Investigation of force measurement in the subsea oil and gas industry

Precision and reliability are essential in the demanding environment of subsea oil and gas projects of utmost importance. Subsea projects, often thousands of meters below sea level, present unique challenges characterized by immense pressure, corrosion and extreme temperatures.

Interface designs and manufactures load cells and other force measurement devices for these types of environments, enabling operators to measure, monitor and control loads, weight, pressure and tension to ensure safety and operational efficiency.

The subsea oil and gas industry is experiencing a sharp increase in deepwater and ultra-deepwater exploration and production activities. Estimates suggest that offshore exploration will increase by 30-40% globally over the next few years. As conventional reserves dwindle, demand for hydrocarbons requires penetration into harsher and more remote environments. This trend is driving the need for robust, reliable subsea technologies, including advanced force measurement solutions.

Force measurement solutions for applications such as pipeline integrity monitoring, riser stress monitoring and wellhead fatigue analysis are essential in subsea projects. Accurate force measurement ensures the safety and efficiency of subsea operations and prevents costly failures and environmental damage.

The increasing complexity of subsea infrastructure and the growing importance of long-term asset integrity are driving the demand for advanced force measurement technologies.

Interface is a preferred supplier for the shipping- and Energy sectorWe work with our partners to provide standard off-the-shelf measuring instruments, custom sensors such as our wireless force pins and sealed load cells for dangerous environments as well as complete customized solutions for submerged-, ATEX and IP protected environments. Interface has the knowledge and experience to ensure our products meet the high demands of the subsea oil and gas market.

Subsea oil and gas projects involve heavy equipment, pipelines and wells that must withstand extreme conditions. Reliable force measurement helps minimize the risks associated with these highly sensitive environments, including structural failures, equipment damage and environmental hazards.

The integration of force measurement into a subsea oil and gas project brings the following benefits, among others

• Structural integrity: Monitoring strains and stresses on critical structures such as risers, flow lines and anchoring systems.
• Operational control: Ensuring that machines such as blowout preventers and drilling rigs operate within safe limits.
• Safety assurance: Providing data that helps prevent catastrophic failures and protect personnel and the environment.
• Production efficiency: Accurate force measurements enable precise machine control, resulting in smoother, more efficient operation and lower energy consumption.
• Proactive maintenance: By providing real-time data on load and stress, load cells enable operators to identify early signs of wear and tear, preventing costly repairs and downtime. The biggest demand for measurement solutions in the subsea oil and gas industry is real-time condition monitoring and predictive maintenance. The industry is increasingly focused on maximizing the lifespan of subsea assets and avoiding costly downtime.

Implementing load cells and force gauges in subsea projects requires careful planning, particularly with regard to the environment in which they will be used. Interface offers a range of product options to ensure the solution meets the environmental requirements of the project.

Corrosion resistance is essential in underwater environments. Load cells must be made from materials that can withstand the corrosive effects of salt water. Pressure resistance is also critical, as load cells must operate reliably at extreme depths where pressures can exceed 10.000 psi, requiring rigorous durability testing.

In addition, reliable data transmission is critical and advanced communication technologies, such as fiber optic cables, ensure accurate data transmission from the load cells to surface facilities, even at great depths.

Subsea Oil and Gas Applications and Use Cases

solution for liquefied natural gas projects

LCM Systems, Interface's specialty sensor business, has developed this 1500kN Ex d (explosion proof) load pin. It will be used on an LNG project where a semi-submersible drilling unit is being converted into a separation and booster unit that will receive production fluids and separate the gas from the liquids.

The load pin must be suitable for use in a Zone 1 hazardous area due to the environment in which it is operated. It is supplied with IECEx and ATEX certification and a 3.1 material certificate for traceability. The load pin has an integrated amplifier that provides a 4-20mA output and allows direct connection via a 50 meter cable to an Ex-d approved stainless steel indicator.

monitoring the riser voltage

Risers are vertical pipes that connect the seabed to surface facilities. Due to dynamic sea conditions, they are subject to constant movement and stress. Load cells help monitor riser tension and provide data for controlling tensioning systems. This is critical to maintaining structural integrity and preventing riser fatigue.

Monitoring the load on pipelines and flow lines

Pipelines transport oil and gas from wells to processing plants. These pipelines are under constant internal and external pressure, making stress monitoring essential. Load cells help measure stretching and bending forces in pipelines, allowing operators to detect early signs of failure or damage.

anchor and anchoring system tension

Offshore platforms and facilities are protected by anchoring systems attached to the seabed that must withstand strong currents and waves. Load cells monitor the tension of these systems and help operators ensure stability and safety, especially in deep-sea environments.

drilling and lifting operations

For drilling and lifting operations Load cells measure force to ensure machinery is not overloaded, reducing the risk of equipment failure. Load cells in cranes, winches and drilling systems help maintain operational control, ensure efficiency and prevent breakdowns.

As subsea oil and gas projects move into ever deeper waters, the demand for robust force measurement technology will continue to grow. New technologies such as wireless subsea load cells and advanced data analytics are paving the way for real-time remote monitoring, enabling operators to make data-driven decisions from shore.

Operators must continuously monitor stress, strain and fatigue by integrating sensors into critical components such as pipelines, risers and mooring lines. This data enables early detection of potential problems, enabling proactive maintenance and preventing catastrophic failures. This results in significant cost savings, increased safety and reduced environmental impact. In addition, the increasing adoption of digitalization and IoT in the industry is driving the demand for real-time data collection and analysis, making advanced force measurement solutions essential for smart subsea asset management.

Our measurement devices, including load cells, torque transducers, load pins, shackles and tension links, support the needs of subsea oil and gas operations. Our wireless and Bluetooth telemetry system components, rugged features and enclosures support continuous monitoring and measurement analysis in these environments.

These solutions enable operators to monitor forces, maintain structural integrity and ensure safety in some of the most challenging conditions on Earth.