Monitoring and inspection tools extend the service life of flexible risers

March 14, 2025
A move toward more comprehensive inspections employing advanced monitoring solutions is changing the traditional approach to riser integrity management.

By Domenico Di Giambattista, Baker Hughes

 

Safely extending asset life becomes increasingly important to project economics as operators begin to weigh the cost of replacing ageing components. Risers are one of the most critical of these components, and many that are in service today are either at or beyond their original design life.

As enhanced recovery technologies have been employed and tiebacks from adjacent fields have been added to host production systems, risers have continued to work in harsh and dynamic deepwater environments where long-term fatigue loading accumulation has taken its toll. For owners working to keep assets in service to sustain production, extending the field life of risers is central to achieving that goal.

Over the past decade, it has been proven that riser service life can be extended safely, but as assets age, regulatory agencies are requiring more evidence that they can operate safely. Owners understand that they must provide proof that older risers are still fit for purpose, but it is challenging to demonstrate riser integrity using traditional inspection methods.

Remote monitoring and inspections

Historically, periodic inspections have been carried out with cameras and ROVs. While visual inspections are important, they are limited in their effectiveness because they only capture surface imperfections. And even when inspections identify a problem, there is no way to know how long the defect has existed. Without an in-depth understanding of the extent or criticality of the damage, the only way to prevent a potential failure is to take an extremely conservative approach to maintenance and repair. Normally, that means taking the riser out of service as expediently as possible to address the damage.

Today, a move toward more comprehensive inspections employing advanced monitoring solutions is changing the traditional approach to riser integrity management. New technologies are being used to continuously acquire accurate, real-time data across pipe architecture, making it possible to identify anomalies as they emerge so owners can make informed and judicious decisions about the type and extent of repairs needed to avoid unnecessary downtime and unplanned disruptions to production. 

For example, riser sheath issues can now be detected using electronic breach detection. An externally mounted tool identifies changes in applied stress in load bearing steel armoring wires and detects unloaded armor wires +/- 15 m from the mounting location. Identified anomalies can be monitored to ensure performance and safety are not compromised, allowing production to continue until the damage warrants attention.

By capturing integrity data in real time in a process that is fundamentally different and more thorough than conventional inspection methods, it is possible to better understand how imperfections impact performance and to determine when the time is right for maintenance and repairs.

Having a better understanding of riser health not only makes it possible to keep a minimally damaged riser in service but also allows an undamaged riser to remain in use safely beyond its projected design life.

Another new technology is a venting gas monitoring system that performs chemical analysis on permeated annulus gases in real time. Changes in chemical concentration indicate the riser has sustained damage and alerts owners that repairs are required.

These advanced solutions also deliver value in greenfield applications, identifying damage during installation that can impact service life. Inspections that begin during installation and continue throughout the service life of the riser can improve operational safety and potentially extend the riser’s field life.

The tools that are advancing riser monitoring today are just the tip of the iceberg. They are part of a continuum of technology development that will put additional power in the hands of owners by enabling a more precise understanding of performance degradation to accelerate improvements in riser integrity management.

About the Author

Domenico Di Giambattista

Domenico Di Giambattista is a seasoned energy executive who serves as vice president of flexible pipe systems at Baker Hughes, an energy technology company. 

Di Giambattista has spent nearly 20 years in the oil and gas industry, leading product lines and regions around the world for Baker Hughes and GE Oil & Gas. In his current role, Di Giambattista oversees the design, manufacturing and installation of Baker Hughes’ flexible pipe systems and is based in Newcastle upon Tyne, England.

Di Giambattista earned a degree in mechanical engineering from Italy’s Università degli Studi dell'Aquila and a degree in project management from the Georgia Tech Scheller College of Business.