Offshore Wind Substation Cooling
Reliable cooling for offshore grid connections
Elevating global standards with exceptional, unmatched Dutch craftsmanship in advanced industrial heat exchange.
What is Offshore Wind Substation Cooling?
Offshore wind substation cooling removes the heat produced by the electrical equipment on an offshore substation or HVDC converter platform. Every megawatt that a wind farm sends to shore passes through power transformers, reactors, switchgear and, on HVDC platforms, converter valves. A small percentage of that power is lost as heat, and on a 1 or 2 GW platform those losses add up to megawatts of heat that must leave the topside continuously.
If that heat is not removed, transformers and power electronics overheat, protection systems reduce output and in the worst case the entire wind farm is disconnected from the grid. Because these platforms are often unmanned and hard to reach, the cooling system must work reliably for the full design life of the platform with minimal maintenance. ICARUS designs and builds the offshore heat exchangers that make this possible.
Dutch excellence in heat exchange
At ICARUS Industrial, we blend Dutch craftsmanship with innovative technology, redefining the gold standard for industrial heat exchangers. Dive into the future of sustainable manufacturing, where our Dutch-engineered solutions elevate energy efficiency to unparalleled heights.
Lower total cost of ownership (TCO)
We go beyond performance with our heat exchangers, sculpting an unbeatable blend of.
Direct manufacturer benefits
Your unique needs are our command. We offer tailored heat exchanger solutions.
Customized solutions
With ICARUS Industrial, you're not just buying a product, you're engaging a partnership. Our direct sales model
Superior durability
Built from robust materials, our heat exchangers are a testament to resilience. They reduce maintenance
Cooling Solutions for Offshore Substations and Converter Platforms
An offshore substation combines several cooling duties on a compact, weight-critical topside. ICARUS supplies the heat exchangers for each of them, engineered for the marine environment and integrated with the platform’s cooling and HVAC systems. Together with the nacelle heat exchangers in the turbines themselves, this covers the complete thermal chain of an offshore wind farm.
Transformer and Reactor Coolers
The main power transformers are the largest heat source on an AC substation. Oil-immersed transformers release their losses through coolers mounted on or next to the tank, either directly to air or through an intermediate water-glycol circuit. ICARUS builds air-cooled oil coolers and water-to-air coolers for transformers and shunt reactors, sized for the full load losses at the highest design ambient temperature. For enclosed transformer rooms, our transformer air coolers remove the heat from the room air without bringing salt-laden outside air into contact with the equipment.
Closed-Loop Air Coolers for Converter and Auxiliary Circuits
Most converter platforms today reject heat to seawater through an open intake. Seawater intakes bring fouling, filters, pumps and chlorination, and new permits put increasing limits on water intake and thermal discharge. Closed-loop air cooling avoids this by rejecting the heat of the freshwater or glycol circuit directly to the air through finned tube coolers. ICARUS builds these as offshore dry coolers for auxiliary circuits, standby cooling and complete closed-loop concepts, designed for the space and weight available on the topside.
HVAC Coils for Transformer, Switchgear and Control Rooms
The rooms on a substation topside are kept within tight temperature and humidity limits to protect switchgear, protection relays and control systems. The air handling units that do this need cooling, heating and dehumidification coils that survive the offshore atmosphere. ICARUS manufactures HVAC cooling coils, heating coils and dehumidification coolers for these units, in materials and coatings matched to the corrosion class of the platform.
Materials for Salt Mist and Seawater
Every component on an offshore platform faces salt mist, high humidity and in many cases direct contact with seawater. ICARUS selects the materials per duty: stainless steel AISI 316L for air-side frames and casings, copper-nickel and titanium tubes where seawater or aggressive condensate is involved, and coated or copper fins for long-term protection of the heat transfer surface. The same principles we apply to our high corrosion environment heat exchangers keep substation coolers performing for the 25 to 30 year design life of the platform.
Redundancy, Weight and Maintenance Access
A substation cannot stop because one cooler fails. ICARUS designs cooling sections in modules that support N+1 redundancy, so a single unit can be isolated, cleaned or replaced while the others keep the platform running. We optimize every unit for weight and footprint, because each tonne on a topside costs structure and installation effort, and we position connections, drains and access panels so service crews can work quickly during short weather windows. Pressure parts can be designed according to PED or ASME Section VIII.
Download products reference list
Download the comprehensive product reference list for heat exchangers and cooling systems.
Partner with ICARUS for Your Offshore Substation Project
ICARUS works with EPC contractors, platform builders, HVAC integrators and transmission system operators on new offshore substations, converter platforms and refurbishment projects. As a Dutch manufacturer close to the North Sea offshore industry, we handle thermal design, production and testing in house and deliver both single coolers and complete series for a platform.
To prepare a proposal for your project, send us:
- The cooling duty: transformer, reactor, auxiliary circuit or HVAC
- Heat load in kW and the fluids on both sides
- Design ambient and seawater temperatures
- Corrosion class or material specification of the project
- Available space, weight limits and the required redundancy
- Applicable codes and the project schedule
Our engineers review your specification and come back with a technical proposal. Early in the design phase? Contact us anyway: involving ICARUS early often saves weight and space on the topside.
Request a quotation
Elevate your efficiency with Dutch-engineered solutions tailored for your needs. Fill out the details below, and our team will provide a personalized quote to help you harness the power of optimized energy in manufacturing. Step into the future, one quote at a time.
ICARUS Heat Exchangers
Quotation Form
Facts about ICARUS
> 27
With over 27 years in business, we’ve carved out a reputation for excellence and innovation.
> 120+
Our global presence is marked by a diverse clientele of over 120 customers worldwide.
> 850+
Moreover, our portfolio boasts more than 850 completed projects.
FAQs about Offshore Wind Substation Cooling
What needs to be cooled on an offshore wind substation?
The main heat sources are the power transformers and shunt reactors, followed by switchgear, auxiliary transformers, protection and control equipment, and on HVDC converter platforms the converter valves. Each of these loses a small percentage of the transmitted power as heat. On large platforms this adds up to megawatts of heat that the cooling and HVAC systems must remove continuously.
Is seawater cooling or air cooling better for an offshore converter platform?
Seawater cooling is compact and has been the standard for most converter platforms, but it requires intakes, filters, pumps and antifouling treatment, and discharge permits are becoming stricter. Closed-loop air cooling avoids seawater altogether and reduces environmental impact, at the cost of more installed surface. Many platforms use a combination. ICARUS can calculate the air-cooled options for your heat load and available space.
Which materials do you use for offshore substation heat exchangers?
That depends on the duty and the corrosion class. Typical choices are stainless steel AISI 316L frames and casings, copper-nickel or titanium tubes for seawater and aggressive media, and coated aluminum or copper fins on the air side. ICARUS matches the material selection to the project specification and the 25 to 30 year design life of the platform.
Can ICARUS supply coolers for refurbishment of existing substations?
Yes. For existing platforms we can replace corroded or underperforming transformer coolers, dry coolers and HVAC coils with units that fit the same connections and footprint. Where the original unit failed early, we improve the material selection or the thermal design so the replacement lasts longer than the original.
What information do you need to quote an offshore substation cooler?
We need the cooling duty, the heat load, the fluids and temperatures on both sides, the design ambient conditions, the corrosion class or material specification, the available space and weight, the required redundancy and the applicable codes. Drawings or an equipment list help us respond quickly. If the project is still in an early phase, send what you have and our engineers will help define the requirements.
