First-Ever Robotized Repair of Subsea Pipeline in Production

On behalf of PTTEP, Kongsberg Ferrotech and Rovula has carried out the world’s first robotic composite repair on a producing subsea pipeline. 

The robotic system solution, named Nautilus, made its worldwide debut in Bangkok, Thailand, operating at 80 meters sea depth. Nautilus is now ready to serve customers and partners in both the public and private sectors of the oil and gas exploration and production industry.

A giant leap

– This is fantastic and a giant leap in transforming today’s underwater interventions. Now we’re able to perform fully robotized repairs from A to Z with minimum production interference, minimum HSE risks and at the same time a substantial reduction in CO2 emission, says Christopher Carlsen, CEO at Kongsberg Ferrotech.

Recognized by two world renowned innovation awards, Nautilus is slated to take oil and gas exploration and production industry to the next level by increasing IRM operational efficiency while significantly reducing time and cost of subsea pipeline maintenance.

IRM in one single mobilization

Nautilus is designed with an underwater habitat equipped with various inspection and repair tools which makes it possible to conduct inspection, repair, and maintenance (IRM) in one single mobilization. Nautilus operates without remotely operated vehicles, divers, and other vessel-supported equipment.

– Nautilus is our pride. For over 4 years, ROVULA, ARV, and our partner Kongsberg Ferrotech have developed this technology together, intending to increase operational efficiency and reduce time and costs of subsea IRM operations in the oil and gas industry. Traditionally, skilled divers must board a pressurized submarine diving deep under the sea to perform these tasks – a life-threatening risk with high operating costs. Nautilus can reduce the operation time from 7-14 days to less than 48 hours, says Dr. Thana Slanvetpan, General Manager of AI & Robotics Ventures.

– With current subsea IRM operations, there are possibilities for mistakes that can cause accidents or cracks and damages to the pipeline – leading to chemical leaks that pollute marine ecosystems and nearby communities, which could become an environmental issue of national level, Slanvetpan adds.

State-of-the-art

– Nautilus is designed and developed with performance and portability in mind; Nautilus can confirm the spot of abnormalities by performing Non-Destructive Testing (NDT) scan and can also repair the damaged spot immediately. A major achievement of the development is that we have achieved DNV qualification for a non-metallic repair subsea – even for leaking pipelines. In essence, we are offering state-of-the art, topside repair technologies – delivered directly on the defect, on the seabed – with minimum lead-time, says Christopher Carlsen, CEO at Kongsberg Ferrotech.

Nautilus remove existing corrosion coating, conduct defect sizing, surface preparation, coating, leak sealing and structural strengthening using carbon fiber – all by robotic means in one single dive. The process is digitally controlled and fully documented.

Throughout four years of development, Nautilus has undergone extensive testing, both in deep water and in workshop facilities to stringent requirements in the industry. Nautilus also gained international recognition by winning the Awards for Breakthrough Technological Project of the Year at the ADIPEC Awards in 2020 and the Spotlight on New Technology Awards at the Offshore Technology Conference Asia (OTC Asia) in April 2022.

Want to know more?

Please contact Kongsberg Ferrotech for a demonstration of how the technology works and how this can be used for your applications.

In 2021 Kongsberg Ferrotech joined forces with Equinor, SINTEF, and Gassco to develop advanced 3D printing technologies for in situ, metal2metal repairs of subsea equipment.

Read more here.