser. Zenith carried out this work by lowering to ground level three main flare lines. Of particular note, is that Zenith were asked to lower two lines simultaneously, followed by the third line. Zenith then installed the new tips and re-installed the three lines to their original position. Following the successful completion of this initial phase, in 2016, Zenith were contracted to carry out a repeat of the process on the other side of the flare riser. Zenith has now been awarded a further five-year agreement which commenced on site in 2022.

The elevated flare system consists of a main structural derrick which supports four risers mounted to the North side and four risers mounted on the South side. The derrick structure is 126m in height and the risers extend a further 14m beyond the derrick structure. The system is designed to be demounted using a winch and canting system, the original design utilised a main winch and canting system mounted at the Northeast elevation and a winch system mounted at the Southeast elevation. This allows for flare tip replacement whilst the other flares remain in service.

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