Epoxy injection at the Culzean platforms in the UK

The challenge

After installation of the three Total-operated Culzean platforms, Total discovered movements of several caissons within the support guides. To ensure a long lifetime for the caissons it was decided to fill up the gaps to prevent fatigue in the caissons or the supporting structure.

Solution, the first phase of the project 

SubC Partner were contacted by Total to engineer a solution. After tests on mock-ups conducted at SubC Partners workshop in Esbjerg, a special epoxy mixture was developed ensuring the right qualities for both strength and flexibility for the epoxy.

The work included the development of custom-made seals, development of epoxy mixture, injection techniques, equipment, offshore operation etc.

Further, training of the rope access technicians was conducted, as the work location is situated 5-16 meters above sea level, to ensure high job performance.

The first part of the project has been performed in 2018, and the method shows a trouble-free way of filling the gap between the caissons and guides. 

Solution, the second phase of the project 

The second phase includes the continuation of the installation of wedges and pumping resin into the gap between the guide funnels and caissons as well as the reinforcement welding on the three platforms.

Three of the guides require a special way of sealing the caisson openings, for the epoxy injection.

A 1:1 mock-up was conducted at our workshop in Esbjerg to verifying the design of the custom-made seals. First, it was partially filled, and next top filled with water. This was done to check leaks at the spill tray area and the top hat. The mock-up test is always conducted to ensure it fulfils our demands.

The second phase of the project will be finished during summer 2019.