In October 2024, ROSEN Asia Pacific completed an 890km single-run inspection of the INPEX Ichthys Gas Export Pipeline (GEP), the longest subsea pipeline in the Southern Hemisphere. The 42-inch diameter pipeline, with a thickness of up to 37.2mm, operates at pressures up to 20 MPa and gas flows of up to 4 m/s. To comply with regulations, INPEX required a highly reliable ILI Tool for defect detection, especially in high-risk areas like the shore crossing.

The inspection involved advanced solutions for subsea launching and extended battery life. A 300-tonne pig launcher/receiver (PLR) was installed offshore by a heavy lift vessel, with the PLR and associated equipment stored in Malaysia. The ILI tool was transported to the Ichthys field, 220km off the northwest coast of Western Australia, requiring meticulous planning and coordination to ensure safe and efficient transport.

The project demanded innovative engineering and global collaboration. Due to constraints on heavy lift vessel availability, only one run of the ILI Tool was planned. INPEX had specific requirements for ILI Tool selection and qualification, focusing on manufacturing quality, failure mode handling, and robustness. A custom dual MFL-A+ and IEC tool configuration with dual redundancy was developed. Pull testing, supervised by INPEX, ensured the tool met the minimum detection requirement, achieving a 90% Probability of Detection (POD) for metal loss in the 29.6mm pipe wall thickness.

The inspection was completed successfully within the tool’s battery lifetime, with zero data loss and no damage to the pipeline or tools. The 1.5TB of data currently under analysis highlights ROSEN’s capability to meet stringent requirements, advancing pipeline integrity management and setting new industry standards. This achievement demonstrates the effectiveness of meticulous planning and cutting-edge technology in overcoming significant technical challenges, ensuring the long-term reliability and safety of the pipeline.