The Background

Hydrus are maufacturing a range of certified lifting caps for recovering various subsea XTs (13⅝” and 18¾”) from the seabed and handling them safely onshore. Each unit is designed to be compatible with multiple XT profiles, fully compliant with lifting regulations, and preserved for rapid deployment to support time-sensitive work scopes.

The Project

Astrimar, our design partner, have designed a set of custom XT lift caps engineered to interface with multiple XT profiles. Our team ensured each lift cap met all relevant certification requirements for subsea lifting operations, while also incorporating preservation measures to maintain readiness during storage.


The units were supplied fully certified, preserved and packaged for mobilisation, giving the client a reliable lifting solution that could be called upon for both planned and reactive scopes. Throughout the project, Hydrus technicians worked closely with the client to ensure the lift caps met their operational, safety and schedule expectations.

The Results

These lift caps meet strict lifting requirements and will remain preserved for rapid mobilisation for when future work scopes demand it. The client now benefits from a versatile lifting solution that supports safe XT retrieval and efficient onshore handling.

The compatibility across XT profiles reduces the need for multiple bespoke tools, while the preserved, ready-to-deploy units streamline future mobilisation and reduce downtime. This project demonstrates Hydrus’ continued focus on providing practical, engineered solutions that strengthen operational safety and efficiency across subsea recovery work scopes.

Background

An international offshore operator engaged Hydrus to refurbish and pressure test a suite of tree cap running tools as part of their subsea asset management programme. These tools, critical to subsea intervention and maintenance activities, had been operational for several years and required inspection, overhaul, and recertification to support upcoming offshore campaigns.

The Project

Hydrus carried out a full mechanical strip-down of the tree cap running tools at its specialist workshop facilities. The team cleaned, visually inspected, and dimensionally checked all components against original equipment specifications. Defective and worn parts were replaced with OEM-approved components, and precision engineering capabilities were used to complete necessary repairs.

After reassembly, the tools underwent a rigorous hydrostatic pressure testing programme to simulate subsea conditions. Testing procedures followed API 6A standards and client-specific acceptance criteria, with third-party witnessing arranged to verify compliance.

Hydrus produced detailed inspection reports and certification packages, providing full traceability for each refurbished tool.

The Results

Hydrus successfully completed the refurbishment and pressure testing ahead of the client’s required mobilisation date. All tree cap running tools were recertified and returned to service, extending their operational life and supporting the client’s offshore intervention schedules with fully reliable equipment. The project showcased Hydrus’s ability to deliver fast turnaround times without compromising on quality or safety.

Background

A client required a full five-year refurbishment and recertification of a critical double-stack Blowout Preventer (BOP) system to maintain operational safety and ensure compliance with offshore drilling regulations. The BOP is a vital component of well control, and any degradation in performance could result in operational downtime or environmental risk. The refurbishment was to be completed within a tight schedule, with zero compromise on quality or compliance.

The Project

Hydrus undertook the project at its certified refurbishment facility, beginning with the complete disassembly of the double-stack BOP system. Major components, including ram blocks, bonnet assemblies, hydraulic circuits, control systems, and sealing elements, were meticulously inspected and assessed using non-destructive testing (NDT) methods. Each component was evaluated against original equipment manufacturer (OEM) specifications and industry standards.

Worn or damaged parts were refurbished or replaced as necessary, with replacement components sourced to match OEM criteria. Skilled technicians reassembled the BOP in accordance with the original manufacturing tolerances, applying rigorous quality checks at every stage.

The system was then subjected to a comprehensive testing programme. This included hydrostatic pressure testing to validate sealing integrity, and full functional testing of hydraulic and mechanical operations to confirm proper actuation and performance under simulated field conditions.

Throughout the process, Hydrus maintained clear documentation and traceability. A complete package of certification documents, including NDT reports, pressure test results, materials traceability records, and recertification approvals, was compiled for client review and regulatory filing.

The Results

The double-stack BOP was successfully refurbished and recertified within the agreed timeframe. The asset was returned to service with extended operational life, assured performance, and full regulatory compliance. The project strengthened the client’s safety-critical infrastructure and reinforced Hydrus’s reputation for precision, quality, and delivery in high-stakes offshore environments.

Background

A major offshore operator engaged Hydrus to perform on-site verification of stress joint and tubing hanger orientation interfaces. This critical task aimed to ensure precise alignment between subsea components, a necessity for the successful integration of equipment from multiple interfacing companies. Accurate orientation is vital to maintain the integrity of subsea connections and to prevent operational issues during deployment.

The Project

Hydrus deployed a specialised team to the client’s site, equipped with advanced orientation elevation check tools. The team conducted meticulous assessments of the stress joint and tubing hanger interfaces, focusing on:

  • Orientation Checks: Utilising precision instruments to measure and confirm the angular alignment of components.
  • Elevation Verification: Ensuring that the vertical positioning met the stringent tolerances required for subsea operations.
  • Interface Compatibility: Assessing the compatibility of components supplied by different vendors to guarantee seamless integration.

Throughout the process, Hydrus maintained close collaboration with all interfacing companies, facilitating real-time adjustments and ensuring that all parties were aligned in their objectives.

The Results

Hydrus successfully completed the on-site verification, confirming that all stress joint and tubing hanger interfaces met the required specifications. This proactive approach mitigated the risk of misalignment during subsea installation, thereby preventing potential operational delays and additional costs. The client’s confidence in the integrity of their subsea connections was reinforced, underscoring Hydrus’s commitment to precision and collaborative problem-solving in complex offshore projects.

Background

A global subsea operator engaged Hydrus to carry out a comprehensive inspection, repair, and function test of a 300-tonne oil and gas riser spider assembly. This heavy-duty equipment is critical to offshore drilling operations, providing secure handling and support of riser sections during deployment and retrieval. The reliability and integrity of the riser spider are paramount to maintaining both safety and operational efficiency in demanding offshore environments.

Given the system’s high load capacity and complex hydraulic control functions, the client required a partner with specialised expertise in handling large-scale, mission-critical equipment. Hydrus was selected based on its proven capabilities in mechanical and hydraulic system testing, refurbishment, and certification.

The Project

The work was carried out at Hydrus’s test and assembly workshop in Brechin, which is equipped to handle heavy offshore equipment. The project scope included:

Equipment Setup

  • Safely positioned the 300-tonne riser spider assembly within the facility to ensure accessibility for inspection and testing while adhering to stringent safety protocols.

Function Testing

  • Conducted a complete operational test of the system, including the hydraulic control panel, jumper control hoses, and spider clamps.
  • Pressure-tested the system to 150 bar gauge (2,200 psi) to validate performance under simulated offshore conditions.

Inspection and Repair

  • Performed a detailed inspection to assess the condition of mechanical and hydraulic components.
  • Identified areas of wear or damage and completed necessary repairs and modifications to restore the system to optimal working order.

Throughout the process, Hydrus maintained continuous communication with the client, offering progress updates and ensuring alignment with performance and quality expectations.

The Results

Hydrus successfully completed the inspection, repair, and function testing of the riser spider assembly. The equipment was returned to full operational status, ready for immediate redeployment in offshore drilling campaigns. The project was delivered on time and within budget, reinforcing Hydrus’s reputation as a trusted partner for high-integrity offshore equipment servicing.

Background

A global oil and gas operator engaged Hydrus to perform comprehensive inspection, repair, and certification of a mechanical and hydraulic riser running tool. This critical equipment is essential for the safe and efficient deployment of risers in offshore drilling operations. Over time, such tools are subject to wear and require meticulous servicing to ensure their reliability and compliance with industry standards.

The Project

Hydrus undertook the project at their Brechin facility, following a structured approach:

  • Non-Destructive Examination (NDE): Conducted surface NDE on all key load-bearing components, including dogs and mechanical lock handles, to detect any signs of wear or damage.
  • Hydraulic Power Unit (HPU) Inspection: Assessed the HPU for damage, calibrated gauges, and ensured optimal functionality.
  • Pressure Testing: Performed pressure tests on the riser running tool to 1.1 times its Maximum Safe Working Pressure (MSWP) and on hydraulic circuits to 1.0 times MSWP, verifying their integrity under operational conditions.
  • System Servicing: Flushed, bled, and filled the hydraulic system, and checked all Pressure Reducing Valve (PRV) settings for proper operation and integrity.
  • Functional Testing: Executed a comprehensive system function test in accordance with AE procedures to validate the tool’s performance.

Throughout the process, Hydrus adhered to stringent quality management procedures, ensuring that all work met the highest industry standards.

The Results

Upon completion, Hydrus issued a service certificate and revalidated the tool’s certificate of conformance, confirming its readiness for redeployment. The project was completed on schedule and within budget, demonstrating Hydrus’s capability to deliver high-quality servicing for complex offshore equipment. This successful execution reinforced Hydrus’s reputation as a trusted partner in the offshore energy sector.

Background

A leading offshore drilling contractor engaged Hydrus to perform the annual inspection, maintenance, and repair of their marine riser system. Given the critical role of risers in offshore drilling operations, ensuring their structural integrity and performance is paramount. The project aimed to identify and rectify any issues to maintain operational efficiency and safety standards.

The Project

Hydrus undertook a comprehensive approach to service the marine riser system:

  • Inspection: Conducted thorough visual inspections and non-destructive testing (NDT) to assess the condition of the riser components, including buoyancy modules, fasteners, clamps, and studs.
  • Maintenance: Performed degreasing and cleaning of the structure and components where necessary to remove contaminants and prepare for further evaluation.
  • Repair: Identified areas requiring repair and executed the necessary interventions to restore components to their original specifications.
  • Testing: Carried out pressure testing and functional assessments to ensure the riser system met all operational requirements.
  • Certification: Provided comprehensive documentation and certification to confirm the riser’s readiness for continued service.

Throughout the project, Hydrus maintained close communication with the client, ensuring transparency and adherence to the agreed timeline.

The Results

Hydrus successfully completed the annual inspection, maintenance, and repair of the marine riser system, delivering the project on schedule and within budget. The riser system was restored to optimal condition, meeting all safety and performance standards. This project demonstrated Hydrus’s expertise in managing complex offshore equipment maintenance and reinforced their reputation as a reliable partner in the offshore drilling industry.

Background

A leading North Sea oil and gas operator engaged Hydrus to conduct a comprehensive Site Integration Test (SIT) on a dual bore subsea system. The objective was to validate the system’s performance, including the Emergency Shut Down (ESD) functionality, under simulated operational conditions before offshore deployment. Ensuring the reliability of such critical systems is paramount to maintaining safety and operational efficiency in offshore environments.

The Project

Hydrus undertook the project at their state-of-the-art Brechin facility, leveraging their extensive experience in subsea systems testing. The scope of work included:

  • System Assembly: Assembling the dual bore system components to replicate the operational setup accurately.
  • Function Testing: Conducting comprehensive function tests to verify the performance of the system under various simulated operational scenarios.
  • ESD Checks: Executing rigorous Emergency Shut Down tests to ensure the system’s safety mechanisms function correctly and reliably.
  • Data Recording: Meticulously recording all test data to provide a comprehensive performance profile of the system.

Throughout the project, Hydrus maintained close collaboration with the client’s engineering team, facilitating real-time adjustments and ensuring all objectives were met efficiently.

The Results

Hydrus successfully completed the SIT and ESD checks, confirming the dual bore system’s readiness for offshore deployment. The thorough testing process provided the client with confidence in the system’s performance and safety, mitigating potential risks associated with offshore operations. This project underscored Hydrus’s commitment to delivering high-quality, reliable solutions in the offshore energy sector.

Background

A major oil and gas operator engaged Hydrus to perform comprehensive refurbishment and testing of a subsea Christmas Tree (XT) system. The XT is a critical component in offshore production, controlling the flow of hydrocarbons from the well. Over time, exposure to harsh subsea environments necessitates thorough maintenance to ensure operational integrity and safety.

The Project

Hydrus undertook the project at their Brechin facility, following a meticulous process:

  • Disassembly and Inspection: The XT was fully disassembled to allow for detailed inspection of all components. This included checking for corrosion, wear, and any structural anomalies that could compromise performance.
  • Refurbishment: Identified issues were addressed through repair or replacement of components, restoring the XT to its original specifications. Special attention was given to sealing surfaces, valves, and control systems to ensure reliability.
  • Reassembly and Testing: The XT was carefully reassembled, ensuring all components were correctly aligned and secured. Comprehensive pressure and function tests were conducted to verify the XT’s performance under operational conditions.
  • Certification: Upon successful testing, the XT was certified for continued use, meeting all relevant industry standards and client specifications.

Throughout the project, Hydrus maintained close communication with the client, providing regular updates and ensuring transparency at every stage.

The Results

Hydrus successfully completed the refurbishment and testing of the subsea XT system, delivering the project on schedule and within budget. The XT was restored to optimal condition, ready for redeployment in offshore production operations. This project demonstrated Hydrus’s expertise in managing complex maintenance tasks and reinforced their reputation as a reliable partner in the offshore energy sector.

Background

An international offshore services company engaged Hydrus to construct, assemble, and perform System Integration Testing (SIT) on an Intervention Riser System (IRS) to support their subsea well intervention operations. The IRS is a critical component in offshore drilling, enabling safe and efficient access to subsea wells for maintenance and intervention activities. Due to the complexity and critical nature of the system, the client required a trusted partner with the technical expertise, specialist workforce, and purpose-built facilities to deliver the project to exacting standards, on time and within budget.

The Project

Hydrus undertook the project at their Brechin facility, leveraging their extensive test and assembly capabilities and experienced workforce. The scope of work included:

Design and Engineering: Collaborated closely with the client to develop detailed engineering plans, ensuring the IRS met all operational requirements and industry standards.

Fabrication: Utilised Hydrus’s 25,000 sq ft fabrication centre to manufacture the IRS components, employing advanced welding and machining techniques to ensure precision and quality.

Assembly: Assembled the IRS components in Hydrus’s purpose-built test and assembly facility, ensuring seamless integration and functionality of the system.

Testing: Conducted comprehensive testing procedures, including full System Integration Testing (SIT), to validate the performance, integration, and reliability of the IRS under simulated operational conditions.

Throughout the project, Hydrus maintained open communication with the client, providing regular updates and accommodating any design modifications or additional requirements.

The Results

Hydrus successfully completed the construction, assembly, and full System Integration Testing (SIT) of the IRS, delivering the project on schedule and within budget. The completed system met all specified operational and safety standards and was confirmed ready for deployment in offshore operations. This project demonstrated Hydrus’s capability to manage complex engineering tasks from concept through to fully tested delivery, further reinforcing their reputation as a reliable partner in the offshore energy sector.

Background

Hydrus played a key role in a complex, multi-well decommissioning campaign, providing bespoke engineering solutions to address the demanding technical and safety challenges of offshore operations. The project involved numerous engineering challenges, including the replacement of aging infrastructure and the development of safe, reliable components to support subsea intervention. Hydrus was selected for its proven capability in delivering high-quality, custom-engineered solutions for offshore operations.

Each Well posed a unique set of requirements and constraints. The need for precise engineering, robust manufacturing, and adherence to strict offshore safety standards was critical to the project’s success. Hydrus’s role encompassed the design, fabrication, testing, and assembly of multiple components, each essential to the seamless execution of our client’s decommissioning efforts.

The Project

Hydrus delivered a wide range of bespoke solutions tailored to individual Well specifications:

  • Subsea Tree Protective Clamps
    Designed and manufactured clamps and rigging for diver installation, replacing 30+ year-old padeyes with compromised structural integrity.
  • ROV Panels
    Developed custom panels mounted on XT frameworks, establishing functional control paths. Scope included design, fabrication, pipework installation, flushing, pressure testing, and provision of ancillary items for the diving team.
  • Utility Connector Stand
    Engineered a secure shipping base for the Tree Cap Test Stump (TCRT), with integrated guidance arms, weights, and NC50 sub for offshore use.
  • Lift Sub & Pup Joints
    Produced 50-tonne SWL pup joints with lift subs for safe handling of utility tools, landing tools, and customer-supplied TCRTs.
  • Test & Lift Cap
    Created a specialised cap to support testing and lifting of the customer’s Tree Running Tool (TRT), compatible with the TRT Test Stump and Shipping Skid.
  • Actuator Adaptors
    Manufactured API 17H Type B Linear override end-profile protectors for actuator cylinder heads, enabling diverless future operations.
  • Protector Caps
    Lightweight, ROV-friendly protector caps designed to safeguard critical equipment.

The Results

Hydrus delivered all components to our client’s exacting standards, enabling safe, efficient offshore decommissioning. Key achievements included:

  • Enhanced Safety – Replacement of outdated structures reduced operational risk.
  • Bespoke Engineering – Custom designs ensured seamless fit and function across varying well environments.
  • Future-Proofing – Diverless-capable components support efficient ongoing operations.
  • On-Time Delivery – All deliverables met schedule, minimising downtime and disruption.

Background

Hydrus was commissioned to design and manufacture a custom Throt Jigging Skid System for a leading offshore operator. The project involved creating a bespoke system capable of withstanding harsh offshore conditions while delivering high performance and operational efficiency.

The client required a robust and reliable jigging skid system to support their offshore operations, with specific design constraints and performance requirements. Hydrus’s expertise in innovative engineering solutions made it the ideal choice for this complex project.

The Project

Hydrus approached the project with a focus on precision engineering and client collaboration, ensuring the system was tailored to the client’s exact needs:

Design and Engineering:

    • Spent time with the client to understand their operational requirements and constraints.
    • Developed a detailed design that balanced structural strength, functionality, and ease of use.
    • Incorporated advanced materials and engineering techniques to ensure durability in challenging offshore environments.

Fabrication and Assembly:

      • Manufactured the jigging skid system in-house, adhering to the highest quality and safety standards.
      • Assembled the system to ensure all components worked seamlessly together.

Testing and Delivery:

        • Conducted rigorous testing to verify the system’s performance, load-bearing capacity, and resistance to offshore environmental conditions.
        • Delivered the completed system on time and provided technical support during installation and commissioning.

The Results

Hydrus successfully delivered the Throt Jigging Skid System, achieving several key outcomes for the client:

  • Enhanced Performance: The system was designed to meet the client’s specific operational requirements, ensuring high performance and reliability.
  • Durability: Advanced materials and coatings provided exceptional resistance to corrosion and wear, ensuring long-term functionality in offshore conditions.
  • Custom Solution: Hydrus delivered a fully tailored solution, demonstrating its ability to meet unique client challenges.
  • On-Time Delivery: The project was completed on schedule, minimising delays and allowing the client to proceed with their operations seamlessly.