NZ offshore oil and gas innovation in action

A groundbreaking milestone has been achieved in pipeline rehabilitation, marking the first known offshore installation of a UV-cured GRP liner in a pressure-rated non-potable water pipeline.

The installation was successfully completed on a floating production storage and offloading (FPSO) facility off the coast of New Zealand, showcasing cutting-edge advancements in offshore asset integrity.

The project, currently underway and set to continue through to 2026, highlights the precision, resilience, and innovation required for offshore environments.

The rehabilitation involved a 600NB steel pressure pipeline within the FPSO’s cargo oil tank (COT), which was lined with a GRP liner, as well as four 600NB steel pressure expansion loops (90° bends) treated using spray-in-place pipe (SIPP) technology.

The ProLine UV-cured GRP liner was installed using the ProKASRO CCU UV Machine, while NuCoat 100 per cent solids two-part epoxy was applied via the Wiwa SIPP system.

The project also required a 30m liner drop through a single confined hatch, sealing with Reliance pressure-rated end seals for long-term durability. Internal surface preparation was carried out using a specialised water blaster with sand injection.

The combination of UV curing technology and trenchless rehabilitation methods is set to redefine offshore pipeline maintenance, reducing downtime and improving long-term pipeline integrity.

“This project demonstrates the potential of advanced trenchless solutions in offshore environments, allowing for high-performance pipeline rehabilitation without the need for extensive downtime or invasive procedures. By working with industry leaders, we’ve been able to push the boundaries of what’s possible in offshore asset integrity,” a spokesperson from Semtex Plumbing and Civil said.

The project was delivered by Nuflow Manawatu and Semtex Relining Solutions (Semtex Plumbing and Civil), with support from Nuflow Australasia, Aquatech Solutions Ltd NZ, ProKASRO Mechatronik GmbH, Pro Line, Rig NZ, Reliance, and BE Pressure.