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The Bittern production flowlines transport fluids from subsea wells to the FPSO separation systems. Risk Based Inspection identified the requirement for intelligent pigging of the 10” P1 and P2 flowlines to validate corrosion modelling and secure long-term integrity. However, the FPSO did not have an installed pig launcher or receiver to safely load and receive pigs.

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Katoni initially undertook a SELECT phase study to evaluate two options: installation of new pig launcher and receiver units, or re-siting and repurposing existing equipment. The study incorporated 3D layout development, deck loading checks, operability assessment and initial interlock philosophy definition. Following technical and construction appraisal, installation of new units was selected as the preferred solution due to improved operability and significantly reduced offshore modification scope.

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During DEFINE, the concept was matured to a fully validated engineering solution. Structural arrangements were refined and assessed against blast loading criteria. Pipe stress analysis and STAAD structural analysis were performed to confirm system integrity and deck capacity. A Procedural HAZOP was conducted to validate the pigging and interlock sequences, with key recommendations incorporated into the final design.

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DEFINE also identified long-lead items and critical procurement risks early. Purchase specifications for the pig launcher and receiver packages were finalised, along with valve and interlock system definitions, enabling early vendor engagement and timely purchase order placement to protect the overall schedule.

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In EXECUTE, Katoni converted the validated concept into a construction-ready solution. Detailed 3D modelling was completed, piping isometrics and support drawings were issued, structural grillage design was finalised and construction workpacks were developed. The support philosophy was reconfigured to remove underdeck trimmer steelwork, reducing offshore installation complexity and access risk.

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The result was a fully integrated pigging facility designed to safely support both gel and mechanical pigging operations without introducing additional process risk to the FPSO.

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The Katoni Way – Project Delivery

This project demonstrates disciplined phase-gated engineering and proactive risk management.

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During SELECT and DEFINE, technical, operational and construction risks were identified early and engineered out before EXECUTE commitment. Critical activities such as blast load validation, interlock operability review and structural verification were completed prior to procurement release, providing the client with confidence in a fixed-price engineering solution.

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Long-lead equipment - including pig launcher and receiver packages, valve assemblies and the interlock system - were defined and specified during DEFINE, allowing early purchase order placement and schedule protection.

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In EXECUTE, Katoni delivered controlled and coordinated multi-discipline outputs including A1 and C1 construction workpacks, TAR valve changeout documentation, vendor technical bid evaluations and SDRL management. Interlock logic was refined following HAZOP findings, including improvements to balance line operation to reduce the risk of mis-launch or partial pig receipt.

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All deliverables were managed under Katoni’s Integrated Management System with structured progress reporting, action tracking and document control aligned to the client’s EDMS requirements.

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Following construction, Katoni supported commissioning activities through updated operating procedures, interlock validation and structured documentation handover, ensuring the system was safely integrated into live FPSO operations.

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