When a major offshore operator faced production constraints at their Central Processing Facility (CPF), they turned to Global Maritime Consultants Group (GMCG) for a solution. Through comprehensive engineering design and phased implementation, GMCG successfully designed the facility’s capacity from 7,000 to 12,000 barrels of oil per day (BOPD) – a 71% increase – while maintaining operational continuity. This complex design upgrade, involving multiple system enhancements and equipment installations, demonstrated GMCG’s ability to deliver large-scale facility improvements without sacrificing production targets or safety standards.

The Client

A leading offshore operator’s Central Processing Facility (CPF) struggled to keep pace with increasing production demands. While functional, the existing infrastructure reached its operational ceiling at 7,000 BOPD, creating a significant bottleneck in its growth strategy. With market conditions favoring expanded production, the client needed a solution enabling them to capitalize on these opportunities without compromising operational integrity.

The Challenge

The project presented multiple complex challenges that required careful consideration.

Production Bottlenecks and Capacity Limitations

The existing CPF infrastructure was operating at maximum capacity, limiting the client’s ability to meet rising production targets. This bottleneck was directly impacting revenue potential and market competitiveness.

Modernizing Core Systems

The facility required substantial upgrades, including new heat exchangers, compressors, and pumps. These additions needed to be seamlessly integrated with existing systems while maintaining operational continuity. The challenge was compounded by the need to modify electrical and control systems to accommodate higher flow rates.

Keeping Production Online

Perhaps the most critical challenge was implementing these significant upgrades while minimizing production downtime. Any extended shutdown would result in substantial revenue loss and could impact client relationships downstream.

Managing Risk in a Complex Environment

The upgrade needed to be executed while maintaining strict compliance with safety standards and environmental regulations. This required careful planning and coordination across multiple engineering disciplines and stakeholders.

This combination of technical complexity, operational constraints, and compliance requirements demanded a sophisticated solution that only an experienced maritime engineering consultant could provide.

The Solution

GMCG designed a comprehensive, multi-phase solution that addressed immediate capacity needs and long-term operational efficiency, starting with a detailed facility assessment.

The Blueprint for 12,000 BOPD: GMCG’s Engineering Design

The heart of the solution lay in GMCG’s detailed engineering design. Our team created specifications for enhanced heat exchanger systems, and advanced pumping & piping systems, all carefully selected to achieve the 12,000 BOPD target.

Upgrading Without Downtime: A Phased Approach

Recognizing the critical need to maintain operations, the upgrade was divided into strategic phases. New equipment installation coincided with planned maintenance windows, minimizing disruption to ongoing operations. Our team coordinated closely with facility personnel throughout the process to ensure seamless integration of new systems while maintaining production levels.

Safety, Compliance, and Performance

The implementation strategy paid particular attention to risk mitigation. Every phase was executed with rigorous safety protocols, environmental protection measures, and quality assurance testing. This careful attention to detail ensured the facility achieved its capacity goals while maintaining full regulatory compliance and operational safety standards.

The Results

The CPF upgrade project delivered immediate and substantial results. The facility’s processing capacity can be increased from 7,000 to 12,000 BOPD, representing a 71% improvement in production capability.

Predictive Maintenance for Enhanced Uptime

Beyond the headline capacity increase, the design and construction upgrade brought significant operational improvements. The new control systems and equipment integration resulted in smoother facility operations and reduced maintenance requirements. Equipment reliability improved markedly, with automated monitoring systems helping to predict and prevent potential issues before they could impact production.

Sustained Success and Future Growth

The most accurate measure of the project’s success has been its long-term performance. The upgraded facility has consistently maintained its enhanced production levels, operating efficiently at a higher capacity without experiencing bottlenecks. GMCG’s forward-thinking approach has already paid dividends, as the client has pursued new production opportunities without concern about processing capacity constraints.

Engineering Solutions That Drive Business Growth

The successful CPF upgrade represents a strategic turning point for our client’s operations. For increasing processing capacity by 71% while maintaining operational continuity, GMCG delivered a solution that transformed a business constraint into a competitive advantage.

As onshore/offshore operators continue to face pressure to optimize production and maintain aging infrastructure, this project is a testament to GMCG’s ability to deliver complex engineering solutions that drive real business value. For more information about how GMCG can help transform your facilities, contact our team of experts today.