Novel Electromagnetic-Based NDT Inspection for Detecting Tensile Armor Wire Ruptures in Flexible Pipes

Abstract The structural integrity of flexible pipelines is vital for ensuring the safe and efficient operation of the oil and gas industry. However, the rupture of tensile armor wires in these pipelines poses a significant threat, particularly in offshore production environments. Factors such as seawater ingress into the annular space and stress corrosion induced by CO2 exacerbate the degradation process, leading to rapid crack propagation and potentially catastrophic ruptures, as disruptions, including leaks, bursts, and complete structural collapses. Therefore, the early detection of any anomaly or damage is essential to avoid catastrophic failures. Is response to that, an innovative, non-intrusive inspection tool – named INSPECFLEX – is being developed, that employs advanced electromagnetic non-destructive testing (NDT) techniques, specifically designed to detect ruptures in tensile armor wires. Operating from the outer sheath, the tool accurately identifies wire breaks in both the outer and inner tensile layers in real time, enabling comprehensive assessments. Compatible with flexible pipelines produced by the three largest manufacturers, the tool is effective for both injection and production pipelines, including those with thermal insulation up to 72 mm thick. By delivering precise inspections and real-time results without disrupting operations, this electromagnetic NDT tool enhances the detection of tensile armor wire ruptures, thereby improving the operational safety and reliability of flexible pipelines in the oil and gas sector.