M.Sc.

ENM233 Materials and Corrosion Seawater Injection Case Study

1. This case study replicates an actual failure which occurred some years ago. Several millions of pounds worth of equipment and lost production was at risk. Clearly, the problem has already been solved, but, as is typical of many large failures, there were a number of technical, organisational and other issues which caused it. The original investigation took some weeks to sort out, and you are being asked to come to an initial conclusion in a few hours of work. Your advantage is that more than sufficient information is at hand for immediate access and you will not have to wait for documents to be found or analyses to be done. Nevertheless, it will be obvious that some urgency and organisation will be required on your part. SCENARIO You are the corrosion engineering specialist of a newly established company of consultants specialising in the provision of Failure Analysis, and other, specialised services to the offshore industry. Choose a name for your company. The Facilities Superintendent of Zonko Offshore PLC wants you to do an investigation into an expensive failure that has occurred on one of their offshore platforms. Your company realises that a good response here could mean a lucrative ongoing contract and you are eager to provide a fast, professional response. The platform (Zonko Sporran Delta) was to be commissioned for oil production next month. In order to improve recovery rates a seawater injection (SWI) system was fitted shortly after the platform was installed in the North Sea six months ago. Yesterday, when the system was to be used for the first time to enhance production, it was found to be leaking in a number of places. The system was immediately shut down and oil production is proceeding at much reduced rates. The main board of Zonko in Houston is pressing for a quick answer (screaming) and you have just left the Facilities Superintendents office. Decide what to do, and proceed with your investigation. A preliminary answer will be required in a few weeks. The Superintendent requires a short, technically complete, report (with recommendations) before you will be paid.

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RUNNING THE CASE STUDY 1. There will be a short initial briefing for the whole class when there will be an opportunity to ask any questions about the general structure of the case study. Everyone will then have an opportunity to consider how to assess the failure. I have a number of items of information which may, or may not be relevant to the problem. You will need to decide what information you may need. I can only give a response to specific requests for information. Vague requests will be met with vague answers. It is helpful if you make your requests in writing so that I can give, if possible, a written response. I will not be deliberately misleading. You will have an opportunity to discuss your main conclusion(s) and recommendation(s) with me. If you are seriously in error then specific guidance will be given at this stage. Subsequently, an individual written report (directed to the Facilities Superintendent) will be required. Assessment will be based on the following: Management and organisation of the investigation Quality of the written report

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Reports should be clear, concise and with specific conclusions and recommendations suitable for the context. While the reports should be technically sound, details should be relegated to an Appendix or (as appropriate) omitted. The word guide is 2,500.

Laurie Power