On-site Activities
Zenith brings world-class innovation and excellence to all of our engineering design capabilities and industry-leading onsite activities. Having all the necessary skills in-house, our highly skilled onsite teams work in demanding industrial environments such as petrochemical, oil, gas and power sectors, adhering to the latest B31.1, BS EN and ASME standards. We provide extensive welding repairs, replacement and installations oftentimes carried out during tight shutdown periods at both low and high levels.
Zenith presents a uniquely different approach to our onsite activities. We bring industry leading specialist access techniques and world-class lifting capabilities.
ExonMobil
Zenith’s extensive welding experience is highlighted on a project for ExxonMobil. We provided a skilled team for the construction of Europe’s largest ground flare, which took place over 18 months on a live petrochemical plant. Our team designed and delivered safe and innovative access solutions while working closely with the wider project team to overcome the complexities of working within a live petrochemical plant.
Project Overview
- Spooling and fabrication of pipework from 1″ to 16″ in …stainless steel and carbon steel.
- Installation of 18m diameter, 31m high combustion …chamber.
- Steel erection of shroud and associated structures.
- Provision of lifting temporary works.
- Lifting supervision for all lifting activities.
- Welding undertaken to ASME standards.
- Improve environmental impact of existing facility.
The complexities of working within a live petrochemical plant required innovative, technical solutions and close collaboration with the wider project team.
Project Next Steps
Following Zenith’s safe and successful installation of Europe’s largest ground flare at ExxonMobil’s Mossmorron site in Fife,Scotland, Zenith was highly recommended by the Mossmorran engineering team to the refinery engineers at ExxonMobil, Fawley who were leading the ‘FAST’ project involving the refurbishment and further construction of a new fourth reactor in the existing residfiner at Fawley.
ExxonMobil’s oil refinery in Fawley, Hampshire is the largest in the United Kingdom and one of the most complex in Europe. Zenith provided all the necessary skills, trades, and equipment, for all of the loop pipework and utilities installation to the residfiner. ExxonMobil’s $1.5 billion Fawley refinery FAST project represents the largest upgrade to a British refinery in decades.
Zenith’s team of mechanical and structural engineers, working together with Zenith’s specialist access, heavy lifting, pipe fitters and welding site operatives installed additional strengthening and support steelwork to the existing reactor structure, which supports the inlet pipework. Once all the new strengthening steelwork was installed, the inlet pipe was prepared, installed, and connected to the steel supports from the existing reactor to the entry point of the new fourth reactor.
At the core of the project lies the installation and welding of 500mm and 400mm Sch 140 (45mm thk) heavy wall Stainless 347 and dissimilar pipe, using processes TIG root and FCAW fill and cap. Zenith brings a wealth of experience and certification in this field, ensuring safety, quality and reliability.
