Another successful special solution from our engineering and tooling department.

In the fall of 2023, Saga Subsea received an intriguing challenge from one of our clients, a leading energy operator. The issue? A wellhead on the seabed had sustained significant damage to one of its locking mechanisms. This task demanded both precision and creativity, and Saga Subsea’s engineering team rose to the occasion.

What emerged from this challenge was the Wellhead Dressing Tool, a cost-saving and innovative solution designed to repair and restore damaged wellheads.

A Complex Problem Demanding a Special Solution

When the client approached Saga Subsea, they needed a tool that could precisely address the damaged locking profiles and polish the internal seal surfaces of the wellhead. Lead R&D engineer Walther Skjærvik explains the complexity:

– Repairing these locking mechanisms required an exceptionally precise solution. Achieving perfection was critical to ensure the tool functioned as intended to repair the damage effectively.

To meet these requirements, the team designed a tool using interchangeable diamond grinding stones and polishing pads to achieve optimal results.

Seeing Potential Beyond the Original Task

What began as a mission with a single objective evolved into something more significant as Saga Subsea and the client saw additional possibilities. The team developed the Wellhead Inspection Tool, designed to complement the Wellhead Dressing Tool by providing high-quality images of the wellhead’s interior.

– It’s difficult to get a clear overview inside a wellhead using traditional methods, Skjærvik says and continues: – The Wellhead Inspection Tool lets us identify the exact location of the damage and evaluate its extent. This precision was crucial to ensure the success of the operation.

The tool also allowed us to verify that the Wellhead Dressing Tool had successfully completed its task.

A Successful Outcome with Substantial Savings

The completed tools were delivered to the client in the summer of 2024, and the operation was a resounding success. The Wellhead Inspection Tool confirmed that the Wellhead Dressing Tool had restored the wellhead to optimal condition.

– The seal dressing operation was successful, and, to our understanding, the client saved a considerable amount compared to alternative repair methods. This was a serious and complex task, and we’re proud that the client trusted Saga Subsea to deliver the solution, says Skjærvik.

Efficiency Meets Subsea Innovation

One of the standout aspects of this project was the speed with which the tools were developed and delivered.

– We always work efficiently but precisely, Skjærvik says and elaborates: – Our deep understanding of our clients’ challenges allows us to deliver solutions faster than many others in the industry. This minimizes downtime and ensures the problem is addressed promptly.

To further guarantee success, Saga Subsea sent a tool technician to assist with the operation, a standard practice for our special solutions projects.

– Having a technician on-site ensures the tools are used as intended. This approach increases the likelihood of success and provides immediate support if adjustments are needed, Skjærvik explains.

Looking Ahead: Broader Applications for the Wellhead Dressing Tool

Although this specific challenge has been resolved, the Wellhead Dressing Tool and Wellhead Inspection Tool have the potential to address similar issues across the industry.

– This success proves our tools can tackle complex problems for other wellheads as well, Skjærvik concludes.

– At Saga Subsea, we thrive on solving tough challenges, and with our expanded engineering team, we’re ready to take on even larger and more complex projects in the future, he adds.

If you face a similar challenge, Saga Subsea’s innovative solutions can help. Contact us to learn how we can deliver results for your toughest operational problems.