NDT Inspection Case Studies

A Northeast US gas midstream operator screened 4.2 miles of insulated 24-inch gas pipe with pulsed eddy current, found 38 CUI hot spots, and verified the worst at 71% wall loss using PAUT.

A Gulf Coast refiner found 6.8 mm wall loss on an FCC reactor shell from high-temperature H2S attack. PAUT corrosion mapping, fitness-for-service, and a $4.2M shutdown avoided.

A US Gulf LNG export terminal ran robotic MFL on a 240-ft full-containment LNG tank inner floor, found 18 pits ≥ 30% wall on the annular ring, and finalized a phased repair scope under API 653.

A US Midwest crude operator ran a high-resolution MFL inline-inspection tool on a 142-mile 20-inch pipeline and found 312 metal-loss features. PAUT and AUT dig verifications, ILI tool tolerance, and PHMSA compliance walkthrough.

A North Sea operator caught 22% wall loss in the splash zone of a 14-inch production riser using PAUT and digital RT. Subsea rope-access procedure, defect mapping, and weld-clamp disposition.

A US PWR plant ran multi-frequency eddy current on 12,580 steam generator tubes in a 21-day outage, plugged 14 tubes for ODSCC, and re-baselined the IGSCC monitoring program against EPRI guidelines.

A Gulf of Mexico platform operator found a 92 mm fatigue crack at a K-node joint in a leg brace using PAUT and ACFM, scoped a class-approved underwater weld repair, and avoided a $34M leg-strengthening project.

A West Texas refiner found a 38 mm lack-of-side-fusion in a crude-tower girth weld using TOFD after RT missed it. Method-selection decision, scan plan, repair, and code-compliance walkthrough.