Solutions Engine

Riser Repair and Replacement

Whatever the cause – corrosion, a hurricane, a passing vessel – damage to offshore risers and other production platform equipment can lead to hydrocarbon leaks, spills, and additional threats to people and the environment. Riser repair and riser replacement are complex projects that typically involve specialized expertise and a customized solution to minimize downtime, limit production loss, and maintain profitability.


TDW enables Offshore Pipeline operators to safely and efficiently repair or replace damaged risers through either non-intrusive inline isolation or hot tapping and plugging.




In the Offshore Pipeline market, risk reduction is of utmost importance. TDW offers safe, proven hot tapping and plugging (HT&P) solutions for a wide array of pipeline defects and maintenance challenges from dents to corrosion to valve failure. 

TDW technicians, who have a long track record of successful offshore projects around the globe, ensure that the work entrusted to the company is done efficiently with minimal interruption to product flow

Whether operators need an emergency pipeline intervention or topside maintenance during a planned shutdown, HT&P offers safe and proven solutions for getting the project completed. The process incorporates a high pressure pipeline fitting, valve, tapping machine, and isolation equipment – all working together to provide a safe and proven isolation solution. Once the area of pipeline that needs work has been safely isolated and evacuated, the line modification can be performed.

TDW isolation technology plays a critical role in this process, and when combined with temporary bypass, it allows repairs to be performed without the need to stop product flow. The STOPPLE® Train Plugging System, for example, uses double block and bleed technology to help increase efficiency and safety during pipeline maintenance and repair. The system – which is able to create a double block and bleed seal through a single fitting – reduces costs associated with fittings, valves, welding, and inspection services. The bleed port affixed on the line ensures that any product that bypasses the first seal is contained and evacuated through the bleed port, which creates a safe zone in high-consequence areas.

Whether operators are purchasing equipment to perform their own HT&P jobs or turning to TDW to execute the service, they can rely on the TDW line of equipment and consumables. The Subsea 1200RC tapping machine, for example, is a topside-driven hot tap machine that can be safely operated down to a depth of 3,000 meters (9842.5 feet). The machine has proven to be a highly reliable shallow and deep-water solution.

To prepare for future challenges, operators also have the option of creating an Emergency Pipeline Repair System (EPRS), which equips them to take a proactive approach to pipeline emergencies. By working with TDW to create a custom system, operators will have planning and resources in place to repair and recommission their pipelines — and restore product flow — in the shortest time possible.


Mitigating riser damage typically requires repairing or replacing entire pipeline sections. TDW provides Offshore Pipeline operators non-intrusive inline isolation solutions that enable work to be done at full line pressure.

SmartPlug® isolation system –TDW double block and monitor SmartPlug™ technology enables:

  • Protection of people, asset, and the environment.
  • Cost and time savings compared to the alternative solution of temporary decommissioning of the entire pipeline.
  • Local hydrotesting of the replaced/repaired area without affecting the integrity of the initial isolation, which can be held in place.
  • Production and flow of other lines tied in to the downstream section of the isolated pipeline to continue uninterrupted.

SmartPlug isolation tools are tracked and identified by the SmartTrack™ two-way communication system. The SmartTrack system is capable of through-wall communication in any pipeline medium and can operate in pipelines up to 50 millimeters (approximately 2 inches) thick. This enables continuous monitoring of downstream pressure and makes it possible for isolation integrity data to be sent in real-time via radio link to the diver support vessel. The system also allows for extremely precise tool positioning, with accuracy of +/- 25 millimeters (approximately 1 inch), depending upon the environment.