Overview
As global oil and gas fields mature, many flexible risers, deployed from platforms or floating production, storage, and offloading vessels, are nearing the end of their original design life.
Operators need assurance that these critical connections remain safe for continued use, especially as replacement is costly and disruptive. End fittings on flexible risers present unique inspection challenges due to their complex construction, large wall thicknesses, and internal components that can mask areas of interest. Offshore work adds further constraints, requiring adapted inspection setups to meet quality targets and tight schedules.
In 2018, our team was tasked with developing a reliable inspection method to verify the condition of flexible riser end-fitting liner holders for a client’s platforms and FPSOs in the Norwegian North Sea. By combining extensive offshore experience with advanced inspection technologies, we successfully tested, deployed, and executed this scope. Since then, we have continued to deliver this service using digital radiography and gamma techniques, providing operators with actionable data to make informed asset-life extension decisions. With more than 3,000 flexible risers deployed globally, the demand for this type of service is rapidly increasing as assets age.
Our Solution
We delivered a robust, multi-phase inspection approach tailored to the client’s needs:
Information Capture and Planning
Each riser evaluation began with thorough information capture, using client-provided drawings, dimensions, photographs, and site visits to assess access limitations and safety requirements.
Onshore Trials and Method Verification
Onshore mock-up trials enabled our teams to validate method statements before mobilization, minimizing offshore disruption, and avoiding unnecessary production impacts. Our technology portfolio allowed us to select the best imaging options for each scenario, including digital X-ray, gamma radiography, computed radiography, and digital detector arrays.
Data Capture in the Field
Specialist offshore crews conducted inspections safely, establishing radiography exclusion zones and holding pre-job safety meetings. Production could continue if external access was sufficient; otherwise, a controlled shutdown was planned for internal detector placement.
Assure and Share
Images were quality-checked in near real time while technicians were on site. Any required reshoots were completed promptly, and findings were expedited to the client, enabling fast integrity and operational decisions.
Our solution provided operators with a reliable, non-intrusive way to verify the integrity of critical flexible riser end-fittings over multiple campaigns. By combining advanced radiographic techniques with disciplined planning and offshore execution, we delivered actionable insight that directly supports safe, cost-effective life extension of aging assets, maximizing production.
Value Delivered
Our methodology transforms a high-risk unknown into a managed process. Operators now have confidence that critical connections remain secure, reducing the likelihood of catastrophic failure and unplanned outages. The ability to verify integrity without intrusive intervention not only safeguards production but also strengthens regulatory compliance and asset stewardship.
Proven Experience
Completed 21 flexible riser inspection scopes in the Norwegian North Sea since 2018.
Comprehensive Testing
Validated inspection methods through dissection and stress testing of 5 pipes and 2 end fittings, ensuring robust integrity assessment under real-world conditions.
Advanced Technology Deployment
Utilized 8 inspection technologies, including digital radiography and gamma techniques, to capture detailed riser data and address complex inspection scenarios.
Actionable Integrity Assurance
Delivered near real-time evidence of riser condition, enabling operators to extend asset life, avoid costly shutdowns, and plan maintenance with confidence.
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