Client: North Sea operator
Location: United Kingdom – North Sea
Challenges
- Hydrocarbon flare line
- Hot work restrictions
- Installation at height
Benefits
- No hot work
- Increased safety
- Cost-effective solution
- Large bore connectors
Scope
A North Sea operator identified a critical issue with its high-pressure flare collection header. The 10″ blowdown pipework was at risk of low-temperature embrittlement and required urgent modification. The repair posed several challenges, including the hydrocarbon nature of the line, its five-metre height, and the constrained shutdown window. To ensure a safe and efficient resolution, the operator collaborated with Katoni Engineering, who designed and engineered the pipework replacement using Quickflange™ technology.
Solution
The scope included the installation of a 10” Sch20 150# Carbon Steel Quickflange™. Before installation, temperature and impact testing requirements were carefully reviewed, with Quickflange™ meeting all compliance standards. The existing pipework was removed using clamshell cutting equipment, ensuring a precise, straight cut for the Quickflange™ installation. Following installation, a hydrostatic strength test was successfully performed using a flange joint tester, verifying proper installation with no leak paths.
Result
The Quickflange™ installation was completed in just one shift, allowing the team to efficiently progress through the remaining shutdown tasks. The elimination of hot work was particularly significant given the hazardous environment, enhancing both safety and operational efficiency. Compared to conventional welding methods, Quickflange™ offered a more economical solution while minimising downtime. Additionally, the client benefited from the availability of large-bore Quickflange™ connectors, perfectly suited for the specific work scope requirements.
For more on our Quickflange™ technology, click here.



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