the challenge
The global energy landscape is shifting toward cleaner, more sustainable sources, making offshore electrification a critical strategy for reducing carbon emissions from oil and gas platforms. A major power-from-shore project on the Norwegian continental shelf required a highly specialized cooling system to support the reliable operation of its offshore electric power systems.
Operating within an ATEX Zone 1 hazardous area, this project presented severe operational and environmental hurdles. To succeed, the system design had to overcome the following key challenges:
- Cooling Medium: A design requirement of 160 cubic metres per hour.
- Operational Flexibility: Providing a highly adaptable system capable of remote switching and partial maintenance without compromising overall cooling performance.
- NORSOK Compliance for Skid: Safely withstanding the threat of fires and heat load.
- Blast and Fire Protection: Safely withstanding the persistent threat of extreme explosive events and external fires inherent to hazardous offshore environments.
- Thermal Expansion: Protecting the system from extremes of temperature.
the solution
To meet these demanding specifications, Calder engineered and manufactured a cutting-edge, skid-mounted offshore cooling pump package built for safety, reliability, and efficiency.
At the core of the Calder system is a closed-loop cooling circuit that circulates a Tri-Ethylene Glycol (TEG) and water mix at a design flow rate of over 160 cubic metres per hour. The medium is pumped through Duplex stainless steel plate heat exchangers, cooled by seawater, before returning to the consumers.
Key engineering features of the solution include:
… cooling medium: The cooling medium will be circulated in a closed loop system with a design flow rate of 160 cubic metres per hour.
… operational flexibility: A modular design enables the pump and motor from one of two lines to be used in conjunction with the heat exchanger from the other, ensuring maintenance does not compromise overall cooling performance.
… NORSOK compliance for skid: The skid base is NORSOK-certified and is treated with a fireproof paint to protect the structure during heat load.
… blast and fire protection: The system is housed in a robust 316 stainless steel environmental enclosure that provides blast and fire protection, noise attenuation, and environmental shielding. It includes an HVAC unit with air filtration, mist elimination, and space heating.
… thermal expansion: A skid-mounted expansion vessel with a nitrogen pre-charge accommodates thermal expansion and supplies suction pressure. Smart temperature and pressure control valves adjust flow in real-time, while dual pressure-safety valves provide overpressure redundancy.
the result
The successful delivery of the Calder cooling pump system provides the client with a safe, stable, and highly efficient solution that requires minimal manual intervention. Real-time automated adjustments optimize energy use while keeping the system within safe operating parameters at all times.
Ultimately, this high-specification system enabled the client to take a measurable step toward decarbonising their offshore operations. Furthermore, the project adds to Calder’s growing portfolio of electric-driven pump packages, demonstrating the technology’s adaptability for future energy transition projects, including offshore wind farms, hydrogen production, and carbon capture and storage (CCS) facilities.
get in touch
To talk through your next project, please call +44 1905 751790, or email sales@calder.co.uk.
