Zenith brings world-class innovation and excellence to all of our engineering design capabilities and industry-leading onsite activities. Having all the necessary skills in-house, our highly skilled onsite teams work in demanding industrial environments such as petrochemical, oil, gas and power sectors, adhering to the latest B31.1, BS EN and ASME standards. We provide extensive welding repairs, replacement and installations oftentimes carried out during tight shutdown periods at both low and high levels.
Zenith presents a uniquely different approach to our onsite activities. We bring industry leading specialist access techniques and world-class lifting capabilities.
Zenith’s extensive welding experience is highlighted on aProject for ExxonMobil. We provided a skilled team for the construction of Europe’s largest ground flare, which took place over 18 months on a live petrochemical plant. Our team designed and delivered safe and innovative access solutions while working closely with the wider project team to overcome the complexities of working within a live
petrochemical plant.
Project Overview
• Spooling and fabrication of pipework
from 1” to 16” in stainless steel and carbon
steel.
• Installation of 18m diameter, 31m high
combustion chamber.
• Steel erection of shroud and associated
structures.
• Provision of lifting temporary works.
• Lifting supervision for all lifting activities.
• Welding undertaken to ASME standards.
• Improve environmental impact of existing
facility.
The complexities of working within a live petrochemical plant required innovative, technical solutions and close collaboration with the wider project team.
Following Zenith’s safe and successful installation of Europe’s largest ground flare at ExxonMobil’s Mossmorron site in Fife,Scotland, Zenith was highly recommended by the Mossmorran engineering team to the refinery engineers at ExxonMobil, Fawley who were leading the ‘FAST’ project involving the refurbishment and further construction of a new fourth reactor in the existing residfiner at Fawley.
ExxonMobil’s oil refinery in Fawley, Hampshire is the largest in the United Kingdom and one of the most complex in Europe. Zenith provided all the necessary skills, trades, and equipment, for all of the loop pipework and utilities installation to the residfiner. ExxonMobil’s $1.5 billion Fawley refinery FAST project represents the largest upgrade to a British refinery in decades.
Zenith’s team of mechanical and structural engineers, working together with Zenith’s specialist access, heavy lifting, pipe fitters and welding site operatives installed additional strengthening and support steelwork to the existing reactor structure, which supports the inlet pipework. Once all the new strengthening steelwork was installed, the inlet pipe was prepared, installed, and connected to the steel supports from the existing reactor to the entry point of the new fourth reactor.
At the core of the project lies the installation and welding of 500mm and 400mm Sch 140 (45mm thk) heavy wall Stainless 347 and dissimilar pipe, using processes TIG root and FCAW fill and cap. Zenith brings a wealth of experience and certification in this field, ensuring safety, quality and reliability.
Fabrication Workshop
Due to our ever expanding mechanical and welding element progressing through the Zenith Group, and at the request of several of our blue-chip clients wanting to negate undue time delays, and to expand our existing comprehensive on-site mechanical and welding offering, Zenith has recently opened a fabrication workshop facility (2,500 sq. ft) to provide welding and fabrication expertise for process piping and
structural steel. To greatly reduce time, whenever possible, we install suspended platforms and provide rope access solutions.
With a global reputation for innovation and excellence, Zenith provides on-site specialist access and an extensive heavy lifting capability utilising a combination of highly qualified steeplejack and rope access welders who possess the latest industry accreditation’s and certificates, meeting both British and American standards. When required, our in-house world-class team of engineers design, and our on-site access specialists install, innovative significant time-saving access solutions.
ZENITH WELDING PROCEDURE QUALIFICATION AND CERTIFICATION:
Execution class: Up to EXC3 According to BS EN1090-2: 2018
• ASME 1X
• BS EN 9606-1
• BS EN ISO 15614 1:2017 and A1:2019
Installation
Personnel Trained to ECITB MJI10 manual torquing
18 tension 19 torquing
Personnel Experience and ECITB trained to
Swagelok Small Bore Tube Fitting Installation
LOKRING®
Zenith is a trained and approved installer of the LOKRING® system and able to install:
• MAS-3000 carbon steel series pipe fittings
• SS40 and SS-3300, 316L stainless steel series pipe
fittings
• CN-200 90/10 copper nickel series pipe fitting
• CN-700 copper nickel pipe and tube fittings
The main advantage in using the LOKRING® method is that it eliminates the need for hot works at height in a refinery environment or offshore.
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