What is Non-Destructive Testing?
Non-destructive testing (NDT) is a non-invasive inspection technique for materials, components, and equipment that does not disrupt the operational infrastructure of process plants, gas pipelines, oil pipelines, and other similar systems. The importance of NDT is reflected in its growing global adoption; therefore, its use in the oil and gas sector is expected to increase by $1.565 billion by 2028 [1]. For example, the use of ultrasonic drones for offshore inspections has reported direct savings of $1 million in preventive maintenance interventions [2].
Benefits of NDT
Inspection using various non-destructive testing (NDT) techniques enables the early detection of potential defects, allowing for informed decision-making that extends asset life, promotes continuous operations, improves process safety, and reduces maintenance costs.
Ultrasound as NDT
Ultrasound (UT) is a versatile and constantly evolving technique; therefore, it has undergone significant technological advances in recent decades [3]. Currently, some of these techniques are becoming new industry standards, providing increasingly valuable information about the assets being analyzed.
Trend: Advanced Ultrasound on High-Temperature Surfaces
A standard limitation of UT inspection is the temperature of the surface being measured. Conventional ultrasonic probes typically tolerate temperatures of up to approximately 50°C. Above this temperature, the probes exceed their thermal limit, and the coupling medium degrades; therefore, in practice, this requires time to cool the surfaces of interest, resulting in economic losses. In this context, specialized transducers and techniques for high-temperature ultrasonic testing (UT) emerge, enabling thickness measurements and weld verification on equipment, pipes, or components operating above 50°C [4].
ITIC GROUP High Temperature Ultrasound Success Stories
ITIC Colombia has experience in ultrasonic inspection of equipment operating at high temperatures. During a recent intervention at one of our leading clients in the oil and gas sector, 80.4 m² of the wall of an in-service regenerator operating at 160°C were inspected. Our team of experts, qualified in advanced ultrasonic inspection techniques, performed a phased array scan, moving in 40 mm wide vertical strips with an 8 mm overlap, ensuring that each point on the surface was covered in compliance with ASME BPVC Section V requirements. A special oil served as an acoustic bridge, while the equipment's software calibrated the actual temperature at each point, as recommended by ASTM E797/E797 M. This calibration is necessary because heat alters the speed of sound in metal and causes thermal expansion of the transducer contact area. The mapping revealed areas where the wall had lost 40% of its nominal thickness; therefore, 10.6 m² were designated for preventive repair.
Thanks to this test, the client obtained a complete diagnosis of the corrosion on their equipment, without interrupting their process. This success story highlights the reliability of the hot ultrasound technique in ensuring the safe operation of assets and avoiding costly unscheduled downtime.
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References
[1] “Global Non-destructive Testing Market in Oil and Gas Industry 2024-2028.” https://www.giiresearch.com/report/infi1581838-global-non-destructive-testing-market-oil-gas.html (accessed May 22, 2025).
[2] “Asset management: Drones deployed for offshore remote inspections | Offshore.” https://www.offshore-mag.com/business-briefs/equipment-engineering/article/55270973/flyability-asset-management-drones-deployed-for-offshore-remote-inspections (accessed May 22, 2025).
[3] N. Jose, H. Azari, and L. Highway Technology Partners, “Implementation of Phased Array Ultrasonic Testing (PAUT) For Bridge Welds,” Feb. 2024, doi: 10.21949/1503647.
[4] R. Kazys and V. Vaskeliene, “High Temperature Ultrasonic Transducers: A Review,” Sensors 2021, Vol. 21, Page 3200, vol. 21, no. 9, p. 3200, May 2021, doi: 10.3390/S21093200.
- Aníbal Alviz Meza.
- David Ruiz García
- ITIC-GROUP