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Oil & Gas Facility Maintenance

Pipelines, facilities & platforms. EPC projects on flowlines and pipelines, the facilities they feed, and the wellhead platforms at the end of them: built, maintained and kept in service.

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The service

Keeping flow stations and platforms in service.

Facility maintenance is a large share of Winsko's record: corroded on-plot piping, flare lines, drain systems, metering skids, inlet manifolds, platforms and helipad structures at flow stations, refurbished for the operators who run them.

The work runs from planned programmes in phases, such as the corroded on-plot piping at Cawthorne Channel 3, to emergency repairs on a test header bypass line, scaffolding erected around live equipment, and the calibration and certification of pressure vessels and valves.

The plant and crews are Winsko's own, so a job can mobilise from the Trans-Woji jetty without waiting on hired equipment, and a crew can live on site on a house boat until the plant is back in service. Repairs on the flowlines that feed these stations sit under flowline and pipeline construction and maintenance.

Technician in red coveralls and a white hard hat working at a valve on a flow station deck
Valve work at a flow stationPhotograph

Where it sits in the project lifecycle

  1. 01Engineering / Design
  2. 02Procurement & Logistics
  3. 03Fabrication
  4. 04Construction / Roads / Erection / Installation
  5. 05Testing / Pre-Commissioning
  6. 06Commissioning
  7. 07Operation, Maintenance & Handover

By the numbers

16"
Flare line replaced
Sectional replacement of the corroded flare line at Krakama flow station (2017)
2016
Flow station piping
Corroded on-plot piping refurbished at Cawthorne Channel 1, 2 and 3, 2016 to 2018
2024
Pressure equipment certified
Pressure vessels and valves calibrated and certified at Awoba
2001
Incorporated
Indigenous Nigerian company, Port Harcourt

Scope of work · 06 work packages

What the work covers.

  • 01

    Flow station piping

    Corroded on-plot piping refurbished in phases, with flare lines, drain systems and bypass lines.

  • 02

    Process equipment and skids

    Metering skids, inlet manifolds, surge vessel bellows, engines, pumps and their associated piping and structure.

  • 03

    Platforms and structures

    Utility house, drain and pump platforms, walkways, helipad structures and safety mesh.

  • 04

    Scaffolding and access

    Scaffolds erected and struck around live equipment, manifolds and metering skids.

  • 05

    Integrity checks

    Inspection and assessment of lines and manifolds to decide what to repair, and when.

  • 06

    Pressure equipment

    Calibration and certification of pressure vessels and pressure safety valves.

Method · 06 stages

From call-out to the plant back in service.

How a facility repair or refurbishment runs, with the checks that close each stage.

  1. 01

    Call-out and assessment

    The operator reports corrosion or an inspection finding. The crew inspects it, judges the wall loss and the access, and agrees with the operator whether to repair, replace a spool or refurbish the unit.

    • Location and size of the defect recorded
    • Repair method agreed with the operator
    • Materials and spools confirmed
    Technician in red coveralls at the open manway of a green pressure vessel on a flow station deck
    Opening a vessel manwayPhotograph
  2. 02

    Mobilisation

    Pipe, fittings and plant load out at the Trans-Woji jetty. Barges take the spread to site; for longer jobs the crew lives on the house boat.

    • Marine transfer plan and life jackets
    • Equipment certificates on board
    • Spill kit with the spread
    Jetty edge with a 'No life jacket, no entry' sign and a barge alongside
    No life jacket, no entry: the Trans-Woji jettyPhotograph
  3. 03

    Isolation and access

    The line or unit is isolated and depressurised with the operator under a permit to work. The crew erects scaffolding to reach the joint, with barriers and permits for the area.

    • Permit to work and isolation in place
    • Gas test before entering the pit
    • Scaffold inspected before use
    Scaffold tubes and boards rigged under a flow station deck above the creek
    Scaffolding under a flow station deckPhotograph
  4. 04

    Repair

    Corroded sections are cut out and replaced with new spools welded to the qualified procedure, structures are repaired, and bolted joints are remade to the specified torque.

    • Material grade and rating matched to the line
    • Welds made by qualified welders
    • Every weld logged
    Crew renewing the steel frame of a flow station deck, the grating lifted to expose the beams
    Deck steelwork renewedPhotograph
  5. 05

    Test and inspection

    Welds are inspected, then the repair is leak-tested or pressure-tested as the operator specifies before the plant goes back into service.

    • Weld inspection reports
    • Leak or pressure test witnessed
    • Coating restored and holiday-tested
    Pressure gauge connected by a hose beside a spanner on an absorbent pad, on a flow station deck
    Pressure gauge and test hosePhotograph
  6. 06

    Reinstatement and close-out

    The pit is backfilled or the scaffold struck, the site is cleaned and reinstated, and the operator receives the repair record.

    • Site left clean, waste removed
    • Plant returned to the operator
    • Repair record handed over
    Crew in life jackets working at a wellhead on a platform over the creek
    Crew at a wellhead platformPhotograph

Plant and equipment

Repair crews that can leave the jetty today.

Maintenance is won on response time. The plant below is on Winsko's own equipment register.

Swamp buggies
8 × Wilco 3200
Speed boats
5, single and twin engine
House boats
40-man and 80-man
Welding machines
27 units, diesel and electric
Generator sets
7 sets, 10 to 150 kVA
Gas testers
3 units
Flush pumps
4 units
Chain blocks
Lots
Generator sets on the covered deck of a house boat
House boat generator deckPhotograph
Low-bed truck and a swamp buggy at the waterfront
Low bed and swamp buggyPhotograph
Tug boats and barges at the jetty
Tugs and bargesPhotograph

Track record

Refurbishments, repairs and certifications on record.

A selection from the list of jobs in the company profile.

  1. 2024Ekulama 2 platform general maintenance and rehabilitationEkulama
  2. 2024Calibration and certification of pressure vessels and pressure valvesAwoba
  3. 2018Corroded on-plot piping refurbishment, phases A and BCawthorne Channel 3 flow station
  4. 2017Sectional replacement of the corroded 16" flare lineKrakama flow station
  5. 2017Utility house platform, drain system, metering skid and inlet manifold refurbishmentKrakama flow station
  6. 2017Emergency repair of the test header bypass line, and replacement of corroded helipad safety meshCawthorne Channel
  7. 2016Corroded on-plot piping refurbishmentCawthorne Channel 1 and 2 flow stations

Inspection and testing

A repair is only finished when it is proven.

Each repair leaves a record the operator can audit: what was found, what was done, and the test that proved it.

01Defect assessmentThe size and cause of the defect, and that the chosen repair suits itWhenBefore the repairRecordAssessment note, photos
02Material checkPipe, fittings and consumables match the specification and the line's ratingWhenBefore fittingRecordMaterial certificates
03Weld inspectionNo rejectable defects in the new weldsWhenEvery weldRecordVisual and NDT reports
04Leak or pressure testThe repaired plant holds pressureWhenBefore return to serviceRecordTest record, witnessed
05Coating restorationThe repaired area is protected against corrosion againWhenBefore backfillRecordHoliday test record
06Valve and vessel certificationPressure safety valves and vessels perform to their set points and ratingsWhenOn the operator's scheduleRecordCalibration and certification reports

Codes commonly specified for this work

  • ASME PCC-2Repair of pressure equipment and piping
  • API 570In-service piping inspection
  • API 510Pressure vessel inspection
  • ASME B31.3Process piping
  • ASME IXWelding qualifications
  • AWS D1.1Structural welding

Health, safety and environment

Working on live plant, safely.

Maintenance happens next to lines and vessels that are, or recently were, full of hydrocarbons. The controls are agreed with the operator before anyone breaks a joint.

  • 01

    Hydrocarbon release

    Isolation and depressurisation agreed with the operator, gas testing before and during the work, and a spill kit on site.

  • 02

    Confined spaces

    Entry only under a permit, gas tested first, a standby person at the entrance and a rescue plan.

  • 03

    Work at height

    Scaffolds erected and inspected before use, harnesses on platforms and edge protection on walkways.

  • 04

    Hot work

    Hot work permit, continuous gas monitoring, a fire watch and extinguishers at the joint.

  • 05

    Swamp and water

    Life jackets on the water and the barge, planned boat transfers, and a rescue plan for every location.

  • 06

    Pressure testing

    A marked exclusion zone, pressure raised in stages, and only the test crew inside the barrier.

Our HSE approach

Video

On site.

Crew at height on a process structure, a colleague watching from the ground

FAQ · 04 questions

Questions, answered.

Short answers about oil & gas facility maintenance at Winsko, from the company profile.

01

What oil and gas facility maintenance does Winsko do?

Refurbishment of corroded on-plot piping, flare lines, drain systems, metering skids, inlet manifolds, engines, pumps, platforms and helipad structures at flow stations, scaffolding around live equipment, integrity checks, and calibration and certification of pressure vessels and safety valves.

02

Which flow stations has Winsko refurbished?

The company profile records refurbishment of corroded on-plot piping at Cawthorne Channel 1, 2 and 3 flow stations between 2016 and 2018, work at Krakama flow station including its utility house platform, drain system, metering skid and inlet manifold, and sectional replacement of the 16-inch flare line there in 2017.

03

How quickly can Winsko mobilise to a repair?

The barges, swamp buggies and welding spread are Winsko's own, so a repair mobilises from its Trans-Woji jetty in Port Harcourt without waiting on hired plant, and a crew can live on site on a house boat until the plant is back in service.

04

Does Winsko calibrate and certify pressure equipment?

Yes. In 2024 Winsko calibrated and certified pressure vessels and pressure valves at the Awoba field location for Newcross Exploration & Production.

Also in the scope

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Operational base / jettyElshcon Close, Trans-Woji (Slaughter), Port Harcourt, Rivers State

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