Ground Flare Maintenance, Repairs & Revamp
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Ground Flare Maintenance, Repairs & Revamp
Ground flare maintenance, repairs, and revamp services are essential to ensure the safe, efficient, and environmentally compliant operation of flaring systems used in refineries, petrochemical plants, and gas processing facilities. Ground flares operate under high thermal and mechanical stress, making routine inspection and preventive maintenance critical for reliable and continuous performance.
Metalok Industries offers comprehensive ground flare services, including inspection, refractory repair, pilot and ignition system maintenance, burner replacement, and flare header modification. Our team uses advanced inspection tools, thermal imaging, and performance diagnostics to detect wear, corrosion, and inefficiencies at an early stage.
We also specialize in flare system revamping and upgrades, incorporating energy-efficient burner technology, low-emission designs, and automated ignition controls. All work is performed in compliance with API 537, API 521, and NFPA standards, ensuring maximum safety, minimal downtime, and long-term reliability of flare systems operating in critical industrial environments.
- Inspect reactor systems and prepare for safe catalyst handling operations.
- Obtain necessary permits for confined space and inert atmosphere work.
- Ensure full isolation, depressurization, and gas-free condition before entry.
- Use nitrogen purging for inerting reactors where required.
- Carefully unload spent catalyst using vacuum or gravity methods.
- Screen, classify, or dispose of spent catalyst as per environmental regulations.
- Inspect reactor internals and repair or clean as necessary.
- Load fresh catalyst in layers according to specified density and bed design.
- Monitor oxygen levels, temperature, and pressure throughout the process.
- Document the complete operation with safety checklists and performance reports.