Ultrasonic Testing for Oil and Gas Operations

Ultrasonic Testing solutions tailored for Reliability Consulting for Oil & Gas Operations operations.

47% Reduction in unplanned downtime
85% Faults detected before failure
3-6mo Average fault lead time
5:1 Typical program ROI

Why it matters

Key Benefits

Ultrasonic Testing for Oil & Gas Equipment Reliability

Our airborne and structure-borne ultrasonic detection program inspects gas compressors, pipeline pumps, turbine generators, fin-fan coolers, and produced water injection pumps to detect compressed air leaks, steam trap failures, bearing lubrication deficiencies, and partial discharge in switchgear. In oil & gas environments — remote wellpad, gathering, processing, and refining facilities with extreme weather exposure and limited on-site staff — geographically dispersed assets with inconsistent connectivity and extreme environmental conditions from arctic cold to desert heat. Our team delivers leak survey maps with estimated CFM losses and ROI calculations for repairs calibrated to the specific failure modes and operating conditions found in oil & gas operations.

Supporting API/OSHA PSM Compliance Through Condition Data

Oil & Gas facilities operate under API 670/610/618 machinery standards, OSHA PSM, and BSEE regulations for offshore operations. Our airborne and structure-borne ultrasonic detection program generates documented condition records that demonstrate api 670 continuous monitoring compliance for critical machinery and psm mechanical integrity audit readiness. This audit-ready documentation reduces regulatory exposure and supports your team during inspections and third-party audits.

Reducing Production Deferral At $10K–$100K Per Day in Oil & Gas

Unplanned equipment failures in oil & gas operations cause production deferral at $10K–$100K per day, flaring, safety incidents, and environmental releases. Remote locations require route-based programs; many sites have no permanent maintenance staff. By applying airborne and structure-borne ultrasonic detection to gas compressors and other critical assets, our program provides the advance warning needed to schedule repairs during available maintenance windows and protect production uptime and deferrals avoided targets.

Context

Challenge & Approach

The Reliability Challenge

Gas leaks at remote facilities may require fugitive emission reporting. IS-rated instruments are required in hazardous classified areas. Multiple remote sites need coverage from limited specialist visits. Valve pass-through on safety-critical isolation valves has process safety implications.

Our Approach

We survey gas systems with IS-rated ultrasonic instruments, identify leaks that may require reporting under LDAR or fugitive emission regulations, assess critical valve seat condition using contact ultrasound, cover multiple remote sites per mobilization trip, and deliver findings in formats supporting both maintenance planning and regulatory compliance.

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Common Questions

FAQ

Questions our clients ask most often about this reliability program.

In oil & gas operations, our airborne and structure-borne ultrasonic detection program focuses on gas compressors, pipeline pumps, turbine generators, fin-fan coolers, and produced water injection pumps. We measure high-frequency sound emissions from friction, turbulence, and electrical discharge to identify compressed air leaks, steam trap failures, bearing lubrication deficiencies, and partial discharge in switchgear before they progress to functional failure. Oil & Gas facilities present specific challenges: remote locations require route-based programs; many sites have no permanent maintenance staff. Our program is designed around these constraints, delivering leak survey maps with estimated CFM losses and ROI calculations for repairs that your maintenance team can act on within the scheduling realities of oil & gas production.

Limited Availability
We onboard a limited number of new facilities each quarter. Secure your assessment slot before our current availability closes. Reserve Your Spot →

Get Started

Request a Free Reliability Assessment

Tell us about your equipment and facility. Our reliability team will review your situation and recommend a tailored reliability program — no obligation.

Free initial assessment
Response within 1 business day
No obligation or commitment

No obligation. Typical response within 24 hours.

Survey Gas Systems for Leaks That Waste Energy and Trigger Reporting Requirements

Every gas leak is potential fugitive emission — we find them and document them for both maintenance and compliance.

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