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Case Study

National Oilwell Varco + University of Strathclyde

To develop a calibration and sensitivity system using advanced ultrasonic inspection of large and complex geometry parts

In-situ PAUT inspection on component

National Oilwell Varco

NOV is a worldwide provider of equipment and components used in oil and gas drilling and production operations, oilfield services, and supply chain integration services to the upstream oil and gas industry. The company operates in more than 500 locations across six continents through three reporting segments: Rig Technologies, Wellbore Technologies, and Completion & Production Solutions.

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What was the need?

The Challenge

The NOV components central to this project are large in scale with complex geometries. Such geometric complexity presents significant challenges for ultrasonic testing (UT), limiting access to certain regions of interest and increasing the likelihood of artefact generation. These artefacts arise from ultrasonic wave interactions with curved surfaces, variable geometry and features, which can complicate signal interpretation and reduce inspection clarity.

Current calibration and validation practices rely on the manufacture of full-scale representative test pieces. These are essential for inspection procedure development and for on-site calibration to verify equipment performance in accordance with industry codes and standards. However, given the substantial size and weight of NOV components, producing these calibration blocks is costly and logistically demanding. Transportation to operational sites further increases expense and complexity.

Field inspections must be both reliable and repeatable to achieve a high probability of detection (POD) for fatigue-related defects. A robust calibration and validation process is therefore critical to ensuring inspection accuracy, building confidence in the results, and demonstrating compliance with industry requirements.

What did we do?

The Solution

To address these challenges, the project adopts an integrated approach combining advanced simulation with targeted experimental validation. The objective is to develop a detailed understanding of ultrasonic wave propagation within large, geometrically complex components, enabling optimisation of inspection parameters and maximising POD.

The methodology is inherently iterative, using simulation tools to model beam behaviour, mode conversion, and geometric interactions before refining the approach through experimental trials. By leveraging simulation software early in the development cycle, the need for repeated manufacture of full-scale calibration pieces can be significantly reduced, resulting in substantial cost and time savings.

The insights gained will directly inform the design of scaled transportable calibration and validation blocks that remain representative of critical inspection challenges while being more practical and economical to deploy. This advancement will strengthen the effectiveness of condition-based maintenance CBM programs, deliver added value and reduce operational costs for customers, and create opportunities for new service offerings within NOV’s Aftermarket business unit.

What changed?

The Impacts and Benefits

Impacts for the Company 

A collaboration with the university offers NOV a structured pathway to accelerate the development and validation of PAUT for in-situ inspection of critical equipment. By combining academic expertise in simulation, modelling and experimental validation with NOV’s field experience and operational requirements, the project can deliver optimised calibration and validation designs that are fully aligned with international codes and standards. This reduces technical risk while strengthening the robustness and defensibility of inspection procedures deployed within CBM programs.

For NOV, the commercial impact is significant. Implementing validated PAUT solutions enables inspection of components without full strip-down, directly reducing labour costs, minimising downtime, and improving asset availability for customers. The capture of high-quality, traceable inspection data also enhances predictive maintenance strategies, allowing more accurate planning of interventions and avoidance of unplanned failures. In addition, reducing unnecessary disassembly and component replacement supports sustainability goals by lowering material waste. Overall, the collaboration positions NOV as a proactive technology leader, delivering safer, more efficient, and data-driven lifecycle support solutions to the energy sector.

 

Impacts for the Academic Team 

The KTP project between the University of Strathclyde and NOV delivers strong academic impact through the generation of novel inspection and calibration methodologies, validated models, and transferable knowledge in advanced NDT. The integration of fast and high-fidelity simulation with experimental validation will advance fundamental understanding of ultrasonic wave, geometry and defect interactions in complex geometries, never encountered by the academic team before, particularly in the context of inspection using multi-skip waves through multi-meter cylindrical oilwell industrial components. This is expected to result in high-quality scholarly outputs, including a Master’s thesis, journal publications and leading conference contributions (e.g. BINDT, and ASNT), as well as underpinning future research proposals and collaborations with the oil and gas sector. Furthermore, the project embeds cutting-edge research into teaching through case study development and undergraduate/postgraduate guest lecture delivery, strengthening the research inspired teaching agenda. Importantly, the co-development of knowledge with our industry partner and its translation into impact case studies and presentations for wider NDE community will enhance the academic visibility and real-world relevance of the research, positioning the work at the forefront of model-assisted phased array calibration, inspection procedure development and innovation.

 

Impacts for the KTP Associate

As a KTP Associate working on PAUT of complex oil and gas drilling components, I benefit enormously from the collaboration between NOV and the University of Strathclyde. This partnership places me at the interface of cutting-edge academic research and real-world industrial application.

Through NOV, I gain direct exposure to industry-scale challenges, including the inspection of geometrically complex, safety-critical drilling components. I develop a strong understanding of operational constraints, commercial drivers, and regulatory requirements, ensuring that my technical solutions are practical, robust, and aligned with business needs. Working within an industrial environment also strengthens my project management, stakeholder engagement, and cross-functional communication skills.

At the same time, the University of Strathclyde provides academic rigor and access to advanced research expertise in PAUT. This enables me to apply state-of-the-art modelling, simulation, and data analysis techniques to improve defect detection and characterisation.

Overall, the collaboration accelerates my professional development, enhances my technical depth in PAUT, and positions me as a specialist capable of translating research innovation into measurable industrial impact.

The People

Meet the Team

David Allan

KTP Associate


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Dr Ehsan Mohseni

Knowledge Base Supervisor


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Steve G Baxter

Company Supervisor


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