Offshore Temporary Boiler Solution – Keeping the Crew Warm

Project Overview

A leading oil and gas exploration company operating in the North Sea required a temporary boiler solution to address a heating capacity issue on their Floating Production Storage and Offloading (FPSO) vessel. Their existing boiler was failing to fully heat the 70-room accommodation deck, posing a challenge in maintaining comfortable living conditions for offshore personnel. Ensuring proper heating was crucial for both operational efficiency and workforce well-being.

To learn more about the operation on an FPSO click here.

Challenges

Operating in an offshore environment presented several logistical and technical challenges:

The FPSO was located approximately 10 miles off the north coast of Scotland, requiring precise coordination for personnel transfers and equipment delivery.
Harsh weather conditions and strict offshore safety regulations limited available work windows.
Every aspect of the installation required permits, adding complexity to the approval process.

The project was originally scheduled for mid-December but was delayed due to the need for replacement winches on the FROG (Personnel Transfer Capsule). Additional weather-related delays in January further complicated logistics. To learn about the function of a FROG click here.

Despite these setbacks, our experienced engineers remained prepared and adaptable.

Engineers using a FROG personnel transfer capsule for safe offshore transportation. Illuminated floating production storage and offloading (FPSO) vessel at night, with cranes and equipment visible, offshore near the Orkney Islands, Scotland.

Equipment Deployed on Project

1 x 1.3 MW Large Packaged Boiler
1 x 9000L Oil Tank
20 x 4″- BRAIDED Hose 5 Meter Lengths HTG PN16 DN100 Flanged
2 x 4″ (DN100) PN16 Flange to 6″ (DN150) PN16 Flange adaptor
2 x – 3/8inch – 5 Metre length of Oil Hose
2 x 415v 32Amp 3 Phase Power Lead 25M

Planning & Preparation

Two of our engineers, Mike and Victoria Hooper, boarded the FPSO for four days to oversee the installation. While Mike had previous offshore experience, this was Victoria’s first time working in an FPSO environment. Their time onboard required navigating the vessel’s five decks, each of which had different functions, such as accommodation, PPE storage and dining. Movement between decks was only possible via staircases, making the transportation of tools and equipment a physically demanding task.

Prior to installation, several key considerations had to be addressed:

Permit Approval: Every step, from switching on the boiler’s internal light to using a cordless electric tool, required approval from the FPSO’s facilities team.
Health & Safety Compliance: Engineers completed a rigorous safety induction, wore anti-static clothing and flame-resistant PPE, and carried gas monitors.
Equipment Selection: A 1.3 MW Temporary Boiler was chosen and configured to run on oil, as no gas supply was available onboard. To prevent freezing in extreme weather conditions, Extended Life Coolant (ELC) was selected over potable water, providing enhanced frost protection.

ELC took nearly nine hours, primarily due to the lack of required equipment aboard the FPSO.

Installation & Execution

The installation process was meticulously planned to account for the offshore environment:

System Integration: Connected the Temporary Boiler to the FPSO’s Plate Heat Exchanger to separate the systems.
Compatibility Checks: Conducted thorough checks of all pre-connected hoses and fittings to ensure compatibility with our equipment.
Adaptation: Tailored fittings for the offshore industry to work seamlessly with our Temporary Boiler.
Hose Management: Managed a 35m flow and return hose run from the existing plate heat exchanger to the boiler location.
Coordination: Strict coordination between our engineers and the FPSO’s operational team ensured all work was completed within designated time slots, avoiding interference with critical vessel activities.

Our engineers received their permit on Tuesday, began the installation and completed the commissioning by Thursday afternoon. The successful execution of this project demonstrates Rapid Energy’s ability to navigate complex offshore environments while maintaining high safety and operational standards. Each step of the process required detailed documentation, ensuring all regulatory and client requirements were met with precision.

A 2MW temporary boiler installed on an FPSO in Scotland, showcasing industrial equipment. A Rapid Energy engineer handling oil drums on an FPSO deck.

Installation and location

Outcome & Client Feedback

✔ Reliable Heating Restored – The Temporary Boiler effectively resolved the heating issue, ensuring crew comfort in harsh offshore conditions.

✔ Seamless Offshore Adaptation – Our team successfully navigated complex logistical challenges, demonstrating adaptability and expertise.

✔ Strict Compliance Met – The installation was completed without incident, adhering to stringent offshore safety regulations.

✔ Client Satisfaction – The client expressed appreciation for our professionalism and efficiency, paving the way for future collaborations on similar projects.

This case study highlights Rapid Energy’s ability to deliver tailored heating solutions in the most demanding environments. Our expertise in troubleshooting, adapting and executing technical installations ensures our clients receive reliable and efficient temporary heating, even in the most challenging offshore conditions.

To learn more about how Rapid Energy can support your boiler hire requirements, call us on 0800 464 7025 or complete the form below.

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