We are katoni engineering
Safer / Greener / More efficient
SAFER|GREENER|STREAMLINED
SAFER|GREENER|STREAMLINED
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Two corrosion failures on the same vessel removed any ambiguity. The next shutdown would either be planned, or forced.
Across ageing North Sea infrastructure, this situation is increasingly common. Equipment operating beyond its original design life, known degradation mechanisms already active, and shutdown windows that leave no room for error.
In this case, the client’s glycol reboiler still column had suffered repeated excessive wall thickness loss due to corrosion of the existing carbon steel vessel. Continued operation presented unacceptable risk. The requirement was clear: deliver a replacement that would not fail in the same way, and that could be installed without disruption to the wider system.
A structured assessment of material performance led to the selection of super duplex stainless steel. Its strength and corrosion resistance provided a step change in durability, addressing the root cause rather than replicating it.
The replacement vessel was defined against strict operational and design criteria, including capacity, pressure, and temperature requirements.
Compliance was embedded throughout, covering:
Regulatory requirements were managed in full, including the Pressure Equipment (Safety) Regulations, PUWER, and LOLER.
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A critical aspect of delivery was strict adherence to the client’s own engineering standards and specifications. These imposed requirements went beyond baseline industry codes and demanded a higher level of rigour across design, fabrication, inspection, and documentation.
Meeting these standards required detailed coordination, robust quality control, and consistent engineering discipline throughout the project lifecycle.
The defining challenge was integration into an existing offshore system.
The replacement still column had to align exactly with all existing piping connections. The shutdown window was fixed and limited, leaving no opportunity for on-site adjustment. The use of closing spools was not viable.
This required:
There was no margin for misalignment. The vessel had to fit first time.
The vessel was engineered, fabricated, and installed within a constrained annual shutdown.
Execution outcomes:
The installation proceeded exactly as planned, with no corrective work required offshore.
The project delivered both immediate assurance and long-term operational value:
Brownfield delivery depends on precision and ownership of detail. This project required both.
Success came from understanding the constraints, engineering to meet them exactly, and maintaining control from specification through to installation.
Strict compliance with demanding client standards ensured quality was not just achieved, but demonstrated at every stage.
An independent structure enabled decisions to be made without delay. When timelines tightened, the response adjusted immediately to protect delivery.
A critical vessel with a history of failure was replaced with a robust, engineered solution designed for long-term performance and seamless integration.
Delivered to exacting standards. Installed without modification. Completed without compromise.
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