Hydraulic power plant for offshore FPSOs

HPU for Off-Shore FPSO in Guyana

Hydroservice containerized HPU for Offshore FPSO in Guyana

Power and Reliability for the Open Sea

For a major project involving one of the world’s largest riser pull-in systems, Hydroservice designed and built a containerized Hydraulic Power Unit (HPU) destined for an FPSO unit operating offshore in Guyana.

The project required very high technical and certification standards to ensure efficiency and safety in a tropical marine environment with high corrosiveness. The system is part of a complex deepwater offshore development, involving a newly built FPSO unit equipped with a spread mooring system and facilities for crude oil processing, storage, and transfer.

The HPU powers a package of high-capacity equipment for managing riser pull-ins, umbilicals, and moorings, including winches rated up to 817 tonnes and components designed to operate continuously for 20 years without disconnection.

Customer Requirement

Carry out operations in extreme weather conditions with high humidity and salinity.

The customer, specialized in the development of tensioning systems for moorings and riser pull-in operations, needed a certified, robust, compact, and reliable HPU for the FPSO, capable of operating in extreme climatic conditions with high humidity and salinity. The HPU had to comply with international safety standards for hazardous environments (explosion-risk zones) while maintaining a configuration that allowed easy transportation and onboard installation.

In addition, the high installation density posed a technical challenge. This was overcome through careful 3D design work, which allowed the integration of all required components within a very limited space without compromising accessibility for routine and extraordinary maintenance.

Installation Area Classification:
– Hazardous Area Zone 2, Gas Group IIA, Temperature Class T3
– Direct exposure to atmospheric and corrosive agents, and solar radiation

The HPU and all its components were engineered to withstand and operate correctly within the maximum inclination and acceleration values expected on the floating unit.

What Hydroservice Delivered

Hydroservice took care of all phases of the project, with special attention to galvanic corrosion prevention

Hydroservice managed all phases of the project internally—from engineering design to final testing—delivering a containerized HPU with the following main features:

Carbon steel structure with continuous welding and anti-corrosion treatment
Stainless steel hydraulic reservoir
Co-engineering with the client for integration of the electrical section
Four certified lifting points, including single-point lift option
Elevated internal floor with anti-slip grating
Protection against water ingress and internal pooling
Continuous oil cleanliness monitoring system
Compliance with IEC 60079, ISO 80079, ISO 4413, and ABS certification
Operation in ATEX zones with air cooling system for tropical climates

Special attention was given to preventing galvanic corrosion, a critical factor for long-term reliability in marine environments.

The Results

A reliable, safe, containerized hydraulic power plant that integrates seamlessly with the Customer's program

The HPU developed by Hydroservice fully met the client’s requirements, ensuring:

Reliable operation in extreme environments
Certified safety for explosion-risk areas
Ease of transport, installation, and maintenance
Seamless integration with the client’s modular offshore standardization program
Direct contribution to one of the world’s most advanced riser pull-in system management setups

This project confirms Hydroservice’s ability to deliver customized, robust, and safe solutions for the most demanding challenges in the Oil & Gas sector.

HPU for Off-Shore FPSO in Guyana