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Offshore Flare Tip Replacement

We have pioneered the design of a purpose-built lifting frame to improve the process of replacing flare tips. The lifting frame is positioned directly below the termination point of the flare stack thereby negating the use of expensive cranes. This has been designed to take the weight of the tip as it is lowered to the ground and lift the new replacement tip into position. This innovative solution to a complex and expensive problem is now being adopted in refineries, petrochemical plants and offshore platforms around the world, and is an excellent example of our design capabilities delivering commercial benefits often in remote and demanding locations.

Flare Tip Replacement

  • Flare Tip Replacement without the use of helicopters or cranes.
  • Tip replacement using crane or Zenith’s purpose made lifting frame.
  • All required rigging studies and temporary works design.
  • Partial Rebuilds
  • Tip supply
  • All required supply and installation of tip components
  • Supply and installation of thermocouples
  • Removal and supply of all pilot lines, steam lines & expansion bellows
  • Cladding and insulation works
  • Supply and Installation of ladders and gantries
  • Grit blasting and paint application.
  • Qualified PCN operatives for UT, DPI & MPI inspection works
  • Qualified site welding capability to:

BS EN 1090-3: 2019

BS EN 1090-2: 2018

BS EN 1090-1: 2009 and A1:2011

  • Main Riser design and supply

Offshore Lifeboat Davit Replacement

As part of Zenith’s services to the offshore industry, we specialise in the replacement of lifeboat davits on gas and oil platforms. Detailed below gives an overview of a recently completed project that was executed in a safe, cost effective and timely manner:

Zenith was contacted by Shell UK Limited, who operates several offshore platforms in the North Sea, to change out the top vertical section (max 2.5Te lifts) on three of their lifeboat stations and to install new lifeboats. The project presented two key problems:

Firstly, the offshore platform crane could not reach the area where the lifeboat stations were located and secondly, the access to and around the stations proved extremely tight for manoeuvrability of necessary plant, equipment and the newly fabricated vertical sections. The client considered using temporary mobile cranes, additional lifting points and how to utilize scaffolding to allow the crane suitable access, however, this solution would prove onerous due to the load bearing on the platform. An alternative solution had to be found. Zenith proposed the following NINE step solution to the client, which was duly considered and accepted.

STEP 1 – Initial Concept Design

STEP 2 – Full Design Works

STEP 3 – Fabrication and Testing of Equipment

STEP 4 – Project Management of Site Works

STEP 5 – Offshore Pre-Outage Works:

  1. Mobilise to Offshore Platform and unload equipment and transport to work areas
  2. Install lifting runway beam and install lifeboat deck level winch
  3. Install diverter system and associated rigging and install platform temporary support trestles
  4. Prepare first new platform on weather deck and lift first new platform on to temporary support trestle
  5. Install fall arrest lines over original first lifeboat and assist with initial stripping of equipment.

STEP 6 – Replace First Lifeboat

STEP 7 – Replace Second Lifeboat

STEP 8 – Replace Third Lifeboat

STEP 9 – Offshore Post-Outage Works

Mechanical & Welding Services

Working in demanding industrial environments including refineries, power stations and cement plants and often having to perform welding repairs during tight shutdown periods, Zenith provides a comprehensive range of welding repair services.

Whether welding is required at low level or even where welding at height requires the design and installation of safe and innovative access, Zenith provides industry leading solutions.


Welding Certification

BS EN 1090-3: 2019

BS EN 1090-2: 2018

BS EN 1090-1: 2009 and A1:2011


Flange Management Certification

Hand Torque Bolted Connection Techniques

Dismantle, Assemble and Hand Torque Flanged Joints

Hydraulically Torque Bolted Connection Techniques



Zenith is a trained and approved installer of the LOKRING® system and we are able to install:

• MAS-3000 Carbon Steel Series Pipe Fittings

• SS40 and SS-3300, 316L Stainless Steel Series Pipe Fittings

• CN-200 90/10 Copper Nickel Series Pipe Fittings

• CN-700 Copper Nickel Pipe and Tube Fittings

The main advantage in using the LOKRING® method is that it eliminates the need for hot works at height in a refinery environment or offshore.

UAV Inspection & Surveying Service

As part of Zenith’s expanding portfolio of services, we are pleased to provide our clients with our PfCO CAA licensed UAV Inspection and Surveying Service carried out by our team of 7 qualified pilots.

We are able to generate 2D and 3D models from captured survey information and existing drawings. We can accurately determine revised capacities and assess the life extensions of existing structures and structural elements.

Decay, loss of section, material properties, geometry and change of use are a number of variables that can affect the performance and life span of any building or structure. This can all be modelled to represent a snapshot in time and assist with determining the structural integrity of existing assets.

A UAV inspection allows for a visual examination of structures providing photographic and video records. Following the survey, a comprehensive report is compiled by our dedicated team of Structural Engineers. UAV inspections allow engineers to identify and assess the general condition of the structure. This combined with Zenith’s hands on survey capability offers clients a full suite of inspection services.

Our UAS platforms can be tailored to suit the prospective operation, whether it be for extended flight duration, thermography, high definition photo or video imagery.

Visual Survey

Using our 30x optical zoom camera we can capture detailed close-up video and still imagery, even when the survey environment does not allow us to fly close to the subject, such as operational flare tips and chimneys.  Ideal for condition surveys and defect identification on buildings and elevated structures.

  • Flare tip condition surveys
  • Cooling tower and chimney condition surveys
  • Roof and gutter inspections
  • Jetty inspections

Our high-resolution cameras are capable of 20Mp images and up to 5.2k definition video for high quality media for project highlights and marketing.

Thermographic Survey

Our thermal camera uses a specialized FLIR Tau 2 thermal sensor and a 4K visual camera along with image processors to render the results on a visual display. We have the capability to interrogate and interpret the survey data to identify temperature differentials and defects.

  • Insulation defects
  • Moisture ingress
  • Building heat loss

Orthomosaic and 3D Point Cloud

We can create high resolution orthomosaic images and 3D models of sites and structures by collecting a large number of individual overlapping photographs and processing them using specialised orthorectification software.

  • Site plans and construction progress
  • Surveying/measurements
  • Asset identification and virtual survey

Topographic Survey and Volumetric Measurements

3D point clouds can be further developed and interrogated using specialist software to produce topographic (contour) maps and surfaces.  Surfaces can be compared to enable volumetric calculations.

  • Site plan
  • Stockpile measurement

ROV Survey

Zenith also own an ROV for underwater inspections providing photo and video images.

  • Hydro scheme inspections
  • Jetty inspections

Structural Assessment

Zenith Consultants operate the most up to date design and analysis software that supports all of our engineering services. In conjunction with a fully trained and experienced team of Engineers, Technicians and Administrators, this forms the core of our business.

In addition to traditional Civil & Structural engineering consultancy services, we are also capable of surveying, assessing and reporting on all types of existing structure, be it a simple precast concrete lintel or a complex multi-level steel frame or stack for our industrial sector clients. Our principles of analysis and utilisation of applicable design standards and codes are the same throughout.

Lifting Design

In conjunction with our engineering, design and modelling capabilities, Zenith Consultants are able to offer solutions for complex rigging and lifting projects.

As full members of the Lifting Equipment Engineers Association, LEEA, we design and detail bespoke fabrications and solutions to our international customer base.

Where precise control, movement and weight measurement is required we are also capable of designing hydraulic lifting and sliding systems.

Structural Design & Remediation

We are able to generate 2D and 3D models from captured survey information and existing drawings. We can accurately determine revised capacities and assess the life extensions of existing structures and structural elements. Decay, loss of section, material properties, geometry and change of use are a number of variables that can affect the performance and life span of any building or structure. This can all be modelled to represent a snapshot in time and assist with determining the structural integrity of existing assets.

All of our software interfaces with our drafting resource allowing us to accurately schedule components for fabrication purposes or cost analysis. By merging this data with our software we can generate powerful and detailed 3D graphical representations of any structure, or structural element, to better present our analysis results to our clients. These models can also be used to assists in desk top reviews of operational requirements where lifting or sliding of complex fabrications require to accurately interface with (or bypass) existing structural components or services.

Demountable Flare Stacks – Riser Replacement & Erection

We are proud to offer our clients a complete riser replacement and flare tip replacement service on flare structures for the petrochemical industry, including all structural engineering requirements.

We are heavy lifting equipment specialists and we operate worldwide and our portfolio of clients include the world’s leading oil and gas companies. Often working under tight time constraints, Zenith has a reputation for safety, efficiency and attention to detail.

In-house, we provide all of the specialist structural engineering, site management, project execution and extensive know-how.

Zenith can design and supply a comprehensive range of replacement rigging equipment including winch supply.

Ground Flares

Zenith specialises in the installation of ground flares for the petrochemical industry. We provide a comprehensive installation service including all mechanical and welding requirements. We are proud to have constructed the largest ground flare in Europe.

We have all of the in-house expertise to offer our clients an unrivalled level of service.

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