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36 Hrs For 8” Riser Replacement at Zaafarana Platform
Paper Abstract 5/21/2005

The purpose of this paper is to present a challenge task successfully done within 36 hrs only. The objective was to repair a production pipeline riser leaking oil within the minimum duration of production shutdown at a minimum cost . An engineered riser modification was carried out by using the most suitable technique, which highlights the fast positive decision and action taken.

This success story happened at Zaafarana platform that locates at the northern part of the Suez Gulf. Such offshore platform is producing about 9,000 BOPD of oil .The produced oil is being transported through 8” pipeline from the platform to the FPSO (Floating Production, Storage & Offloading Facilities) vessel.

An oil leakage in the 8” pipeline riser was observed where a hole in the splash zone portion was detected , an immediate action has been taken by using temporary conventional leak prevention solutions (such as PLIDCO SMITH CLAMP and reinforced coating)

The leakage reasons have been investigated and it has been found out that the leakage hole was a result of a weak coating at such point, which led to sever corrosion due to the high oxygen content at the splash zone area.

The water depth is 60 meters at the platform area, so all proposed and assumed solutions were prepared based on the following criteria: 1. To minimize the production shutdown period as possibe, 2. To minimize diving activities as much as possibe3. To minimize the repair works cost .

Decision has been taken to conclude the solution to a certain selection that verifies these criteria by replacing the riser splash zone corroded portion with another spool piece prepared to be installed.

This “spool piece” was assumed to be assembled to the riser within minimum time as the sea conditions can not be secured to be suitable for welding activities at the splash zone area.

Decision was made to apply a cold cut and assemble the spool piece, hence a search was carried out to define the most suitable mechanism in such a case, and the result was revealed to apply pipe end connector called MORGRIP QUICKFLANGE application. The MORGRIP QUICKFLANGE installation and testing has been discussed in details, the production shutdown hours have been determined as 36 hours. In reality all arrangements have been done including the MORGRIP QUICKFLANGE installation/testing, also the hydro test for the pipeline after the riser installation. Successfully with only 36 hrs , after which more than 9,000 BOPD were being produced to the FPSO

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