The client is a major, global energy company operating offshore oil and gas production facilities. With complex infrastructure spread across multiple continents, they depend on continuous, reliable operations to meet energy demand while maintaining strict safety and environmental standards.
After years of offshore operation, one of our client’s gas production trains, consisting of two compressors, a gearbox, and a gas turbine, needed a major overhaul on all equipment. To minimise production losses, everything had to be done in a single 3-week shutdown.
Major overhauls offshore are complex. Multiple OEMs, tight weather windows, systems that depend on each other, and a shutdown clock that’s always ticking. If one supplier is late, if one team misunderstands the plan, if coordination breaks down – the delays cascade fast.
On top of that, critical spare parts can take up to a year to source, special tools need to be ready, and any planning missteps could extend downtime, blow the budget, and even create safety risks.
For this client, a failed overhaul wasn’t an option. Production revenue, safety, and regulatory compliance were all at stake. They needed a partner who could own the entire process - from sourcing, preparation, and coordination of trades to handling multiple OEMs - and make sure nothing fell through the cracks. We had experience with overhaul of individual sections on gas compression trains, but never a full overhaul of a complete train in a single shutdown.
Projects rarely stay within their original scope – especially complex ones offshore. We were brought to help with planning, spare parts, and special tools. But once we started digging into the details and asking the right questions, the real scope became clear.
So, we stepped up and ended up handling the entire project, from sourcing through to commissioning.
1) Preparation and planning
One year ahead, we identified all critical spare parts, defined and designed new custom tools, and defined lifting and mechanical handling procedures – so nothing would delay the planned shutdown. Preparation, planning, and purchasing were carried out directly in the client’s SAP system.
2) Scope management
Detailed work orders, sequencing of tasks, and coordination of all internal resources, including riggers, electricians, and welders, kept execution smooth and downtime minimal.
3) OEM coordination
We aligned three different OEMs on procedures, approvals and schedules – ensuring everyone worked on the same plan.
4) On-site execution
We managed mechanical completion, commissioning of the turbine, gearbox, and compressors while maintaining full HSE compliance throughout.
5) Maintenance integration
We optimised layouts, kits, and procedures for future operations – protecting uptime long after commissioning.
“Our initial task was to help the client define tooling, spare parts, and assistance with updating the lifting procedures. This was the the plan. But we ended up running the entire project through to commissioning. The technical details mattered, but what really made it work was our ability to get riggers, electricians, welders, and three different OEMs working together smoothly in difficult offshore conditions.” Terotech
Through careful preparation, clear communication with all stakeholders, and hands-on expertise, we delivered a fully overhauled production train within the three-week shutdown window. Without compromise on safety, quality, or warranty.
What we delivered:
Complex projects offshore rarely go exactly to plan. This one did.
Major overhauls fail when you only think about the teardown and the rebuild. They succeed when preparation, coordination, and long-term maintenance are built into every step.
With Terotech, you get:
