NDE Solutions was proud to support Santos with one of its largest and most critical shutdown projects – the Darwin LNG (DLNG) Life Extension.

The Darwin LNG Life Extension Project (DLE) by Santos aimed to confirm plant integrity post a lengthy period where inspection had not been undertaken. Over a three-month period, 25 multi-disciplined NDE personnel were engaged on the DLE project, working hand-in-hand with the Santos project team.

The Challenge

With the commercial imperative to extend the life of the critical DLNG plant, Santos engaged numerous contractors to support the extension of this critical infrastructure. NDE Solutions, as primary NDT and inspection contractor, was required to undertake advanced test and inspection methods to detect critical defects and provide detailed visual evidence and data. Extended periods between comprehensive inspections presented challenges to plant reliability assessments. Ensuring asset readiness within tight timelines added complexity to the evaluation process.

How NDE Supported the Project

Over the course of a time-constrained and challenging multi-disciplinary project, NDE’s leading team of NDT and inspection professionals proudly supported the critical DLE project, delivering and executing on Santos’ plans for the critical plant.

In delivering these NDT and inspection scope of works, NDE sought to meet our Santos’ expectations in accordance with the following key values:

1. Innovation centric: NDE is proud to support our clients, including Santos, with the leading inspection technology including drones, crawlers and laser profilometry to provide strong and precise inspection data and findings.
2. Striving for a safe future: During this 3-month period, 16,126 hours delivered no recordable safety incidents or near misses, demonstrating a strong commitment to safety culture.
3. Strong and cohesive teamwork and project management: Our team was managed by onsite shutdown coordinators with significant project and team management experience to ensure Santos schedules were met.
4. Adaptability: NDE Solutions overcame remote conditions, emergent and unexpected scopes, and other constraints throughout the project.

Key Technologies Used

• Snowy crawler: Enabled efficient vessel and confined space inspections.
• Drone inspections: Accessed remote areas with laser profilometry and mapping.Advanced tube inspection: Used near-field array methods as alternatives to IRIS.
• Phased array and other advanced methods: Delivered precise wall thickness and flaw detection.

The Results

• Increased productivity: Tailored inspection methods ensured scope execution success and minimised asset downtime.
• Enhanced safety: Remote tools significantly reduced the need for confined space entries and promoted safety.
• Data precision: Delivered actionable data with repeatable accuracy.

Through innovation and dedication, NDE Solutions set a benchmark for excellence, achieving impactful outcomes for Santos and the DLNG Life Extension Project.

“NDE Solutions played a pivotal role within the shutdown. The level of experience and cohesion within the NDE team was exceptional. They were very approachable, friendly and brought a good team environment workplace. The team adapted to emergent work requirements without fuss. I would highly recommend NDE Solutions for any future work.”

Heath Summerville – Commissioning
Execution Superintendent