Stork delivers significant savings with leak free Turnaround

Challenge

Stork was contracted by a major North Sea operator to provide full flange management services for 852 flanged joints during a 60 day turnaround campaign. The challenge was to complete the campaign incident free, target zero leaks on N₂ (nitrogen) testing, avoid any costly re-tests and ensure start-up in line with the planned schedule.

Solution

Stork’s Onsite Machining & Bolting team took 100% ownership and accountability for all disturbed joints. To address the challenges competently, all Stork technicians involved in the turnaround attended an internal half day training course on ‘Behavioural Changes in Flange Inspection & Assembly Techniques’. The course reinforced the core principles of flanged joint accountability and encouraged individual ownership at every stage of the project, including applying lessons learned from previous campaigns.

Using a robust procedure, controlled bolting equipment, in-situ flange facing machines, applying the core principles of a leak free turnaround, and taking a fresh approach to recording the flange face condition was paramount in achieving the desired results.

By instilling ownership in all of the technicians involved, using a proven and effective flange management procedure and applying a ‘right first time’ approach, no costly N₂ re-tests were required.

Benefits

• First leak free turnaround for the Operator, which delivered substantial costs savings no N₂ re-tests were required
• Platform was back in production on schedule
• Multi-skilled personnel reducing POB (personnel on board)
• Project was completed on time, within budget, no incidents to personnel or harm to the environment