The Challenge
The Escravos Gas-to-Liquids (EGTL) facility required controlled bundle pulling and reinstallation activities within an operational hydrocarbon processing environment. The intervention involved large-diameter exchanger bundles integrated within critical process systems where access constraints, lifting coordination, and shutdown schedule exposure presented significant execution risks.
The work scope demanded precise mechanical handling, coordinated lifting operations, and alignment control to prevent tube damage, flange integrity issues, and extended maintenance downtime. Brownfield operating conditions, elevated piping infrastructure, and confined access areas further increased execution complexity.
Execution planning prioritized controlled extraction methodology, lifting path management, personnel safety coordination, and minimized disruption to adjacent operating systems.
Our Approach
Fairtex deployed a dedicated mechanical intervention team to execute exchanger bundle pulling and installation activities under controlled lifting and maintenance procedures. Activities were coordinated alongside plant maintenance personnel to support safe isolation, staged removal, inspection access, and reinstallation readiness.
Specialized bundle extraction equipment and hydraulic pulling systems were utilized to manage controlled movement of exchanger internals while maintaining tube sheet alignment and equipment integrity throughout the intervention cycle.
Execution activities included:
- Pre-job mechanical and lifting assessment
- Exchanger opening and access preparation
- Bundle extraction and controlled handling
- Inspection access support coordination
- Bundle reinstallation and alignment verification
- Flange management and bolting support
- Post-installation integrity checks
- Shutdown coordination and worksite control
Phased Delivery
Assessment & Planning
The maintenance scope was reviewed to establish lifting requirements, exchanger access limitations, scaffold interfaces, and shutdown execution sequencing.
Mobilization
Mechanical crews, lifting accessories, hydraulic bundle pulling equipment, and safety systems were mobilized to support continuous maintenance execution within the processing facility.
Bundle Extraction & Intervention
Controlled extraction activities were executed using aligned pulling systems designed to minimize mechanical stress on exchanger components while enabling inspection and maintenance access.
Reinstallation & Alignment
Following maintenance completion, exchanger bundles were reinstalled under monitored alignment procedures with coordinated flange reinstatement and mechanical verification activities.
Validation & Handover
Final reinstatement checks and mechanical confirmation activities were completed prior to system handover for operational reintegration.
Outcome
The project supported planned maintenance execution across critical process equipment while reducing shutdown schedule exposure and preserving exchanger system integrity throughout intervention activities.
Fairtex delivered coordinated mechanical handling services within active industrial conditions while supporting safe execution, controlled lifting operations, and operational continuity objectives at the EGTL facility.
