Dust-free surface preparation at height on a offshore platform

Offshore pipe blasting without shutdown, contamination or safety risks? That’s exactly what Shell achieved with the Pinovo PiSys 100 on a offshore platform

Challenge: Corroded pipework in a sensitive offshore environment

They faced a major maintenance challenge: 125 metres of 6” diameter pipework with heavy corrosion and degraded coatings needed urgent attention. Located on the outboard side of the cellar deck across modules C1 to C4, the pipework was not only difficult to access—it was also surrounded by sensitive equipment and live operations.

Using traditional open grit blasting would have required:

Full encapsulation and extensive masking
Shutdowns of surrounding systems
Significant HSE measures
Over 1,500 man hours of work

Shell needed a cleaner, safer, and more efficient method. That’s where the Pinovo PiSys 100 closed-loop blasting system came in.

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Solution: Rope access blasting with the Pi-connect tool

Instead of scaffolding, rope access was used for nearly all blasting activities. The PiSys 100, combined with the Pi-connect tool and the 6” adapter, enabled spot and sweep blasting of the corroded surfaces to SA 2.5 with an anchor profile of 70–80 µm—without producing dust, sparks, or secondary waste.

Key benefits observed:

809 man hours saved compared to traditional blasting
No encapsulation needed
Zero media clean-up and no contamination
Minimal PPE required (no full air helmet needed)
No access restrictions for surrounding personnel

The job was executed while the pipe remained in service, under the live line blasting procedure.

Results: Cost savings, safety gains and proven quality

They reported a significantly safer and faster project:

Clear and easy operation
No breakdowns or downtime
High-quality blast profile
Fast tool setup and shift handover

Thanks to the PiSys 100 and Pi-connect tool, the fabric maintenance was completed to coating spec using ACOTEC HUMIDUR ME and TC at 400 µm—extending the pipe’s life expectancy up to end of field life (EOFL).

“The PINOVO closed loop blasting system has clearly demonstrated that it is a cost efficient technology to conduct Fabric Maintenace. Not only does it provide the optimum surface profile and cleanliness available to extend the lifecycle of a coating it has demonstrable HSE benefits, not only for the blasting technician but for the personnel on the asset.”
— Shell Fabric Maintenance Coordinator, Nelson Asset

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FAQ

How efficient is Pinovo compared to traditional blasting?

Pinovo’s closed-loop blasting system saved over 800 man hours during the Shell Nelson project. By eliminating the need for encapsulation, media cleanup, and scaffolding, projects can be completed significantly faster, especially in hard-to-reach or live environments.

How much surface profile (micron) can the system achieve?

The PiSys 100 system consistently achieved an anchor profile between 70–80 µm, which is suitable for high-performance coatings in offshore environments. Spot blasting to SA 2.5 was easily maintained across various pipe surfaces.

Is the system heavy or difficult to use during rope access?

Not at all. The Pi-connect tool is lightweight, easy to manoeuvre, and was specifically chosen by Shell for rope access work. Technicians reported clear visibility while blasting and minimal physical strain during operation.

Does it really eliminate media cleanup?

Yes. The system captures and recycles abrasive material in a sealed loop, which means no residual grit, no dust, and no contamination, even in sensitive areas near equipment or vent systems.

How much PPE is required during operation?

Minimal PPE is required. Operators do not need full air-supplied helmets or heavy-duty blast suits. This reduces operator fatigue and simplifies logistics on site.

What kind of training is needed to operate Pinovo?

Pinovo offers intuitive, well-documented instructions and supports “Train the Trainer” models. In the Nelson trial, the personnel were quickly trained and able to onboard new users without delays.

Can it be used on live systems?

Yes. In the Nelson project, the pipework remained in service and was prepared under Shell’s live line blasting procedures, without needing to shut down operations.

Can Pinovo be used for both spot and sweep blasting?

Absolutely. Spot blasting was used for heavily corroded areas, while sweep blasting refreshed existing coatings for overcoating. Both were achieved efficiently with the same system.

Is water or high pressure washing required beforehand?

For optimal results, Shell performed a high-pressure freshwater wash to remove non-visible contaminants before blasting. This is recommended as best practice.

What air pressure is needed to run the system?

The system operates best at 8–10 Bar. Ensuring a stable air supply within this range guarantees efficient performance and consistent blast quality.

What pipe sizes can the system handle?

During the trial, 6” pipework was successfully treated using both the Pi-connect tool and a 6” adapter. Larger and smaller configurations are available based on project scope.