On-Stream Inspection of Flanges: A Digital Approach to Corrosion Management (C2026-00371)

Mamdouh Alotaibi, Hussain Ali Al-Hadhban

In oil and gas facilities, flanges are crucial locations where localised corrosion and gasket deterioration can result in leaks, unscheduled shutdowns, and expensive repairs. Depressurisation and disassembly are usually necessary for conventional inspection techniques, which interrupt production and raise operating expenses. This study presents a digitalised on-stream inspection method for raised face flanges that makes use of complementing non-intrusive monitoring approaches and Phased Array Ultrasonic Testing (PAUT).
Field case studies from upstream and midstream operations show how early identification of wall loss, pitting, and surface degradation is made possible by combining digital corrosion management platforms with on-stream inspection. In order to improve asset integrity and save lifetime costs, the gathered inspection data is trended and examined to prioritise maintenance, aid in predictive decision-making, and optimise shutdown schedules. Optimisation of the inspection workflow, adherence to pertinent industry standards (such as API 570/574), and methods for integrating inspection findings into more comprehensive corrosion risk assessment models are among the lessons learnt. This methodology demonstrates how operators seeking to reduce failure risks and reinforce corrosion management principles across a variety of oil and gas assets can achieve a scalable solution by integrating modern non destructive evaluation with digital management tools.