In 2020, a key client in the offshore energy sector engaged Oceaneering seeking a solution to replace a pair of ageing generator coolers onboard one of their production vessels in the North Sea.
The replacement of the coolers was a critical upgrade to ensure the asset's continued production and to prevent unplanned downtime. Oceaneering's team was already on-site as part of a larger work scope, providing inspection and maintenance services for the vessel’s equipment. This positioned them well to tackle the complex project. The task, divided into two phases, involved significant logistical and technical challenges, including the size, weight, and location of the coolers, the complex workspace, and the inherent risk of completing lifting operations in an offshore environment.
The team was challenged to innovate and develop bespoke engineered solutions to address the project’s complexities.
The confined workspace, coupled with the coolers being installed at a height of 17.5 feet (5.3 m), rendered conventional methods of extracting and replacing the coolers, including using the vessel’s onboard crane, impractical. Adding to the complexity, the replacement process needed to occur without disrupting the vessel’s critical operations and within a suitable weather window.
Operating in an offshore environment demanded an uncompromising focus on safety, requiring the team to implement rigorous safety protocols and detailed risk assessments to mitigate inherent hazards.
Collaborative planning between Oceaneering engineers and the vessel’s crew was essential, ensuring clear communication and alignment at every stage of the project.
Following an initial on-site assessment, the project team recognized the need for an engineered lift solution. This required developing a detailed plan that included Finite Element Analysis (FEA) to simulate the structural stresses involved in the lift. Using a 3D model to evaluate various scenarios, the team ensured that all equipment and procedures were robust enough to handle the unique constraints posed by the vessel environment. Critical equipment included:
Scaffolding
To provide secure and stable access to the elevated coolers, the team worked with the manufacturer of scaffolding already on the vessel to confirm its suitability for use. Using the scaffolding ensured safe and efficient access for personnel and equipment during removal and installation of the cooler.
Custom Lifting Yoke
The team engineered a bespoke lifting yoke to safely handle the heavy cooler at height. This solution accounted for the weight distribution and precise alignment needed to avoid structural strain on the cooler and ensured smooth movement during critical maneuvers.
Specialized Trailers
Recognizing the confined layout, the team engineered custom trailers equipped with precision handling systems. These allowed the coolers to be maneuvered out of their restricted area safely and efficiently, prior to being attached to and lowered via the yoke. Prior to implementation, the lifting equipment and rigging components were rigorously tested to confirm compliance with industry standards. Oceaneering engineers worked closely with the vessel's crew to integrate operational insights and address any unforeseen variables.
To ensure safety and minimize risks, a comprehensive risk evaluation was conducted as part of the planning process. This assessment informed the development of detailed lifting procedures and contingency plans. Additionally, Oceaneering coordinated closely with the vessel's safety team to align on protocols and emergency measures.
Due to the need to fit the actual removal and replacement into the operational schedule and to complete operations during a suitable weather window, the first cooler was addressed in autumn of 2022. The operation was executed seamlessly, showcasing the effectiveness of the tailored solutions. The custom scaffolding provided safe and unobstructed access to the elevated coolers, while the lifting yoke ensured precise and stable handling of the heavy units during removal and installation. The specialized trailers navigated the confined workspace with ease, enabling smooth transportation of the coolers without delays.
The collaboration between Oceaneering’s team and the client’s personnel exemplified seamless integration, enabling the project to be completed safely, efficiently, and without incidents. This partnership ensured that the client’s vessel remained operational during the process, minimizing downtime and maintaining critical productivity.
The client benefitted from Oceaneering's innovative problem-solving and execution capabilities, which provided tailored solutions to address their specific challenges.
The success of this phase reinforced Oceaneering’s reputation for delivering complex engineering solutions under challenging conditions. As a testament to this positive experience, the client has chosen to continue working with Oceaneering for the replacement of their second cooler. This ongoing collaboration underscores their confidence in Oceaneering’s ability to deliver high-quality results while prioritizing safety, efficiency, and operational continuity.
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