Case Studies

Customer Type

International OEM

Project Location

North Sea Offshore Platform

Project Summary

Wellhead tie down pin removal using cold cutting method

Challenge Set By Customer

To provide a bespoke solution to remove pins within a wellhead which has very limited access.

Outcome

Upon completion of onshore trials which proved the method and procedure. We were then able to successfully remove the seized pins offshore.

Benefits

We successfully carried out the required operations in a timely manner thus minimizing rig downtime. We engineered and manufactured a specialist solution within the required timescale which then enabled the customer to proceed with further operations.

Customer Type

Tier 1 Subsea Construction

Project Location

North Sea, Aberdeen

Project Summary

Manufacture, inspection and testing of weld deposited CRA overlay on carbon steel pup-pieces to be used for HSP power fluid and water injection midline tie-in joints

Challenge Set By Customer

The customer experienced issues of poor quality with their previous supplier. Even though the supplier was provided the service at a low cost, the issues of poor quality meant the customer looked for another supplier that could complete the work within the timescale and that met there standards of quality.

Outcome

Wellclad were contact by the customer due to feedback on the high quality of their work. Once the specification was agreed, Wellclad, along with Roberts Machining Solutions & Professional Testing, were able to complete all the work required while meeting the high quality requirements.

We worked alongside the customers design teams to provide engineered solutions. By using our own weld team, level 3 inspectors and Roberts machines, we were able to control the quality of the work being produced.

Benefits

We were able to offer the customer a turnkey service through 3 of our divisions. They received the project fully cladded, machined, tested and ready for weld. The ultrasonic element was carried out by our level 3 inspector which ensured high quality work for the customer.

Customer Type

Construction Yard / International Operator

Project Location

South Korea

Project Summary

Production Nozzle removal on Fin Fan Cooler Flanges.

Challenge Set By Customer

To provide a technical solution using Cold Cutting Pipe cutting equipment on site to remove various production nozzle, production pipe work in place and no ingress of cuttings to system

Outcome

Maximising our expertise we came up with a Bespoke technical solution Roberts Machining Solutions carried out various on site demonstrations using bespoke engineered equipment.

Benefits

The customer originally wanted to purchase equipment and for Roberts Machining Solutions to deliver training but due to the nature and limited scopes this was not viable. Roberts Machining Solutions provided a cost efficient service whilst keeping to customers exacting timescales.

The success of this work has enabled Roberts Machining Solutions to secure a lasting relationship with the customer and continue to provide support as and when required.

Customer Type

International Construction Yard / Operator

Project Location

South Korea

Project Summary

2” Class 300 vent and drain nozzle removal.

Challenge Set By Customer

To Provide a Technical Solution using Bespoke Trepanning and Prepping equipment to give the required finish. Roberts Machining Solutions had to design manufacture Bespoke Trepanning andPrepping Machine C/W all ancillaries.

Outcome

Using our in house engineering capabilities we designed and engineered a bespoke machine to carry out the operation, Roberts Machining Solutions carried out various site demonstrations and Trails.

Benefits

Bespoke Cold Cutting Solution giving the Client ease to carry out other operations.

Production was bettered using this technique reducing any downtime an hot work permits.

Customer Type

International OEM (Subsea & Manufacturing Companies)

Project Location

Invergordon - Scotland

Project Summary

Drilling of piles within fabrication yards and provision of subsea pile drilling & cutting equipment. Works carried out throughout Europe and Americas.

Challenge Set By Customer

No.1 – Drill 8 holes for pile pinning prior to dispatch to end client. Customer required to turn around structure within 1 week relying on the efficiency of Roberts Machining Solutions .

No.2 – Provision of equipment capable of drilling piles for pile pinning with the contingency of pile cutting equipment. Customer required equipment immediately.

Outcome

No.1 – Roberts Machining Solutions mobilised equipment and technicians to be onsite 8am next day. Work site was 6 hours from base. All holes drilled and completed to customer satisfaction within 3 days.

No.2 – Due to the size of the pile, the cutting equipment had to be modified and as Roberts Machining Solutions had in house capability this equipment was modified to suit within 24hrs then dispatched immediately with the drills.

Benefits

No.1 – As Roberts Machining Solutions completed works within 3 days from receiving enquiry the customer was then ahead of schedule enabling them to cut over time and costs to meet their required date.

No.2 – Equipment was on site within 48hrs of receiving equipment reducing downtime and significant cost savings of vessel standby time.

Customer Type

International Drilling Contractor

Project Location

Singapore

Project Summary

Re-machining of the sealing areas of risers.

Challenge Set By Customer

The customer had previously used a third party machining company which took 36 hours to complete machining for each riser flange. The customer require a significant reduction in this and preferably a less complex machining operation.

Robert Machining Solutions was asked to consider an alternative approach to this.

Outcome

Roberts Machining Solutions invested significant time at the design stage and as a result developed a new product: a Riser Boring Machine.

Whilst new, it applied the tried and tested Roberts Machining Solutions approach using cold cutting technology and its standard hydro-static bearing design.

Benefits

The Riser Boring Machine was a great success, significantly reducing machining by 6 hours and minimising handling time due to the portability of the machine.

In addition, the customer had full control of the machining operations as opposed to relying on a third party.

As well as the direct reduction in machining time, the engineered solution provided by Roberts Machining Solutions enable wider operating efficiencies for the customer.

Customer Type

International OEM (Subsea & Manufacturing Companies)

Project Location

Aberdeen

Project Summary

External Key Milling 2 x Slots 180 degrees apart

Challenge Set By Customer

Riser section was manufactured incorrectly and had no slots milled, the Client

required the riser section to be offshore imminently as the schedule had already been delayed.

Outcome

Roberts Machining Solutions were contacted to provide an engineered solution to perform the scope of cutting 2 x slots 180 degrees apart with within the tight tolerance given, Roberts Machining Solutions gave this scope the attention required and had the solution within hours a solution of how to get the slots milled complete with the 30 degree flared ends.

Benefits

Due to the experience in-house in this type of work Roberts Machining Solutions were able to come up with a fast solution and carry out the scope with limitd downtime for the client.

Customer Type

International Oil Company

Project Summary

North Sea subsea pipeline issue.

The customer had a collapsed stainless steel liner on a subsea pipeline in the North Sea, where the test plug could not be retrieved and as a result production could not be re-started.

Challenge Set By Customer

The customer asked Roberts Machining Solutions to find a solution to allow the plug to be retrieved within an extremely short timescale of 14 days

This was a technically challenging situation, involving identifying a solution and then designing and manufacturing equipment which would successfully allow retrieval of the plug

Outcome

By pooling together the engineering knowledge and experience within Roberts Machining Solutions and leveraging the cold cutting technology developed over many year, the team designed a bespoke solution

Roberts Machining Solutions proactively managed internal resources and the external supply chain to manufacture the machine and delivered it to the customer within the 14 day deadline after successful testing.

The customer was delighted with the outcome, especially due to the creativity applied and the speed of response within the tight deadline

Benefits

A major benefit to the customer was that they had proven solution and a tested trial which was witnessed by them in advance of deployment.

Due to the fact that the issue had a direct effect on production, the speed of solution provided by Roberts Machining Solutions ensured that this would be mitigated.

In addition, Roberts Machining Solutions’ cold cutting technology would minimise HSE exposures.

The project was a good demonstration of Roberts Machining Solutions’ engineering knowledge and ability to find a bespoke solution to a technically challenging issue within an extremely tight timescale

Customer Type

Worldwide Operator (Field Management & Operations)

Project Location

UK Offshore

Project Summary

Emergency work to be carried out during compressor breakdown , Various flanges required immediate remedial work. Work was carried out on an offshore platform.

Challenge Set By Customer

The Platform was shutdown when enquiry was received due to equipment breakdown. Roberts Machining Solutions were required to mobilise manpower and equipment immediately for offshore support. (3hrs) – Air Freight equipment and Technician.

Outcome

Roberts Machining Solutions provided the customer with the required equipment & manpower within 3hrs to resolve the flange defects previously found. Within 2 days of receiving the enquiry all work was complete to the customers satisfaction and compressor was back in operation.

Benefits

Operator did not have to extend the shutdown making significant savings. Due to Roberts Machining Solutions having immediate response capabilities.

Customer Type

International OEM (Manufacturer of Hub Connectors)

Project Location

South Korea

Project Summary

Inspection then re-machining of damaged connectors on new build separators at fabricators for semi submersible production unit in the Far East. (Vessel Manufacturer –Italy , Final Inspection - Korea)

Challenge Set By Customer

The customer required one of its approved service providers with specialist machining capability to carry out inspection and machining scope of the project.

Given the project location, it also needed a company with the ability to mobilise resources internationally.

Outcome

The project was successfully completed over a four- month period to allow leak testing to be carried in line with the customer's specified timeframe.

The customer was very satisfied with the quality of work completed and the QA package provided.

Feedback received from the customer stated they were keen to use Roberts Machining Solutions for similar work scopes in the future on major international projects.

Benefits

The success of the project meant that the customer was back on track within the overall project delivery timeframe.

In addition, the replacement of spools and pipework with connectors was avoided, hence reducing cost to the customer.

Customer Type

Operator

Project Location

North Sea Offshore Platform

Project Summary

Internal Cutting of 2” Class 300 Nozzle on Discharge Pulsation Damper

Challenge Set By Customer

To provide bespoke equipment to internally cut through a 2” 300 nozzle within a tightly restricted area.

Outcome

Using our in house engineering capabilities we designed, engineered and manufactured a bespoke solution to complete the operation.

Benefits

Operator made significant savings as there was no requirement to shutdown production. We provided a cost efficient service whilst keeping to the customers tight deadline.

Customer Type

International Operator

Project Location

UK Offshore

Project Summary

• Perform necessary Milling of the Hatches approximately
• 600mm wide x 500mm deep thru 25mm plate

Challenge Set By Customer

The customer required hatches to be cold cut FPSO bulk heads to allow inspection of enclosed pipe work in a very tight and congested area without shutting down production.

Given the project complexity, it also needed a company with the ability to engineer the solution and mobilise equipment and resources rapidly.

Outcome

Roberts Machining Solutions provided the customer with an engineered solution with the required equipment & manpower within 3 days to resolve the flange defects previously found. Within 21 days of receiving the enquiry all work was complete to the customers satisfaction with the pipe work inspection being carried out as planned.

Benefits

Operator made significant savings. The customer was also able to concentrate on other requirements whilst Roberts Machining Solutions solely resolved the issues brought to light.

Customer Type

OEM Wellhead Subsea Systems (Manufacturer)

Project Location

Aberdeen / Global

Project Summary

Various machining scopes all ad hoc and urgent works requiring immediate resolution. Works carried out on sites worldwide.

Challenge Set By Customer

The customer required a specific solution for external turning of 200 pipes. For urgent offshore load out , Roberts Machining Solutions developed boring slides and machine modifications in 2 days and mobilised for day / nightshift to achieve the deadline.

The customer also required a weld prep machined onto a short housing and due to the features/short length Roberts Machining Solutions used an alternative method, as the standard cutting machines would not be capable due limited length of diameter.

Outcome

1.With the assistance of our in house design team Roberts Machining Solutions had equipment modified/manufactured specific to customer requirements within 2 days. All equipment was onsite with SMS technicians within 3 days of receiving enquiry. All work was completed within 10 days to the customers satisfaction.
2.With reference to the centre image – Roberts Machining Solutions provided an engineering solution to meet customer needs and was able to complete the works required within 2 days of receiving enquiry. Housing was then sent to customer same day for fabrication.

Benefits

1. Customer was able to deliver pipes ahead of schedule receiving praise from end client and in turn securing additional works.

2.Customer fabrication shop had significant savings and reduced downtime as Roberts Machining Solutions provided a turn key solution instead of sending to 3rd party machine shop.

Customer Type

International OEM (Field Joint Coating Applicator)

Project Location

Italy

Project Summary

Field Joint Machining of 12” 5LPP Coated Pipes

Challenge Set By Customer

The customer required 5LPP test pipes machined for immediate dispatch. Due to the complexity of the works they called on SMS with their specialist capability to complete the works. A 7 day deadline was set prior to dispatch of test pipes.

Outcome

The project was successfully completed over a 5 day period to the customers satisfaction. As this was ahead of schedule the customer was then able to proceed with dispatch of pipes 2 days earlier than planned.

Benefits

The customer originally wanted to purchase equipment and for Roberts Machining Solutions to deliver training but due to the nature and limited scopes this was not viable. Roberts Machining Solutions provided a cost efficient service whilst keeping to customers exacting timescales.
The success of this work has enabled Roberts Machining Solutions to secure a lasting relationship with the customer and continue to provide support as and when required.

Customer Type

Pipe laying company (through welding contractor)

Project Location

UK

Project Summary

Coating cutback and preparation of 6m and 12m length pipes in the MJ and PH Piping stations

Challenge Set By Customer

The customer required 5 layer PPT coating on pipelines of various diameters to be cut out in 6m and 12m lengths of pipe of diameters 6” to 20” as preparation for cutting to prior to pipe lay. The client needed a safer, and more accurate cut-out solution as opposed to the traditional cutting methods using for example electric planers, chain saws which are inaccurate and produce a high amount of dust.

Outcome

Roberts Machine Solutions received the scope, met with the end client to understand exact requirements. We then proposed 3 different Clyde coating removal machines. Prior to the job, extensive dialogue took place with the end client and RMS provided the machines and training to both the welding contractor and end user.

Benefits

The customer purchased the equipment, and received training on usage, in addition to their welding contractor. The job completed successfully and the client retained the machining equipment to be utilised on further pipe preparation work around the world. The success of this work has enabled Roberts Machining Solutuons to secure a lasting relationship with the customer and continue to provide support as and when required.

Customer Type

OEM (International Pipe Coating Company)

Project Location

Batam – Indonesia / Kuantan - Malaysia

Project Summary

Creation of Buckle Arrestors on 44” OD Pipes. Works carried out on various sites across APAC.

Challenge Set By Customer

The customer, within a very short time frame, required 700 plus pipes to undergo outside diameter machining to create a buckle arrestor profile. This size of pipe modification had never been carried out before onsite and a bespoke solution to eliminate out of roundness using a hydraulic internal rounding tool to achieve the machining tolerances. These were tight deadlines to meet as the customers schedule had already been delayed due to no buckle arrestors being installed on the current pipeline which was in the process of being laid offshore.

Outcome

Within days of receiving the enquiry, SMS designed and manufactured specialised equipment to suit the application. Technicians where then mobilised with the equipment to APAC. Working on a rotational pattern the work was completed, 3rd party inspected and passed within weeks of receiving the original enquiry. Project was completed to customer satisfaction.

Benefits

Due to the experience, expertise and quick response from SMS and Roberts the customer was able to dispatch the pipes with minimal delay and with significant savings on downtime.

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