The pipeline inspection industry faces a myriad of challenges, particularly when dealing with extensive and complex networks. Our client, a leader in this field, frequently inspects pipelines in diverse environments like roads, rivers, power plants, and offshore sites Identifying and addressing issues like corrosion under insulation (CUI) is essential but often time-consuming and expensive with traditional methods. Ensuring pipeline safety and reliability is crucial. The need for innovative, efficient, and cost-effective solutions is more urgent than ever due to recent economic pressures and competitive tendering systems.
There were quite a few challenges faced by our client. One of the issues lay in the identification of corrosion under insulation (CUI). The conventional inspection method of removing insulation was both time-consuming and costly for asset owners. Also, with an extensive pipe network spread across diverse environments such as roads, rivers, power plants, offshore topside pipework, jetty lines, and refineries, the difficulty of identifying CUI amplified.
Secondly, the increase in the adoption of tendering systems with the L1 criteria, which awards contracts to the lowest bidder, resulted in our client being hesitant to invest in new, high-cost inspection solutions due to the reduced rates making it challenging to justify the expenses associated with these solutions (ROI).
The proposed LRUT solution included a system with transducer rings placed around a pipe. The proposed LRUT solution involved placing transducer rings around a pipe to generate low-frequency waves that provided complete coverage of the pipe wall, including clamps and buried sections. These waves detected changes in wall thickness, indicating corrosion or damage. Apart from that, to secure our client’s confidence, we partnered with Guided Ultrasonics Ltd. (GUL), UK, and invited them for a successful demonstration in India. This included a comprehensive trial at a major fertilizer company in Gujarat with the SGS team, resulting in technology approval by both the fertilizer company and our client. Subsequently, we collaborated with GUL to explore a bundled LRUT system with all necessary collars and negotiated a special discounted offer for SGS with attractive pricing.
As we diligently monitored all inspection tenders from asset owners, we conducted meetings supported by comprehensive data and facts. The analysis indicated that our client stood to secure 250 to 270 days of LRUT inspection work from these tenders issued by government asset owners across India. This substantial volume of work was crucial for our client, as it promised to significantly contribute to achieving a favourable return on investment for the LRUT cost.
During the implementation, we requested GUL to include training charges in the bundled offer. Upon receiving the equipment, GUL’s technical experts visited India to train our client’s engineers. Additionally, a select number of our engineers also received training on GUL LRUT equipment to prepare for any future technical support our client would need. After multiple rounds of meetings with GUL, they also agreed to provide loaner equipment to our client during the warranty period.
The implementation of our LRUT solutions resulted in significant benefits:
a) Reduced Inspection Time: LRUT enabled rapid inspection of corrosion under insulated pipes. It screened a 100-meter length in just 10 minutes, eliminating the need to remove insulation, saving considerable time.
b) Faster Project Completion: LRUT facilitated efficient completion of inspection projects within timeframes set by asset owners. This not only resulted in cost savings but also avoided the time and expense of removing and reinstalling insulation for the entire inspection.
c) Inspection of Buried Pipes: Previously inaccessible pipelines under roads and bridges were seamlessly inspected using LRUT. This provided valuable data on corrosion in these hard-to-reach areas.
