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Case Study | 15th July 2025
To manage inspection and integrity management across twelve flowlines and three choke points, traditional manual ultrasonic testing (UT) campaigns were costly and disruptive, especially during high production periods when measurement frequency increased.
Client
Location
These campaigns required specialist access solutions such as scaffolding and rope access, further driving up costs.
Our client required a safe, reliable and cost-effective solution to monitor wall thickness without the recurring expenses and operational disruptions of manual UT.
A North Sea operator was faced with the complex task of managing a high volume of manual UT measurements distributed across twelve flowlines and three choke points.
During periods of high production, the frequency of required measurements increased significantly, placing additional strain on resources and budgets. Each manual UT campaign demanded extensive surface preparation, which was both time-consuming and costly. Accessing many of the measurement points required scaffolding or rope access teams, further escalating operational expenses.
While wireless fixed UT probes were considered, their high cost made them impractical. Compounding the issue, the manual UT data lacked the repeatability required to accurately trend internal wall loss rates, limiting its value for long-term integrity management.
To address these challenges, Altradcollaborated with the platform’s stakeholders to identify a cost-effective and practical solution.
Our team deployed more than 100 WAND sensors across the flowlines and chokes, replacing the traditional single-point manual UT approach. These permanently installed sensors eliminated the need for repeated surface preparation.
To further enhance accessibility, REACH400 extension cables were used to connect sensors in hard-to-reach areas, removing the need for scaffolding or rope access at these locations. Data collection was streamlined using a WAND handheld device, allowing onsite personnel to gather accurate thickness measurements monthly without specialist intervention. Each sensor was also equipped with Radio-frequency identification (RFID) tagging, enabling quick identification and efficient data management.
This integrated solution not only improved safety and data quality but also delivered substantial cost savings and operational efficiencies.
Significant Cost Savings:
Improved Data Accuracy:
Reduced Personnel on Board (PoB):
Access to Previously Hard to Reach Areas:
Efficient Data Management:
By implementing WAND sensors and REACH400 technology, the platform achieved a step-change in corrosion monitoring efficiency, reducing costs, improving safety, and enabling better asset integrity management.
Quite simply, a journey at Altrad begins with a desire to create a better tomorrow.
