Upstream | Galp 90 X-FLEX Workshop | Upcoming Energies

Galp 90 – X‑FLEX is an R&D project focused on the development of an ROV‑operated X‑ray inspection tool capable of detecting structural damage in the tensile layers of flexible production and injection lines while in operation. Unlike conventional inspection methods, X‑FLEX uses advanced X‑ray imaging (tomography‑based) to identify internal defects such as wire cracking, spacing anomalies, and integrity degradation – issues that are otherwise inaccessible without line removal. 

The technology is designed to operate in deep‑water environments (up to ~2,500 m) and to be fully deployable by ROV, allowing non‑intrusive inspection of critical subsea assets. By providing high‑resolution, image‑based diagnostics with minimal risk of false positives, X‑FLEX enables more accurate integrity assessment, remaining life prediction, and maintenance planning, supporting safer operations and avoidance of unplanned production shutdowns.

X‑FLEX is part of Galp’s broader asset integrity and SCC‑CO₂ mitigation strategy, and is complementary to other inspection technologies such as ROVSCAN, ensuring full coverage of flexible line integrity across different layers and damage mechanisms. The project is developed with a consortium of industrial (Integral, ISQ Brasil, Petrobras) and academic partners (COPPE/UFRJ – LIN), combining subsea engineering, non‑destructive testing, and inspection expertise. 

The X‑FLEX project is currently in an advanced development and pre‑qualification phase. Preliminary imaging tests have successfully demonstrated the tool’s ability to detect internal defects in flexible lines with high resolution.

The next phases focus on system qualification, including laboratory and hyperbaric testing, followed by pilot offshore field trials using ROV deployment to validate performance in real operating environments and support future industrial deployment.