Leaking joints reduced to less than one per cent, and substantial cost savings - in excess of £100,000 by avoiding re-work alone - have been achieved on the BP Magnus EOR (Enhanced Oil Recovery) project, by Vector International working with the Wood Group. The successes are the result of a new leak reduction management service offered by Vector.

This new approach to leak reduction - involving close management of every stage from joint component manufacture and supply to installation - has been successfully proven to see leaking joints plummet to less than one per cent on commissioning. This is significantly lower than is often observed - according to HSE data cited by UKOOA recently, 17 per cent of hydrocarbon releases can be attributed to leaking joints and 25 per cent of leaks occur on start up.
Time, and therefore cost, savings were substantial as a result of implementing Vector's leak reduction initiative, both by minimising the repair and modification work needed offshore, and by ensuring leak-free joints first time - avoiding delays while leaks were rectified. Not only can the contractor benefit from completing in line with (or ahead of) commissioning deadlines, but any potential loss of production caused while repairing leaking joints is also virtually eliminated.

Among the key elements of the initiative is the inspection of all joint components - Vector connectors and associated interfacing equipment - on-shore, at each stage of production and testing, prior to shipment. This guarantees that all components are in working order, and is crucial to the high levels of leak-free connections first-time, which generated the significant cost savings.

"By inspecting and testing all joint components at every stage, we're able to identify any problems at a point at which it costs significantly less to rectify them - the cost to repair or replace components can be ten to fifteen times greater once offshore - and before transportation and initial installation costs have been incurred," explains Ian Robinson, sales and marketing director at Vector International. "It means all components arrive offshore fit for purpose. Furthermore, by inspecting before the goods have been supplied to the project, the cost of any re-work remains the onus of the supplier or fabricator," he adds.

Extensive training is a further key element of the management service, so that all those involved in handling the connection components at any stage - start of project to final installation and commissioning - fully understand the requirements of the joint and its make-up. This ensures that damage commonly caused unwittingly in construction, testing, transportation or assembly (particularly of the sealing surfaces) is avoided, and correct and effective installation achieved.

"Whether by mishandling, chemical cleaning, over-torquing, or many other ways - how easily damage can be caused and the severely detrimental effect it has on joint integrity (even an apparently 'minor' defect) is often simply not understood, so effective competence training can make all the difference," Robinson explains. "Indeed, the key role of training in successful joint management is stressed in the UKOOA guidelines launched in the autumn - a further recognition of its importance."

Offshore, the availability of trained, skilled and experienced Vector technicians as part of the leak reduction service allows all sealing surfaces to be thoroughly checked, and ensures that joints are assembled in accordance with Vector's operational standards. It also enables any non-conformances and necessary remedial actions to be dealt with rapidly.

Moreover, significant time and cost savings were achieved on BP Magnus EOR through use of Vector's new RIT (Reverse Integrity Testing) rings - a means of testing and verifying individual joint integrity, in-situ, as the joints are installed, without having to conduct a full line leak-test. What's more this method uses far lower levels of test medium than a traditional full system test, saving money and improving safety, especially when using a traditional gas leak test. RIT rings are also proven to be a more effective method of detecting leaks than a traditional test.
Wood Group project manager on BP Magnus EOR Terry Daniels says: "The use of RIT rings to test flowline and compressor discharge pipework decreased installation and commissioning times and gave confidence in the system's high pressure containment integrity."

The benefits and resounding success of the leak reduction initiative were apparent on commissioning BP Magnus EOR. "That no clamp connector joint failures were reported during commissioning more than justifies the up-front cost of the service, which is significantly less than the potential cost of repairs that would otherwise have been required as each leaking joint was discovered," Daniels enthuses.

Drewan Mouat, BP's offshore completions manager adds: "Traditionally problems such as leaking joints discovered during commissioning can mean significant delays in start-up, and of course lost production - at considerable expense. The trouble-free start-up the Magnus EOR project achieved by ensuring no leaking joints first-time justified the cost of the inspection, training, testing, and management services provided by Vector. It's been a great success, and should definitely be adopted by all projects."