In 2024, Caspian Engineering Solutions successfully executed a complex and large-scale project involving the repair of the flare stack tip head located in Unit No. 26 of the “Ethylene-Polyethylene” plant under the “Azerikimya” Production Union. The purpose of this project was to enhance the reliability of the existing industrial infrastructure, ensure operational safety, and maintain the continuous operation of the plant.

During the project, a special crane with a lifting capacity of 1,200 tons was used to lift the flare tip head, which weighed 22 tons. For the mobilization of this crane, 4,500 m² of land was excavated and replaced with new subbase material. In addition, a plate load test and sand cone test for compaction were conducted by our team. The flare tip head was carefully and safely lifted from a height of 120 meters and lowered to the ground under the professional supervision of engineering and technical personnel. Given the high-risk nature of this operation, worker safety and environmental protection were treated as top priorities. All lifting and handling operations were carried out using state-of-the-art technologies and equipment, with no damage or accidents reported.

Once lowered, the flare tip head was transported to a dedicated technical base for repairs, where comprehensive inspection and refurbishment works were performed. All mechanical elements, corroded parts, and defects were identified and addressed. The repair process included both structural reinforcement and replacement of damaged components. All activities were completed in full compliance with industrial standards, meeting high safety and quality requirements.

Following the completion of the repair works, the 22-ton flare tip head was lifted again and precisely reinstalled at a height of 120 meters using the crane. During installation, all connection points, welds, and assembly elements were thoroughly inspected and confirmed to meet safety and stability standards.

Another significant part of the project involved the rehabilitation of staircases and service platforms on the flare stack. A total of 6 tons of materials were used in the restoration of metal structures, including painting and corrosion protection works. These efforts significantly improved both the functionality of the flare system and the safety and operational conditions for workers.

All works were completed with high professionalism, using modern technical tools, and in full compliance with occupational safety rules, within a period of only 15 calendar days. Through this project, Caspian Engineering Solutions once again demonstrated its capability to manage complex technological processes in the industrial sector, its strong technical capacity, and its commitment to delivering work that meets high international standards.