Condition monitoring with Non-Destructive Testing (NDT)

Detect in-service corrosion, wear and damage to support safe operation and targeted maintenance

For operators responsible for structures, tanks, piping and other critical assets, limited insight into condition during operation creates uncertainty and risk. Ageing, corrosion, wall loss and cracking can develop unevenly and remain unnoticed until they affect safety, availability or compliance.

Tracking asset degradation during operation

In-service non-destructive testing provides a direct view of how assets change over time, identifying degradation where it matters most. Condition data supports targeted maintenance, clearer prioritisation and more reliable operation, helping operators avoid reactive repairs, unplanned stoppages and uncertainty about fitness for service.

Technicians perform in-service non-destructive testing on a suspension bridge cable using rope access, inspecting structural condition and corrosion while the bridge remains in operation. — Technicians perform non-destructive testing to monitor the condition of a suspension bridge cable, assessing corrosion, wear and structural integrity in an exposed, hard-to-access location.

Challenges

When asset condition remains uncertain during operation, risk and inefficiency increase

Restricted access limits inspection coverage
Critical areas are located in confined, elevated or shielded positions that are difficult to reach during operation, leaving parts of the asset outside normal inspection routines.

Progressive wall thinning reduces structural margin
Corrosion-related wall loss develops gradually and may not be visible through spot checks, reducing remaining strength before intervention is triggered.

Service-induced damage evolves between inspections
Fatigue, wear and cracking can initiate and grow under operating loads between planned inspections, narrowing the window for preventive action.

Incomplete condition data weakens maintenance decisions
When degradation is uneven across components, limited or fragmented data makes it difficult to prioritise repairs, justify interventions or plan maintenance with confidence.

Benefits

Make confident maintenance decisions and avoid surprises

Earlier detection, fewer unplanned stoppages

In-service non-destructive testing reveals degradation before it affects safety or output, helping avoid sudden interruptions and reactive maintenance.

Targeted intervention, lower maintenance waste

Reliable condition data reveals exactly where corrosion, wall loss, or damage is most advanced, reducing unnecessary repairs and focusing effort where it delivers the most value.

Clear trends, more confident lifetime decisions

Documented changes in condition highlight how assets age, supporting well-timed repairs, safe life extension and long-term planning.

Extended reach, fuller understanding of asset health

NDT techniques and access solutions enable the assessment of areas that are normally out of reach, providing a more comprehensive and reliable view of the in-service condition.

Let’s make sure your condition monitoring needs are met

We can help you clarify what to monitor, which NDT methods fit your assets and how the results support maintenance planning and documentation.

Service scope

NDT methods for evaluating assets in operation

Magnetic particle testing (MT) detects surface and near-surface cracking in ferromagnetic structures subject to fatigue or impact loading during operation. Penetrant testing (PT) reveals fine surface defects on components affected by wear, environmental exposure or operational stresses. 3D Magnetic Flux Leakage (3D MFL) maps surface and near-surface deterioration in ferromagnetic components exposed to operational loads.

Ultrasonic testing (UT) measures wall thickness, detects corrosion and identifies internal flaws as components age in service. Phased array ultrasonic testing (PAUT) delivers detailed views of internal flaws, corrosion profiles and weld conditions to track changes over time. P-scan provides repeatable ultrasonic data for monitoring the development of indications across multiple inspection intervals. Time of Flight Diffraction (ToFD) measures the location and size of service-related cracking in welds and structural joints with high accuracy.

Digital radiography (DR) provides internal imaging of in-service welds and components to detect cracking, wall loss or localised damage. Radiographic testing (RT) assesses internal conditions where access limitations or complex geometries require image-based evaluation. Visual testing (VT) identifies visible deterioration, deformation or surface damage under real operating conditions. Rope access enables condition assessment of structures in hard-to-reach locations without the need for scaffolding or shutdowns.

Standards

Recognised frameworks for in-service condition assessment

Establishes how measurement quality and traceability must be demonstrated in condition evaluations carried out on operating assets.
Read more
Describes the competence requirements for inspectors qualified to perform in-service non-destructive testing.
Read more
Explains how to examine tanks and piping exposed to corrosion, wall thinning and ageing while in operation. Owner or sector specifications define documentation requirements for maintenance, integrity and operational decisions.
Read more