OFFSHORE INSTRUMENT AIR: The challenges you don’t see

Sinergia recently supplied an instrument air treatment system for an upgrade project in a conventional oil field located in shallow waters in the UAE.

Being ADNOC Offshore the end client, the project required a high level of customization: Two instrument air packages equipped with oil-free screw compressors designed under API 619 requirements, heatless desiccant dryers, and dedicated control panels. With compressor motors rated at approximately 500 kW to deliver the greater capacity of 3,900 Nm³/h, and with offshore space at a premium, the systems were engineered to meet the distinct design requirements of two platforms, one located in a safe area and the other subject to a different hazardous area classification.

But this challenge goes beyond the equipment itself: installing a complete instrument air generation system offshore raises the bar in terms of engineering, materials, integration, and long-term reliability. So, what are the key aspects to consider for Offshore installation?

✅Material selection: For this project, the entire package is designed in 316L stainless steel, with selected critical components manufactured from 904 stainless steel, requiring specialized manufacturing processes.

✅Surface protection: The coating system complies with the client’s specifications and C5-M corrosion protection requirements. Sinergia also has the expertise to manage more demanding surface protection systems in-house.

✅Dimensional contraints: One of the main challenges is designing and manufacturing a turnkey system with a high level of component integration, within a confined footprint and balanced weight distribution, while ensuring the required performance even under extreme ambient conditions of up to +55°C.

✅Structural vibration isolation: While vibration isolation is typically focused on the rotating equipment only, this project required a solution covering the entire package structure, adding another layer of engineering complexity.

✅Long-term component lifetime: Unlike many onshore installations, offshore projects usually require longer service intervals and extended component lifetimes, particularly for critical consumables, as for the desiccant material in the supplied air dryers is specified for an expected service life of approximately eight years.

Offshore turnkey projects demand requirements undoubtedly raise the technical challenge, but they also narrow the field to suppliers capable of delivering the right solution.
With years of experience in this sector, Sinergia is proud to be among them!