Project Overview
An offshore client operating in the North Sea required a overhead crane lifting solution capable of safely handling large components from beneath the drill floor. The existing rig cranes could not reach this area, so an additional lifting system was essential. One of the key lifts involved a Christmas Tree assembly, a heavy and complex structure with valves, spools and fittings used to manage well flow, pressure and production.
The client needed an ATEX-certified overhead crane that would operate safely in a Zone 1 hazardous environment. They also required full supporting documentation to meet strict offshore compliance standards. Red Rooster Lifting was contracted to design, manufacture, supply and install a custom design 10 tonne pneumatic overhead crane that could fit within the challenging constraints of the rig and support critical lifting operations.
Client Requirements
- A 10 tonne lifting system to access large components from below the drill floor
- ATEX Zone 1 compliant pneumatic driven solution
- Capacity to lift and manoeuvre assemblies such as a Christmas Tree
- Custom underslung configuration to suit existing structural limitations
- Full offshore documentation and procedural support
- Offshore installation and commissioning by certified offshore personnel
Our Approach
Early Engagement & Technical Understanding
The project began with several technical meetings at the client’s premises. These discussions allowed our engineering and production teams to gain a clear understanding of the platform layout, access limitations, environmental factors, and operational demands. As a result, we gained a clear technical picture of the environment and the requirements. This early engagement ensured that our proposed solution aligned fully with the client’s needs.
Custom Design & Engineering for an Offshore Overhead Crane
Our production and design teams worked closely to develop a custom design overhead crane system, supporting the clients specialised requirements.
The designers worked to the client parameters, using STP files and CAD models supplied to ensure design feasibility. During this process FEA (Finite Element Analysis) stress analysis is carried out using software to predict how physical components will behave under real-world conditions. This allows production to be confident that the materials chosen for manufacturing are fit for purpose. The design concept is then passed back to the client for approval before manufacturing commences.
Documentation & Offshore Compliance
To meet offshore regulations, we supplied a comprehensive documentation package.
This included:
- Thorough project status reports
- Datasheets covering weight, noise and technical specifications
- Detailed operational, erection and installation procedures
- Packing, preservation, handling and shipping instructions
- Weld procedures, NDE results and FAT documentation
- Surface preparation and coating records
- Pre-commissioning and commissioning procedures
- Certificates of compliance and 3.1 material certificates
This package gave the client full traceability and clear visibility of every project stage.
Installation & Commissioning
A Red Rooster offshore-qualified engineer installed the crane on the platform. The work included structural checks, mechanical fit-up and pneumatic connection. We then completed functional testing and final commissioning. After these steps, the system was fully certified and ready for operational use. The client could now carry out lifts that had previously been inaccessible.
Project Outcome
The ATEX-rated 10 tonne overhead crane allowed the client to lift critical components safely and efficiently from beneath the drill floor. The system removed access limitations, improved lifting capability and maintained compliance with all offshore safety and operational standards. The project highlighted the value of a tailored engineering approach supported by a complete documentation and installation service.
Speak to Our Team About Your Overhead Crane Requirements
We recently published a blog post that takes a closer look at our approach to designing bespoke hoists and overhead cranes. If you want to understand the full custom design process, including engineering considerations, ATEX compliance, and offshore requirements, check out our Custom Hoist Solutions blog.
If you need a custom-designed overhead crane or a pneumatic lifting solution for hazardous or restricted environments, our engineering team can help. Contact us today.