Article written by Gerard van der Steen and Niels Pörtzgen from Applus+ Global Project Services department.
In the oil and gas industry, where efficiency and safety are paramount, maintaining the integrity of subsea pipelines is a critical challenge. These pipelines endure extreme underwater conditions, requiring specialized repair and inspection methods. The Pipeline Repair System (PRS)—developed by Equinor and Applus+—is an advanced solution for subsea welding and tie-in operations, enabling precise repairs on the ocean floor.
A key innovation within this system is the IWEX ultrasonic inspection technology, designed for hyperbaric conditions. It features a scanner mounted on a guiding band, which a diver-technician positions around the pipeline inside a controlled habitat. Once in place, the scanner begins inspection, while data collection and interpretation are managed remotely from the vessel.
Before inspection, the IWEX system undergoes calibration using a separate block placed on the pipe. It employs Full Matrix Capture (FMC) ultrasonic imaging, generating detailed 2D and 3D images to detect weld defects and structural features. Additional Time of Flight Diffraction (ToFD) channels can enhance analysis.
This article delves into the challenges of underwater pipeline repairs and the technical requirements of deep-sea welding, highlighting how the Pipeline Repair System (PRS)—developed by Equinor and Applus+—addresses these complexities. Designed for subsea pipeline welding, the PRS is used for both repairs and tie-ins of pipeline extensions. It comprises various equipment deployed on the seafloor to facilitate operations such as cutting, bevel preparation, pipe positioning, welding, and weld inspection. A key component of the PRS is the IWEX system, an advanced ultrasonic inspection technology recently validated for ensuring the integrity of girth welds with exceptional precision and reliability.
It also highlights a recent 2023–2024 project, where the system successfully scanned multiple tie-in welds, demonstrating precision, reliability, and teamwork in subsea pipeline maintenance.
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