the challenge
For this NORSOK and ATEX Zone 2 compliant pump package, the challenge was the limited footprint. Never have we had to fit so much equipment into such a small space. As such, the Calder engineers had to dig deep into their experience of designing compact pump skids.
The limited available space for this pump skid is due to it being a brownfield development – in this case, a subsea tieback to an existing platform. Space on offshore platforms and rigs is expensive and, therefore, usually limited. On new-build projects, the design incorporates all of the necessary equipment and the platform is built in stages, one deck at a time, so access is not an issue. With brownfield developments, where an existing platform has equipment added to it, the space for a pump skid is minimal. Access to the location is frequently even more problematic as the new pump skid has to be fed between existing equipment. With the rise in the electrification of existing platforms and life extensions on old platforms, demand for compact and modular pump skid packages has increased significantly over the last 15 years.
the solution
A good starting point for this project was the space we saved through good pump selection. The Hammelmann HamPro pump has a vertical design, giving a much-reduced footprint to that of other pumps. Through rigorous 3D modeling and spatial planning, every single component’s location and orientation was analysed to maximise efficiency without compromising the strict safety requirements of an ATEX environment.
Whilst other space savings were achieved through component selection, the success of this package is down to good design. For every component on this skid, consideration was given to its positioning. Our engineering team have many years of experience designing compact pump skids, and they relished the challenge presented by this project.
In addition to maintenance access, an important aspect of the design is component removal and replacement. You can see from the images that the Hammelmann pump is easily accessible and there is an ample aperture through which the pump can be removed. For the electric motor, complicated though the removal may look, the process is relatively straightforward. The stainless steel enclosure above it, which houses the air blast cooler, was designed with motor replacement in mind. The enclosure is designed so that each panel section is easily removed leaving a significant space through which the motor can be lifted and removed/replaced with minimal operational downtime.
A significant advantage for Calder is that our design office adjoins the factory. This means the design team are able to watch the build progress and were on hand to support the build team with what was a challenging project. Whilst it is a complex pump skid, we have achieved excellent access.
the result
Our customer received a methanol injection package:
- designed for the exceptionally restricted footprint available, thus avoiding costly platform modifications.
- with excellent maintenance access and major component replacement that translates directly to less system downtime and higher overall productivity.
- fully ATEX Zone 2 compliant to operate safely within explosive offshore environments, mitigating risk for platform personnel.
- benefitting from Calder’s integrated design and manufacturing process ensuring that the strict spatial constraints do not compromise the system’s structural integrity or performance reliability over its operational lifespan.
get in touch
To talk through your next project, please call +44 1905 751790, or email sales@calder.co.uk.
