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Case study
Live Hot Tapping on Titanium Seawater Line – Valhall Platform
Background
Aker Solutions AS required the addition of a 3-inch vent line to an existing 12-inch titanium seawater pipeline on the Valhall offshore platform. Due to operational constraints, a shutdown of the system was not feasible. The client needed a solution that would allow for safe and efficient modification of the pressurized line while maintaining continuous operation.
Key Deliverables
Custom-engineered Super Duplex hot tapping clamp.
Full offshore installation and hot tap execution.
No system shutdown or production impact.
Leak-tested and certified in accordance with offshore standards.
Documentation package including IOM manual, design report, test reports, and material traceability.
Client Benefits
Maintained continuous operation of a critical titanium seawater line
Eliminated the need for costly and complex shutdown procedures.
Received a complete turnkey solution with full documentation and offshore support.
Mitigated technical and operational risk through IK’s expertise and certified equipment.
Challenge
Titanium presents unique challenges for pressure-containing modifications due to its high strength, low modulus, and limited availability of compatible sealing and cutting tools. The offshore environment also imposed strict requirements for safety, reliability, and minimized disruption. Traditional welding or mechanical tie-in solutions were not viable options due to the live nature of the line.
Solution
IK provided a complete hot tapping solution, tailored specifically to the requirements of the Valhall platform and the titanium pipeline. The scope included:
- Design and supply of a 12″ x 3″ 150# hot tapping clamp, manufactured from Super Duplex stainless steel
- Provision of certified hot tapping equipment
- Offshore installation and execution of the hot tap, including site preparation, leak testing, and isolation of the tapping machine via a client-supplied 3″ ball valve
All design, fabrication, and testing were completed in accordance with relevant offshore and pressure equipment standards, including EN 13445, ASME B16.5, and NORSOK M-650. The solution was designed for a 20-year service life, with packer replacement recommended after 10 years.
Results
The operation was completed safely, on schedule, and without any impact on ongoing platform operations. The clamp installation and hot tap were executed in accordance with predefined procedures, including job safety analysis, pressure testing, and post-installation verification. Aker Solutions successfully avoided system downtime and met its operational goals.