ThinJack Service

Seized Well Flange Separation

ThinJack is a unique service to separate seized well flanges where conventional techniques either do not work or are unsuitable. As well as separating the flange, the ThinJack's hydraulic power draws seized and rusty studs through the bolt holes and overcomes seal friction. It delivers hundreds of tons of controlled force, exactly where it is needed, which is significantly higher than from conventional hydraulic spreaders or the pulling-power of drill strings. ThinJack's hydraulic power can separate in any direction whilst protecting sealing faces and hanger necks.

Our service is truly unique and for many of our clients, we are quite literally the only possible solution....

Against All Odds: A 240-Hour Mission in the North Sea

The call came in at 5pm on a Friday. Weekend plans? Forget about them.

A North Sea team was stuck – two flow line flanges, seized solid by rust and hemmed in by awkward pipework, had brought a crucial project to a halt. Until they came free, a produced water reinjection system couldn’t be completed.

With the rest of the team waiting and the clock ticking, ThinJack got the call. The pressure was on, but our crew got stuck in. This was exactly the kind of challenge we’re built for. Here's the thing about ThinJack: we'd successfully separated four well flanges for this client over the previous years. But this particular project team had never worked with us before. So when we jumped on that pre-job conference call, we could practically hear the scepticism crackling through the phone line.

‘Are you sure these guys can do it?’

Fortunately, one team member had worked with us for five years. They stepped up: ‘Trust me, if anyone can solve this, it's ThinJack’.

That endorsement turned the tide, and suddenly we had the full team's backing.

The Perfect Storm of Problems

Now, here's where it gets interesting. Remember, this is Friday evening, and we need to mobilize immediately. Our two key technicians? One was on holiday, the other was literally packing for a job in Malaysia.

In a big corporate machine, this might have been game over. But ThinJack isn't a big corporate machine: we're the kind of company that thrives on solving the impossible. By Sunday evening, both technicians were on their way to Great Yarmouth.

Monday morning: project meeting. Monday afternoon: helicopter to the platform.

By Wednesday evening: first flange separated, and the client asking us to tackle the second well immediately.

Racing Against Time

Thursday morning brought a new challenge. We needed more ThinJacks for the second well, and we needed them now. Steel was cut that same afternoon. Our team worked through Thursday and Friday evenings, welding and fabricating. Saturday morning: finishing and packing, with two of our European team members literally walking parts through supplier sites, personally quality-checking everything. Here's where it gets cinematic: our Managing Director, Guy Bromby, hand- carried the critical equipment to Norwich airport, clearing customs at 11pm Saturday night and inadvertently bypassing the platform’s usual logistics hub in Great Yarmouth (thus saving the project an extra day). He checked the equipment onto a 5am Sunday helicopter flight and sent it on its way.

When Plan A Disappears

Sunday morning crisis: one of our equipment cases had vanished somewhere in its multi-country journey. Our MD spent Sunday morning at Norwich airport, trying to track it down. (Plot twist: it eventually turned up at Glasgow airport six weeks later, mysteriously missing both tracking labels.)

Plan B kicked in immediately. 

Sunday afternoon: emergency car parts courier contacted.

Their mission? Race through the night from Louisiana, USA, to deliver backup
ThinJacks to Norwich by Monday morning.

The Moment of Truth

Meanwhile, out on the platform, our team was working with less equipment than ideal, applying 146 tonnes of controlled force to separate a completely seized flange. They developed new techniques on the spot – techniques we still use today, over a decade later.

Sunday: second flange separated successfully.

The Reunion

Monday afternoon at Norwich airport: the team reunited, celebrating a 100% successful project delivered exactly 240 hours after that first Friday evening phone call.

The client scored us 141 out of 150 (94%) across 15 different assessment areas. But more importantly, they got their project back on the critical path.

The Real Heroes

This story isn't really about equipment or engineering – it's about people going above and beyond when it matters most. Mike and Bob delivering superb work on the platform. Lesley keeping everyone informed with multiple daily updates. Richard and Guy managing the complex logistics across multiple countries. Five suppliers dropping everything to help with zero notice. Our travel company arranging 18 commercial flights across six countries. And at the heart of it all: a client who trusted us completely, even when things looked impossible.

Why This Matters

In the high-stakes world of offshore operations, even a small mechanical issue can bring a complex project grinding to a halt. That was exactly the case here: until the seized flanges were separated, the final phase of a produced water reinjection system couldn't move forward. Every hour of delay meant rising costs – and mounting pressure on the team. This story captures what ThinJack is really about: being the partner who steps up when conventional solutions fall short, when there's no room for ‘maybe next week’, and when your project's success depends on making the impossible happen in record time. Because sometimes, the difference between success and failure isn't just about having the right equipment – it's about having the right people, with the right mindset, willing to move heaven and earth to get the job done.