Get in Touch

Phased Array Ultrasonic Inspection of High-Pressure Piping Assemblies

Non-Destructive Testing for Structural Integrity Certification Prior to Plant Commissioning

Challenge & Approach

A major petrochemical plant required comprehensive non-destructive testing (NDT) of over 2,000 high-pressure piping welds and structural steel connections before commissioning. The client needed to detect internal volumetric discontinuities, weld porosity, and lack of fusion that could compromise safety under operating pressures exceeding 300 bar. Traditional radiography was impractical due to complex geometry and tight schedules. Our team deployed phased array ultrasonic technology (PAUT) using multi-element probes and advanced beam steering to inspect critical weld zones. We developed custom scanning patterns for each joint configuration, ensuring full volumetric coverage. The approach reduced inspection time by 40% compared to conventional methods while providing detailed C-scan imaging for precise defect characterization.

Results & Certification

The inspection campaign successfully evaluated 2,147 welds across 14 piping systems and 8 structural steel frames. We identified 23 critical discontinuities requiring repair, including 12 instances of volumetric porosity exceeding code limits and 11 lack-of-fusion indications in thick-wall pipe joints. All repairs were re-inspected and certified compliant with ASME Section V and API 1104 standards. The project was completed 12 days ahead of schedule, enabling the plant to commence commissioning on time. Our detailed inspection reports, including phased array data files and defect mapping, provided the client with auditable documentation for regulatory approval. The structural integrity certification contributed to a zero-incident startup phase.

Trusted by Industry Leaders for Precision NDT Services

Our phased array ultrasonic technology has been certified by over 50 plant commissioning projects, detecting internal discontinuities with 99.8% accuracy. Clients consistently rate our structural integrity assessments as the most reliable in the sector.

From high-pressure piping assemblies to steel frameworks, our team ensures every weld meets the strictest safety codes before commissioning. We are proud to have earned the trust of major engineering firms across India.

Request a Consultation
Cookie Consent

This website uses cookies to improve your experience. By continuing to browse, you agree to our use of cookies. You can manage your preferences at any time.