Offshore tooling hydraulic tubing installation and pressure testing

Project review

Project overview

Client

Howco Group

Contractor

Global Fluid Controls Ltd

Location

Howco Group facility, Irvine, Scotland

Scope

Offshore tooling assembly, hydraulic tubing installation, system pressure testing, quality assurance and commissioning support

Introduction

Global Fluid Controls Ltd was contracted to support the assembly and preparation of offshore tooling equipment at the Howco Group facility in Irvine. The project involved the complete installation of hydraulic tubing systems, integration of hydraulic components, and comprehensive pressure testing to verify system integrity prior to deployment offshore.

The work was carried out to meet the stringent quality, reliability and safety standards required for offshore oil and gas operations, where hydraulic systems play a critical role in the performance of subsea and topside tooling.

Project objectives

• Install hydraulic tubing throughout the offshore tooling package.
• Ensure all tubing systems were routed, supported and secured in accordance with engineering drawings and client specifications.
• Perform pressure testing to verify system integrity and leak-free operation.
• Maintain full traceability and quality documentation throughout the project.
• Deliver a fully tested and verified hydraulic system ready for offshore deployment.

Scope of work

Hydraulic tubing installation

Global Fluid Controls Ltd carried out the complete installation of hydraulic tubing across the offshore tooling package. Key activities included:

• Interpretation of engineering and instrumentation drawings.
• Fabrication and bending of stainless steel hydraulic tubing.
• Installation of tube supports, clamps and brackets.
• Assembly of hydraulic fittings and connection points.
• Routing of hydraulic circuits to protect against vibration and operational loads.
• Compliance with offshore industry standards and client requirements.

The installation team ensured all tubing was accurately measured, bent and fitted to achieve a clean, professional layout while minimising stress on fittings and connection points.

Offshore tooling assembly support

Alongside the tubing installation, our team worked closely with the Howco project team to support the mechanical assembly of the offshore tooling package. This included:

• Hydraulic component integration.
• Valve and manifold connections.
• Interface checks between mechanical and hydraulic systems.
• Verification of hydraulic circuit functionality.
• Resolution of engineering queries encountered during assembly.

Close collaboration between all parties ensured efficient progress and adherence to the project schedule.

Pressure testing and verification

A critical phase of the project involved pressure testing the installed hydraulic system. The testing programme included:

1. Visual inspection of all hydraulic tubing and fittings.
2. Verification of installation against engineering drawings.
3. Controlled system pressurisation using approved test equipment.
4. Monitoring of pressure stability over specified test periods.
5. Inspection for leaks, deformation or component deficiencies.
6. Recording and certification of test results.

Results

The hydraulic system successfully achieved the required test pressure without leakage or pressure loss. Key outcomes included:

• 100% completion of hydraulic tubing installation.
• Successful pressure test certification.
• Zero reportable safety incidents.
• Full compliance with quality and customer requirements.
• On-time project delivery.

Health, safety and quality

Safety and quality were maintained as top priorities throughout the project. Measures implemented included:

• Daily toolbox talks and risk assessments.
• Strict adherence to permit-to-work procedures.
• Use of calibrated pressure testing equipment.
• Inspection and verification of all hydraulic components.
• Comprehensive quality records and test documentation.
• Compliance with client-specific and offshore industry standards.

The project was completed without any lost-time incidents, demonstrating our commitment to safe working practices.

Project benefits

• Assurance of hydraulic system reliability before offshore deployment.
• Reduced risk of offshore commissioning delays.
• Enhanced equipment integrity and operational performance.
• Full traceability and documented testing records.
• High-quality workmanship supporting long-term equipment reliability.

Conclusion

The offshore tooling project at the Howco Group facility in Irvine demonstrated Global Fluid Controls Ltd's capability in delivering specialist hydraulic installation and testing services for the offshore sector. Through skilled fabrication, precise hydraulic tubing installation and rigorous pressure testing procedures, we delivered a fully verified hydraulic system ready for operational deployment.