Client Name: Leading EPC Company
Summary of the Project
Subsea Innovation, a Unique Group Company, designed, engineered, and manufactured a rapid repair clamp solution to re-enable the capability of a ruptured 10” water injection pipeline within 9 weeks, thus restoring its integrity.
Client Requirement
Our client, a leading EPC company, required a solution for a rupture on the water injection supply line at a Platform in the UK’s North Sea. The objective was to design, test, and manufacture a pressure-retaining repair clamp to restore the capability of the 10” water injection pipeline.
Challenges Faced
The project team had to address several key challenges:
- Tight project timelines: With the pipeline out of service, quick project execution was essential. The team had to source S355 plate material in lieu of traditional forged material. It was sent for external testing to ensure it would meet the correct specifications.
- Coating concerns: The client was unsure if the pipe’s 2LPP coating would need to be removed. Subsea Innovation clamps, which have proven sealing capabilities on both PP-coated and bare steel pipes, addressed this concern and reassured the client.
- Close proximity of welds to the rupture: The rupture’s location near a weld posed a challenge for sealing. Subsea Innovation leveraged their expertise in sealing over weld beads to reassure the client and ensure the design’s success.
Hydraulic setup and seal activation testing
Unique Solution Delivered
Subsea Innovation, a Unique Group company, designed and manufactured a hinged repair clamp to address the rupture. From the purchase order to installation, the entire project was completed in just nine weeks. Key aspects of the solution included:
- Design and engineering: Customized clamp halves to fit the damaged pipeline.
- Materials and spares: Long-term durability was guaranteed by premium materials.
- Testing and documentation: Comprehensive pre-installation pressure testing and supporting documentation.
- Installation assistance: Offshore technicians supported clamp installation and pressure testing.
The repair clamp was designed as a hinged, split structure for easy subsea installation. During installation, the clamp was lowered over the damaged section with the hinge open. Divers manually closed the clamp around the defect and inserted stud bolts to secure the halves. The hinge was removed, and the bolts were tensioned to form a complete seal, verified by pressure testing.
The clamp’s adaptability allowed it to seal over coatings and welds, providing a robust solution for the pipeline’s local damage.
Benefits Delivered
- Safety: The solution was implemented safely, with all technical details evaluated at the project’s early phases.
- Fast turnaround: Full project execution within nine weeks minimized pipeline downtime.
- Effective sealing: The clamp was capable of sealing over coatings and welds, ensuring a two-year service life. With the materials selected this was well within the normal service life of a clamp.
- Comprehensive support: End-to-end involvement from design to installation by Subsea Innovation.
- Versatile design: The clamp design adds to Subsea Innovation’s portfolio of successful subsea repair solutions and can be adapted for similar projects.
- Future applications: Subsea repair clamps are a proven solution for local pipeline damage, especially in emergency scenarios. The design approach and lessons learned from this project can be applied to other situations requiring reliable sealing over coatings or welds
Client Name: Leading EPC Company
