DCN was contracted by a major Oil & Gas operator to develop and deliver a specialized hyperbaric repair methodology and system for the permanent repair of multiple cracks in brace connections on an existing offshore platform in UK waters.
Previous repair attempts using conventional habitat systems had proven unsuccessful, highlighting the technical complexity of the project. In response, DCN engineered an innovative Micro Habitat solution, specifically designed to operate in challenging hyperbaric offshore conditions. For this innovative invention, DCN was awarded the Subsea Expo Award.
The scope of work covered a fully integrated approach from engineering through to offshore execution. This included the development and fabrication of the Micro Habitat system, along with Factory Acceptance Testing (FAT). Welding procedures were developed and qualified, and diver welders were certified at DCN’s Hyperbaric and Wet Test Centre in Bergen op Zoom.
To ensure reliability and performance, the system underwent a rigorous testing program at DCN’s in-house facilities. Following successful validation, DCN mobilized the complete welding spread and specialist team onboard a Diving Support Vessel (DSV) for offshore operations.
Subsea preparatory works were carried out, including cleaning and the installation of dedicated work platforms. The Micro Habitat was then installed at the required locations, after which repair works were executed at four locations on the platform. These activities included excavation, hydro-arc gouging, pre-heating, and welding in accordance with the qualified procedures.
All welds were verified through subsea Non-Destructive Testing (NDT), followed by an as-left survey to confirm the integrity and final condition of the structure.
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