Flare Seal Replacement Project

A world-leading refiner awarded a contract to JML to replace the flare seal for one of its refinery plants located in Singapore. This particular flare, at 150 metres high, is one of the highest flares in Singapore. We were tasked to replace 16 tons of the flare seal at the height of 150 metres and install the necessary piping related to the replacement works using a 600 ton crane.

We identified several challenges in the planning stages, prior to the execution of the actual work. The biggest challenge encountered was the limited access to survey the work place due to the live flare. As a result, we had to conduct the project planning activities to identify modifications to existing platforms and critical processes which included the dismantling of the existing flare seal, disconnecting pipes at height, installing new seal and thereafter reconnecting the pipes, during the plant shutdown window which left us with very little room for errors and re-work.

JML2.0 Initiative is JML’s thinking hat to adopt the latest cutting edge technology to enhance construction and safety processes. Initially, drones were flown to record video footage of the flare. This was challenging because of the intense radiation emitted from the live flame. With the video footage, we managed to employ Virtual Reality (“VR”) technology to create an immersive flare environment. This enabled us to simulate work steps and sequence efficiently. With VR technology, we now have the capacity to study the scope in greater detail together with all stakeholders, and formulate efficient work method statement.

Leveraging on the VR technology, our workers are trained on immersive environment in our workshop to get accustomed to the workplace conditions and perform risk analysis. Multiple rehearsals were conducted with each and every step studied thoroughly and fine-tuned to achieve optimum time schedule. Mast climber was used to access the tip of the flare during the shutdown to facilitate the movement of workers and transport equipment. The replacement works were successfully completed within two weeks with our workers mobilized round the clock.

Workers used wearable tablets, known as Realwear’s Head Mounted Tablet (HMT-1) for witnessing gas tests, LoTo and remote monitoring and mentoring. Live stream of all work activities could be monitored at the control centre at ground level through these wearable tablets worn by workers when work was performed. The adoption of this digital innovation has won us commendation from the client.

JML2.0 Initiative redefines us, and we will continue to leverage on digital innovation.