Development of a robot for in-service radiography inspection of subsea flexible risers

The extreme operational environmental conditions and aging conditions of subsea structures pose a risk to their structural integrity and is critical to their safety. Non-destructive testing is essential to identify defects developing within the structure, allowing repair in a timely manner to mitigate against failures that cause damage to the environment and pose a hazard to human operators. However, in order to be cost effective, inspections must be carried out without taking the risers out of service. This poses significant safety risks if undertaken manually. This paper presents the development of an automated inspection system for flexible risers that are used to connect wellheads on the seafloor to the offshore production and storage facility. Due to the complex structure of risers, radiography is considered as the best technique to inspect multiple layers of the risers. However, radiography inspection in turn requires a robotic system for in-situ inspection with higher payload capacity, precise movement of source and detector which is able to withstand an extreme operational environment. The deployment of a radiography inspection system has been achieved by developing a customized subsea robotic system called RiserSure that can precisely provide the scanning motion of a gamma ray source and digital detector moving in alignment. The prototype has been tested on a flexible riser during shallow water sea trials with the system placed around a riser by a remotely operated vehicle. The results from the trials show that the internal inner and outer tensile armour layer and defects in the riser can be successfully imaged in real operational conditions.