A worker in an orange high-visibility suit climbs a flare support structure against a clear blue sky. The structure is painted orange, matching the worker's attire, and is equipped with safety railings and platforms. The worker is secured with safety harnesses and ropes, indicating adherence to strict safety protocols. The photograph is taken from ground level, looking up and emphasising the structure's height and scale within the expansive sky's expansive backdrop.

NRA Guy Wire Replacement

The North Rankin Complex (NRC) Facility is located offshore of the Northwest Shelf of Australia and processes gas for transfer to the Karratha Gas Plant. The facility is made up of the North Rankin A & B Platforms (NRA & NRB) and has a Flare Bridge that supports the Flare Stack, High Pressure (HP), and Low Pressure (LP) piping. Personnel were only allowed on the flare stack when the flare was offline due to the risk of flare heat radiation. The guy wires on the Flare Stack were overdue for replacement, and a mobile crane could not be used for the work due to equipment unavailability.

Background

The North Rankin Complex (NRC) Facility, comprising the North Rankin A & B Platforms (NRA & NRB), is located offshore of the Northwest Shelf of Australia at a nominal water depth of 124.3m. It processes gas for transfer to the Karratha Gas Plant.

NRA has an 184m long Flare Bridge, which supports the Flare Stack, High Pressure (HP), and Low Pressure (LP) piping to the flare stack, along with met-ocean instrumentation, radar, and flare knockout drums. The Flare Stack supports the HP and LP flare tips and is supported by eight guy wires. The complete flare assembly is approximately 36m high.

Due to the risk associated with flare heat radiation, personnel are only allowed on the flare stack when the flare is offline. Further, due to the flare stack’s corrosion of the platforms and stairways, rope access was to be used when working on the flare stack.

The guy wires are typically replaced every 10-15 years, but the current guy wires have been in service past this period. The last guy wire replacement was completed in 2006, with the work scope completed using a mobile crane mounted on a trolley that, in turn, was mounted on a pair of crane rails that run along the top of the flare bridge. The mobile trolley used then was no longer available, and the crane rails were no longer suitable for mounting a similar-sized trolley on the crane rails.

Phase 1: Guy Wire Replacement Study

An offshore oil platform is illuminated against the twilight sky. The sprawling structure is a complex of pipes, towers, and equipment extending into the sea. A prominent flare structure rises on the right, mirrored by the bridge connecting the platform to the smaller structures on the left. The sky transitions from warm sunset hues to the deep blue of the approaching night while the calm sea stretches to the horizon, reflecting the last light of day. The image captures the industrial might set against the natural beauty of the ocean at dusk.

Woodside engaged Vertech Group to execute a study to replace the 8-guy wires of the flare tower On North Rankin Alpha using rope access within the 24-day “gas to gas” window of the 2023 turnaround.

The area was to be accessed using Rope Access Techniques, and a scaffold was erected to lay down areas and temporary barriers at various working areas.

Phase 2: Project Planning & Engineering

Four industrial workers in bright orange coveralls and white helmets are seated together on a deck, reviewing documents and engaged in a discussion. The sea is visible in the background, suggesting they are on an offshore platform. They are surrounded by various work equipment and safety gear, indicating a break or planning session amidst their tasks. The workers appear focused and involved in their work, highlighting the importance of teamwork and communication in such environments.

Working closely with the Woodside shutdown team and other specialist contractors such as Alliance Engineering, the Vertech project team provided the necessary deliverables, including a baseline project schedule, project execution POB profile an execution schedule, detailed and comprehensive implementation work packs, work method statement(s) for our site teams, an implementation bill of materials, lift Plans, detailed tensioning procedures and Vertech completed an onshore work method trial.

Phase 3: Pre-Shutdown Work

An industrial worker in orange safety gear, including a helmet with a mounted light and hearing protection, works on a vertical structure above the ocean. The worker is harnessed and using a descent control device attached to a rope, indicating rope access work. They appear to be inspecting or repairing a series of pipes on the side of the structure, which is streaked with rust, showing the harsh maritime environment. Below, the blue sea stretches out, emphasising the height at which the worker is operating.

The Guy wire replacement is a complex and critical path task. As such, detailed close visual inspection, load testing and NDT were required once the flare was fully blown down and isolated before the installation of any rigging equipment. Once completed, the team installed all the initial rigging arrangements, inertia reels, rope access equipment, davits, air hoses and pig receivers and established dropped object protection.

It was necessary to complete fabric maintenance on some regions of the flare stack and pilot line pipe support, remove several potentials dropped objects, and then de-rig all materials before moving into the detailed sequence of guy wire replacement and tensioning for each wire.

Phase 4: Guy Wire Replacement

A group of workers in high-visibility orange suits and white helmets are on a metal scaffolding structure high above the ground. The scaffold is supported by a large rusted metal beam that angles upwards, with cables attached for added stability. They are working against an almost cloudless sky, which highlights the height at which they are working. This industrial scene occurs on an offshore oil rig structure requiring elevated construction or maintenance work.

The Guy wire replacement is a complex and critical path task. As such, detailed close visual inspection, load testing and NDT were required once the flare was fully blown down and isolated before the installation of any rigging equipment. Once completed, the team installed all the initial rigging arrangements, inertia reels, rope access equipment, davits, air hoses and pig receivers and established dropped object protection.

It was necessary to complete fabric maintenance on some regions of the flare stack and pilot line pipe support, remove several potentials dropped objects, and then de-rig all materials before moving into the detailed sequence of guy wire replacement and tensioning for each wire.

Client Testimonial

“The scope was completed over a 4-week period involving significant coordination with rigging, scaffolding, and rope access. Not only was the job completed efficiently and without any incident, but the team also found improvements and adapted along the way. An outstanding team effort…”

  • NRA HSEC

Want to know more? Contact us below:

"*" indicates required fields

Subscribe
This field is for validation purposes and should be left unchanged.
A group of industrial workers on an offshore platform pose for a photo. They wear bright orange coveralls, safety helmets, and protective glasses. Most are standing, and some are kneeling, with smiles indicating a moment of camaraderie or completing a job well done. The background features the metal structures of the platform, painted with visible rust, and the ocean extending to the horizon, suggesting a remote and harsh working environment. The clear sky and natural daylight enhance the visibility of the team's features and safety gear.
A group of industrial workers on an offshore platform pose for a photo. They wear bright orange coveralls, safety helmets, and protective glasses. Most are standing, and some are kneeling, with smiles indicating a moment of camaraderie or completing a job well done. The background features the metal structures of the platform, painted with visible rust, and the ocean extending to the horizon, suggesting a remote and harsh working environment. The clear sky and natural daylight enhance the visibility of the team's features and safety gear.
Industrial workers work in construction or maintenance on an offshore platform above the sea. They are working on a metal scaffold structure, secured with safety harnesses and wearing helmets for protection. The ocean provides a deep blue background, and the weather appears clear and sunny. The scene reflects the complexity and risk involved in offshore operations, where safety and precision are crucial due to the challenging environment.
Workers in orange safety gear are on a narrow metal walkway above the open sea, with a clear blue sky. The walkway, showing signs of rust and wear, is supported by diagonal beams and leads to a scaffolding structure, indicating ongoing maintenance work. The workers are equipped with safety harnesses and helmets, adhering to safety regulations while working in this challenging and exposed offshore environment. The vast ocean stretches to the horizon, emphasising their work's isolated and expansive setting.
Workers clad in safety gear, including orange coveralls and white helmets, engage in offshore oil rig maintenance activities. They are surrounded by a complex lattice of metal beams, pipes, and safety railings, indicative of the rig's intricate infrastructure. The sea provides a vivid blue backdrop, highlighting the offshore environment where such industrial operations occur. The focus and coordination of the team suggest a high level of skill and attention to safety in a challenging work setting.
A worker in an orange high-visibility suit climbs a flare support structure against a clear blue sky. The structure is painted orange, matching the worker's attire, and is equipped with safety railings and platforms. The worker is secured with safety harnesses and ropes, indicating adherence to strict safety protocols. The photograph is taken from ground level, looking up and emphasising the structure's height and scale within the expansive sky's expansive backdrop.
A complex metal framework against a clear blue sky, part of an industrial or offshore structure, possibly a drilling rig. The metal is painted in varying shades of white and orange, with some areas showing signs of rust and use. The horizontal and diagonal beams are visible, creating a geometric pattern with a central vertical element that may be part of the machinery. No workers are seen, but safety railings and platforms suggest that it is designed for human activity. The clear sky indicates fair weather conditions for outdoor operations.
A complex metal framework against a clear blue sky, part of an industrial or offshore structure, possibly a drilling rig. The metal is painted in varying shades of white and orange, with some areas showing signs of rust and use. The horizontal and diagonal beams are visible, creating a geometric pattern with a central vertical element that may be part of the machinery. The clear sky indicates fair weather conditions for outdoor operations.
Four industrial workers in bright orange coveralls and white helmets are seated together on a deck, reviewing documents and engaged in a discussion. The sea is visible in the background, suggesting they are on an offshore platform. They are surrounded by various work equipment and safety gear, indicating a break or planning session amidst their tasks. The workers appear focused and involved in their work, highlighting the importance of teamwork and communication in such environments.
Workers assemble scaffolding on an elevated metal platform against a clear blue sky. They wear safety gear, including harnesses, helmets, and high-visibility clothing. Diagonal beams support the structure they work on and are part of an offshore facility. The workers' focused actions reflect the precision and care required for potentially hazardous construction tasks.
A worker in an orange high-visibility suit climbs a flare support structure against a clear blue sky. The structure is painted orange, matching the worker's attire, and is equipped with safety railings and platforms. The worker is secured with safety harnesses and ropes, indicating adherence to strict safety protocols. The photograph is taken from ground level, looking up and emphasising the structure's height and scale within the expansive sky's expansive backdrop.
An industrial worker, secured with safety gear, climbs a vertical ladder on a large rust-coloured metal structure, part of an industrial or offshore facility. Metal pipes, railings, and cables parallel to the ladder are visible. The sky is clear, indicating good weather conditions for outdoor work. The perspective is from below, looking up towards the worker, highlighting the height and scale of the structure.
A towering metal structure with platforms, ladders, and safety railings rises against a clear blue sky. The structure, exhibiting a weathered rust patina, is equipped with pulleys and cables, indicative of its use for lifting or adjusting heavy equipment. The perspective is from the ground, looking up the structure's full height, emphasising its significant elevation and the work's verticality.
Workers in orange safety gear are gathered on a suspended metal platform against a clear blue sky and ocean backdrop. They appear to be engaged in a construction or maintenance task on the framework of an offshore structure. The platform is supported by rust-streaked beams that crisscross below it, contributing to a sense of height and open space around the workers. The calm sea extends to the horizon, emphasising the isolated and expansive environment where these offshore activities occur.
A group of workers in high-visibility orange suits and white helmets are on a metal scaffolding structure high above the ground. The scaffold is supported by a large rusted metal beam that angles upwards, with cables attached for added stability. They are working against an almost cloudless sky, which highlights the height at which they are working. This industrial scene occurs on an offshore oil rig structure requiring elevated construction or maintenance work.
Industrial workers are perched on a scaffolding structure extending from a large, complex rig against the vast expanse of the ocean and under a clear blue sky. The structure is a lattice of rusted metal, and it includes safety features such as railings and stable platforms. Cables run alongside the scaffolding for additional support. This image captures the scale of offshore operations and the challenging environments workers face, emphasising the verticality and precariousness of their daily tasks.
A towering metal structure with platforms, ladders, and safety railings rises against a clear blue sky. The structure, exhibiting a weathered rust patina, is equipped with pulleys and cables, indicative of its use for lifting or adjusting heavy equipment. The perspective is from the ground, looking up the structure's full height, emphasising its significant elevation and the work's verticality.
Workers in orange safety gear are gathered on a suspended metal platform against a clear blue sky and ocean backdrop. They appear to be engaged in a construction or maintenance task on the framework of an offshore structure. The platform is supported by rust-streaked beams that crisscross below it, contributing to a sense of height and open space around the workers. The calm sea extends to the horizon, emphasising the isolated and expansive environment where these offshore activities occur.
Workers in orange safety gear are gathered on a suspended metal platform against a clear blue sky and ocean backdrop. They appear to be engaged in a construction or maintenance task on the framework of an offshore structure. The platform is supported by rust-streaked beams that crisscross below it, contributing to a sense of height and open space around the workers. The calm sea extends to the horizon, emphasising the isolated and expansive environment where these offshore activities occur.
A worker in an orange high-visibility suit climbs a flare support structure against a clear blue sky. The structure is painted orange, matching the worker's attire, and is equipped with safety railings and platforms. The worker is secured with safety harnesses and ropes, indicating adherence to strict safety protocols. The photograph is taken from ground level, looking up and emphasising the structure's height and scale within the expansive sky's expansive backdrop.
A group of industrial workers on an offshore platform pose for a photo. They wear bright orange coveralls, safety helmets, and protective glasses. Most are standing, and some are kneeling, with smiles indicating a moment of camaraderie or completing a job well done. The background features the metal structures of the platform, painted with visible rust, and the ocean extending to the horizon, suggesting a remote and harsh working environment. The clear sky and natural daylight enhance the visibility of the team's features and safety gear.loading=
Industrial workers work in construction or maintenance on an offshore platform above the sea. They are working on a metal scaffold structure, secured with safety harnesses and wearing helmets for protection. The ocean provides a deep blue background, and the weather appears clear and sunny. The scene reflects the complexity and risk involved in offshore operations, where safety and precision are crucial due to the challenging environment.loading=
Workers in orange safety gear are on a narrow metal walkway above the open sea, with a clear blue sky. The walkway, showing signs of rust and wear, is supported by diagonal beams and leads to a scaffolding structure, indicating ongoing maintenance work. The workers are equipped with safety harnesses and helmets, adhering to safety regulations while working in this challenging and exposed offshore environment. The vast ocean stretches to the horizon, emphasising their work's isolated and expansive setting.loading=
Workers clad in safety gear, including orange coveralls and white helmets, engage in offshore oil rig maintenance activities. They are surrounded by a complex lattice of metal beams, pipes, and safety railings, indicative of the rig's intricate infrastructure. The sea provides a vivid blue backdrop, highlighting the offshore environment where such industrial operations occur. The focus and coordination of the team suggest a high level of skill and attention to safety in a challenging work setting.loading=
A worker in an orange high-visibility suit climbs a flare support structure against a clear blue sky. The structure is painted orange, matching the worker's attire, and is equipped with safety railings and platforms. The worker is secured with safety harnesses and ropes, indicating adherence to strict safety protocols. The photograph is taken from ground level, looking up and emphasising the structure's height and scale within the expansive sky's expansive backdrop.loading=
A complex metal framework against a clear blue sky, part of an industrial or offshore structure, possibly a drilling rig. The metal is painted in varying shades of white and orange, with some areas showing signs of rust and use. The horizontal and diagonal beams are visible, creating a geometric pattern with a central vertical element that may be part of the machinery. No workers are seen, but safety railings and platforms suggest that it is designed for human activity. The clear sky indicates fair weather conditions for outdoor operations.loading=
A complex metal framework against a clear blue sky, part of an industrial or offshore structure, possibly a drilling rig. The metal is painted in varying shades of white and orange, with some areas showing signs of rust and use. The horizontal and diagonal beams are visible, creating a geometric pattern with a central vertical element that may be part of the machinery. The clear sky indicates fair weather conditions for outdoor operations.loading=
Four industrial workers in bright orange coveralls and white helmets are seated together on a deck, reviewing documents and engaged in a discussion. The sea is visible in the background, suggesting they are on an offshore platform. They are surrounded by various work equipment and safety gear, indicating a break or planning session amidst their tasks. The workers appear focused and involved in their work, highlighting the importance of teamwork and communication in such environments.loading=
Workers assemble scaffolding on an elevated metal platform against a clear blue sky. They wear safety gear, including harnesses, helmets, and high-visibility clothing. Diagonal beams support the structure they work on and are part of an offshore facility. The workers' focused actions reflect the precision and care required for potentially hazardous construction tasks.loading=
A worker in an orange high-visibility suit climbs a flare support structure against a clear blue sky. The structure is painted orange, matching the worker's attire, and is equipped with safety railings and platforms. The worker is secured with safety harnesses and ropes, indicating adherence to strict safety protocols. The photograph is taken from ground level, looking up and emphasising the structure's height and scale within the expansive sky's expansive backdrop.loading=
An industrial worker, secured with safety gear, climbs a vertical ladder on a large rust-coloured metal structure, part of an industrial or offshore facility. Metal pipes, railings, and cables parallel to the ladder are visible. The sky is clear, indicating good weather conditions for outdoor work. The perspective is from below, looking up towards the worker, highlighting the height and scale of the structure.loading=
A towering metal structure with platforms, ladders, and safety railings rises against a clear blue sky. The structure, exhibiting a weathered rust patina, is equipped with pulleys and cables, indicative of its use for lifting or adjusting heavy equipment. The perspective is from the ground, looking up the structure's full height, emphasising its significant elevation and the work's verticality.loading=
Workers in orange safety gear are gathered on a suspended metal platform against a clear blue sky and ocean backdrop. They appear to be engaged in a construction or maintenance task on the framework of an offshore structure. The platform is supported by rust-streaked beams that crisscross below it, contributing to a sense of height and open space around the workers. The calm sea extends to the horizon, emphasising the isolated and expansive environment where these offshore activities occur.loading=
A group of workers in high-visibility orange suits and white helmets are on a metal scaffolding structure high above the ground. The scaffold is supported by a large rusted metal beam that angles upwards, with cables attached for added stability. They are working against an almost cloudless sky, which highlights the height at which they are working. This industrial scene occurs on an offshore oil rig structure requiring elevated construction or maintenance work.loading=
Industrial workers are perched on a scaffolding structure extending from a large, complex rig against the vast expanse of the ocean and under a clear blue sky. The structure is a lattice of rusted metal, and it includes safety features such as railings and stable platforms. Cables run alongside the scaffolding for additional support. This image captures the scale of offshore operations and the challenging environments workers face, emphasising the verticality and precariousness of their daily tasks.loading=
A towering metal structure with platforms, ladders, and safety railings rises against a clear blue sky. The structure, exhibiting a weathered rust patina, is equipped with pulleys and cables, indicative of its use for lifting or adjusting heavy equipment. The perspective is from the ground, looking up the structure's full height, emphasising its significant elevation and the work's verticality.loading=
Workers in orange safety gear are gathered on a suspended metal platform against a clear blue sky and ocean backdrop. They appear to be engaged in a construction or maintenance task on the framework of an offshore structure. The platform is supported by rust-streaked beams that crisscross below it, contributing to a sense of height and open space around the workers. The calm sea extends to the horizon, emphasising the isolated and expansive environment where these offshore activities occur.loading=
Workers in orange safety gear are gathered on a suspended metal platform against a clear blue sky and ocean backdrop. They appear to be engaged in a construction or maintenance task on the framework of an offshore structure. The platform is supported by rust-streaked beams that crisscross below it, contributing to a sense of height and open space around the workers. The calm sea extends to the horizon, emphasising the isolated and expansive environment where these offshore activities occur.loading=
A worker in an orange high-visibility suit climbs a flare support structure against a clear blue sky. The structure is painted orange, matching the worker's attire, and is equipped with safety railings and platforms. The worker is secured with safety harnesses and ropes, indicating adherence to strict safety protocols. The photograph is taken from ground level, looking up and emphasising the structure's height and scale within the expansive sky's expansive backdrop.loading=
NRA Guy Wire Replacement Case Study
PDF 416.1 KB