Expedited Overhaul of Seawater Coarse Filter Assembly for BP Clair Ridge
Overview
Client
BP Clair Ridge
Timeline
Six (6) working weeks.
Sector
Oil and gas
Project
Expedited overhaul of super duplex seawater coarse filter assembly
Objective
Breakdown, inspection and repair, including provision of critical proprietary components, reassembly and testing.
Result
Equipment back into service in the agreed time frame
Background
BP Clair Ridge, a major oil and gas production facility located in the North Sea, relies on treated seawater to support its offshore operations. The seawater coarse filter package operates 2 x 100% filters, duty/standby, each processing up to 2,700m3/hr of seawater. The package provides filtered seawater at 80 microns to a potable water maker, the fire water system, cooling system and the EOR (enhanced oil recovery) system. The duty filter experienced performance issues and was taken off line, exposing a threat to operations, necessitating an urgent overhaul.
BP Clair Ridge operations team approached CFL to provide an expedited repair solution. CFL developed a detailed project timeline outlining each phase of the repair process, demonstrating their abilities and providing confidence to BP that the seawater coarse filter assembly could be restored to optimal working condition. The project required meticulous inspection, potential replacement of damaged components, and precise reassembly within a given timeframe, in order to minimise exposure to operational downtime.
Objectives
Expedited repair
Quickly and efficiently overhaul the seawater coarse filter assembly to reduce exposure to down time.
Thorough inspection
Conduct a comprehensive breakdown and detailed visual inspection of all components.
Component replacement
Replace and repair critical proprietary components exhibiting signs of wear or failure.
Precise reassembly
Ensure accurate reassembly and rigorous testing to verify performance prior to release.
Solution Provided by CFL
CFL employed a structured approach to overhaul the seawater coarse filter assembly, focusing on expedited repair and comprehensive component analysis. Key steps included:
Full strip-down
Disassembly of the complex multi-component seawater filter assembly to allow for detailed inspection and repair.
Detailed visual inspection
Thorough examination of individual components for signs of wear and failure, with findings documented in a formal report to the client.
Replacement and repair
Targeted replacement and repair of critical components identified during the inspection.
Reassembly and testing
Reassembly of the equipment with precision, followed by rigorous testing to ensure operational integrity before releasing it back to the client.
Implementation
1. Disassembly and inspection
CFL mechanical and technical team conducted a full breakdown down of the seawater coarse filter assembly. This process involved the careful disassembly of multiple complexed components to expose all parts for inspection. Each component was meticulously inspected for wear, corrosion, and signs of impending failure. Findings were compiled into a comprehensive report, highlighting critical areas needing attention.
2. Detailed reporting
The detailed visual inspection report was submitted to BP Clair Ridge operations team, providing a clear understanding of the current condition of the filter assembly. The report included photographs, condition report for individual components, and recommendations for component replacement or repair.
3. Replacement and repair
Based on the inspection findings, CFL replaced damaged proprietary components and repaired others to restore functionality. Key actions included:
- Pickle and passivation of individual super duplex screen assemblies to remove solidified marine material, and to restore the protective oxide layer.
- Repair of main drive shaft and drive components.
- Repair of backwash assembly.
- Replacement of rotating component bearings.
- Replacement of soft seals and gaskets.
4. Reassembly and testing
Following repairs, CFL reassembled the seawater coarse filter assembly with precision. The reassembly process included:
- Re-alignment of components to ensure accurate fit and function.
- Installation of new soft seals and gaskets.
- Calibration of rotating parts for optimal operation.
- Mechanical rotation testing to simulate in service operation to ensure reliability.
Results
Enhanced reliability
The overhaul restored the seawater coarse filter assembly to optimal condition, enhancing its reliability and extending its service life.
Reduced downtime
The expedited overhaul process removed the exposure risk, allowing BP Clair Ridge to quickly resume normal operations.
Comprehensive documentation
The detailed inspection report provided valuable insights into the condition of the assembly, aiding future maintenance planning.
Conclusion
CFL’s expedited overhaul of the seawater coarse filter assembly for BP Clair Ridge successfully addressed critical wear and failure issues. Through a systematic approach involving detailed inspection, targeted repairs, and precise reassembly, CFL delivered a robust solution to restore the filter’s reliability and efficiency. The project exemplified our ability to provide quick and effective maintenance solutions in order to satisfy the complex needs of offshore operations.
Key Takeaways
Expedited repair
Efficient overhaul process minimised exposure to potential operational downtime.
Thorough inspection
Comprehensive visual inspection identified and addressed critical wear and failure points.
Precise reassembly
Accurate reassembly and rigorous testing ensured optimal performance.
Client satisfaction
Client Feedback
“The expedited overhaul and repair of our seawater coarse filter assembly provided by CFL was crucial in restoring treated seawater supply to our potable water maker, fire water requirements and our EOR (enhanced oil recovery) system. The expedited inspection and precise overhaul process minimised our expose to potential downtime of the plant. We appreciate the detailed reporting and professional approach throughout the project.”
