Leak repair of Xmas Tree Flange

Project Description

The IK Subsea team undertook an urgent repair on a X-mas tree flange couple positioned at a water depth of 820 meters. This critical repair was essential for the uninterrupted supply of gas crucial for power production in the Philippines.

The team faced a considerable challenge—a leak in a flange couple with a pressure of approximately 200 Bar, compounded by limited space and accessibility. Initial studies by the team generated multiple potential solutions. One innovative idea involved utilizing a special sealant that solidifies and seals specifically where there is a drop in pressure. In this approach, a custom clamp with an integrated sealant injection port  would encircle the flange, and the sealant would be injected into the leakage. While such a process is typically executed from within, the unique circumstances and accessibility issues required a different approach.

Following numerous trials, tests, the development of various prototypes, and Factory Acceptance Testing (FAT), the installation proved to be successful, resulting in significant cost savings. Shell acknowledged IK Subsea’s exceptional efforts by presenting them with an “Outstanding Achievement Award” in recognition of our successful and innovative resolution to the urgent repair.