Cook Spool

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Objective

Our client identified a leak on the Cook Production XT at the connection to the flow base. As a temporary production-critical solution, Aurora was contracted to design and fabricate a bypass spool to reinstate production. The project was delivered on a fast-track schedule, with engineering and fabrication teams working around the clock to meet tight deadlines. The objective was to design, fabricate, and deliver a 6” bypass spool solution to safely restore production from the Cook field within a highly compressed timeframe.

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Challenges

  • Production-critical scope requiring accelerated delivery and 24/7 working
  • Dependency on flow base availability for survey and trial fit at HCS Inverurie
  • Complex engineering requirements including stress, vibration (VIV/FIV), and HISC assessments
  • Tight integration tolerances requiring laser scanning and physical mock-up verification
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Solution

  • Full engineering design including isometrics, stress analysis (PD8010-2 / ASME B31.4), and vibration screening (DNV standards)
  • Fabrication of 6” bypass spool and 1600mm contingency spool using client-supplied super duplex materials
  • End-to-end delivery including trial fit, NDT, hydrotesting, coating, and final delivery for offshore installation
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Value to Client

Aurora successfully delivered the full scope within a highly compressed schedule, enabling rapid offshore installation and restoration of production by 31 December 2025. High-quality fabrication ensured zero issues during trial fit and installation, demonstrating reliability under pressure. The project highlighted Aurora’s agility and technical capability in executing fast-track, production-critical scopes, minimising downtime and protecting asset performance.

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