Project engineering: Innovation and precision for unique challenges

Engineering in complex projects is the key to transforming unique challenges into tangible and safe solutions. In the dynamic energy and maritime sector, special projects, such as offshore LNG project operations, require a combination of creativity and advanced, detailed engineering that presents unusual features or requirements, including extreme conditions, high technical complexity, customized needs, or innovations that do not exist in the market. 

From a complex structure located in seismic zones to an industrial plant designed for unique processes, these projects require an engineering development different from the conventional one. In them, creativity and precision are essential to turn complex ideas into concrete and safe solutions.

What differentiates a common project from a special project? 

To answer this question, I will turn to the definition of a project: “It is a temporary effort to create a unique product or service”. Within this universally accepted definition, a project by nature is finite, is not cyclical or continuous, and creates or gives rise to a single result. 

From the description above, I highlight two concepts that will help us answer our initial question: the project lifetime and the efficient use of this time to create the product or service. Nowadays, we have technological tools and project management methodologies that help us structure the stages, steps, and phases in an orderly manner, giving us direction and allowing us to estimate the project’s timeline. 

Unlike conventional initiatives, special projects are characterized by their innovative nature and unique challenges. They must meet tight budgets and timelines, just like any other project. However, their distinction lies in the need to devise and implement solutions that do not yet exist in the market. 

Distinctive features of special projects 

Some characteristics of the special projects, without being limiting, are: 

1. High technical complexity: They involve structural calculations and simulations that exceed conventional standards.

2. Operating boundary conditions: Hostile environments such as tidal, explosive environments, high pressures, corrosive environments, or confined spaces.

3. Customized design: Need for customized solutions due to functional, regulatory, or integration requirements with pre-existing systems.

Success story: Offshore LNG project in Mexico 

Background of the special project: Mexico’s Pacific coast shortens maritime routes to Asia compared to other regions, reducing transportation times and costs. This factor positions Mexico with great potential to become a major exporter of liquefied natural gas, capable of competing directly with countries such as Qatar and Australia. 

In this context, the development of specialized LNG infrastructure has attracted foreign interest and investment, requiring the creation of new terminals and pipelines, as well as the modernization and expansion of existing infrastructure.

Requirements and needs 

In the current context of upgrading and expanding infrastructure for massive LNG exports to Asia, the owners and operators of an LNG plant on the Mexican Pacific coast have the specific need to replace its four (4) marine loading arms (MLA): two (2) dedicated to liquid handling, one (1) for steam and one (1) hybrid. 

This replacement responds to the natural wear and tear generated after 15 years of continuous operation, a period during which 68 vessels have been unloaded. The renovation seeks to extend the useful life of the facilities for at least 15 additional years and optimize the costs associated with the unloading process. 

Project feasibility

The owner of the LNG plant requested a comprehensive feasibility study of the project from a specialized international consultant. This process began with detailed technical, economic, and regulatory analyses to comprehensively assess its feasibility, considering the challenges inherent to offshore projects. The results highlighted that there is no comparable or similar project previously executed worldwide. 

During this stage, the LNG plant managers contacted our company, recognizing us as the only possible local suppliers capable of executing the required services. The other potential suppliers were located in the United States, Panama, Chile, Holland, France, and Australia.

Unique features that make the project special

This project stands out for several exceptional factors: the loading arms to be replaced are the heaviest ever manufactured by the supplier (60 tons). This implies a significant challenge in lifting maneuvers, especially considering that the physical limitations of the plant make a ground replacement impossible. 

Therefore, the operation had to be planned offshore. In addition, the climatic conditions of the Mexican Pacific, the limited availability of specialized equipment, and the operational need to maintain three functional arms significantly reduced the execution windows. 

Applying project engineering, in the conceptual engineering phase, it was established that the maneuver should be carried out by sea between the months of July and September. This implied having a self-raising barge with a minimum capacity of 400 tons and a crane capable of lifting at least 250 tons. It was also necessary to design specific accessories to guarantee safe transportation and adequate anchoring of the loading arms. 

Finally, it was identified that most of the suppliers qualified to perform these tasks were located outside Mexico. This condition added logistical and operational complexity to the project, requiring a greater effort in the management and international coordination of the teams and specialists involved.

Detailed engineering, new challenges, and simulations 

Once our project engineering group was assigned the scope of the assembly, replacement, installation, and transfer of the new and existing loading arms to their final destination, we were proud to be the only Mexican company actively involved in the detailed engineering and execution of the project. Our team worked closely with the technical staff of the LNG plant, the manufacturer of the arms (MLA), and specialized consultants. 

Immediately, a thorough planning process was initiated, carefully analyzing every resource necessary for the execution of the project. One of the most significant challenges was the limited availability of a Jack-Up Barge in the international market. In the absence of immediate options, it was decided to acquire a JUB Combifloat C7 naval vessel located in Panama. 

Although this decision allowed progress to be made, new technical requirements arose. It was determined that the required capacity of the crane was 300 tons, instead of the 250 tons initially planned. This implied reevaluating critical aspects of stability and navigation of the barge, since there was no history of using a crane of this size on a C7 platform. 

Due to this situation, a specialized firm recommended by the manufacturer was called in to perform detailed stability and navigation analyses and simulations of possible operational failures. Also, given the uniqueness of the project, the international reinsurers required additional technical documentation, increasing the administrative and logistical complexity. 

The delay caused by customs problems and other operational factors forced the maneuvers to be performed outside the ideal weather window, exposing the equipment to more adverse conditions typical of the Mexican Pacific. Specific critical risks were identified, such as the potential recontact of the arms with the vessel during the lifting maneuvers. 

Finally, with the support of a Norwegian firm with expertise in maritime operations under extreme North Sea conditions, the technical feasibility of the project was confirmed. A detailed boundary conditions matrix was developed that integrated physical, meteorological, and operational variables. This rigorous planning was essential to mitigate risks and ensure the success of the project.

Implementation and lessons learned 

Thanks to the application of project engineering, which included meticulous planning and the integration of technological innovations, the offshore project was successfully executed in only 7 weeks, considerably reducing the time initially planned, despite facing adverse weather conditions. The eight critical maneuvers were carried out without incident, rigorously complying with the highest safety standards and guaranteeing at all times the well-being of the team involved. 

Three months later came the final test: the actual discharge of 140,000 m3 of LNG. This operation fully validated the applied engineering and confirmed the quality of the previous project preparation. The performance achieved was optimal, fully achieving the proposed objectives: to extend the useful life of the facilities for another 15 years and to offer an innovative technical solution to successfully meet an unprecedented challenge.

Conclusions 

This article, based on the experience of our group, aims to highlight and internalize that engineering development in special projects, including those in offshore environments, represents a fundamental pillar in the creation of technical solutions to complex and unique challenges. 

Through the effective combination of innovation, rigorous analysis, and advanced methodologies, these projects make it possible to turn seemingly impossible challenges into operational realities, significantly driving technological progress and contributing to the well-being of mankind. 

HB Grupo is a Mexican company specialized in engineering for offshore and special projects, with an outstanding track record in the energy and maritime sectors. More information at: www.grupohb.com.

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This article was developed by HB Grupo and published as part of the fifth edition of Inspenet Brief magazine August 2025, dedicated to technical content in the energy and industrial sector.