In the offshore oil and gas industry the pipeline integrity during the whole life cycle is an aspect of paramount importance. During Installation phase pipeline structural integrity can be compromised by fabrications defects and by the action of external forces in case of accidental events, that could generate pipe instability and, in the worst-case scenario, thepipe collapse. Current offshore regulations provide the requirements to be respected during pipelaying operations in terms of Buckle Detection to meet the pipeline Piggability requirements. The debate on the use of a Mechanical Buckle Detector (MDB), i.e., a gauge plate trolley pulled through the pipeline by a wire connected to the vessel and placed at a certain distance behind the touchdown point, is still open. Indeed, Buckle Detection by deploying the MBD may introducesome operational risks, i.e., the cable break, the stacking during motion and the damage of the internal coating. This may lead toadditional vessel time, extra launch/recovery operations and false readings/bias. With the main target to overcome the above issues, Saipem has developed a tool based on acoustic technique to detect deformations of the internal sections of pipes during installation operations: the Integrated Acoustic Unit, IAU (Patented Technology, see Ref. [1]). The tool works by means of a non-intrusive technique andcan provide the continuous characterization of the whole pipe span up to the touchdown point in a single shot. This paper gives an overview of recent developments of Saipem Integrated Acoustic Unit. It describes the working principle and the available IAU Functions, the pipe defects characterization campaign through modelling (FEA) and laboratory tests, the system validation activity through the experimental campaign, the third-party qualification and the new Saipem Procedure for Technology Qualification that was at the basis of the process.

Offshore pipelay is a complex activity that is subject to some risks due to the challenging operating scenario. The risks may concern the workers during pipes handling, the subsea environment that may be subject to huge seabed rectification works and the integrity of the pipeline. This paper will present the technological roadmap developed by Saipem to implement a more sustainable pipelay operation, focusing on the safety and integrity of the environment, personnel and pipeline. Four innovative tools will be described. The Hands Free Lifting Beam (HFLB) is a system for automatic offshore lifting of pipes, removing human intervention and keeping the workers away from the line of fire. The AFT (Anti Flooding Tool) is a remotely operated tool for pipeline protection from flooding in case of a wet buckle occurrence during lay. The I.A.U (Integrated Acoustic Unit) can perform a safe and non-intrusive, continuous piggability monitoring of the pipeline catenary during lay. The UCB (Underwater Cold Bending) is a solution for crossing sharp slope transition avoiding seabed preparation work and associated environmental impacts. The HFLB grabs and lifts the pipes from cargo barge to pipelay vessel under the control of the operator located in a safe area. The AFT runs inside the laid pipeline during the entire lay, remaining in the safe section already laid (free from possible buckling running effects); it automatically plugs the pipe in case of an accidental flooding event, keeping safe the portion of the pipeline already laid. The I.A.U exploits the acoustic reflectometry and can be integrated with the ILUC (Internal Line Up Clamp) on firing line. It is an alternative to Mechanical Buckle Detector (MBD) which is an intrusive system with associated risks for the pipeline like wire break and loss of the device inside the pipeline, device stacking and possible damage of internal coating during pulling. The UCB is a combination of a new installation method and new subsea bending machine ROV operated, to realize cold bends safely and effectively on the pipeline profile without interrupting the continuous pipelay operation. The UCB can realize the bends underwater, directly on the pipeline catenary when the pipe joint to be bent is landing or close to landing on the seabed, reducing the operational cost while increasing the sustainability. The presented tools can pave the way for safer worker operations during pipe handling (with HFLB); for de-risking the flooding of laid pipeline in case of wet buckle event avoiding the use of a dewatering spread and chemicals for seawater treating, reducing costs and environmental impact (with AFT); for de-risking the monitoring of pipeline during lay (with I.A.U) and for a sustainable crossing of steep escarpment without excavation works (with UCB).