Non-Destructive Testing (NDT) for DAR Petroleum Operating Company (DPOC)

Project Overview

Between 2021 and 2023, Esnad Supplies successfully delivered a landmark NDT project for DPOC, safeguarding critical oil and gas infrastructure across South Sudan.

Operating in some of the region’s most remote facilities, the project aimed to enhance operational safety, reliability, and compliance of assets including processing plants, storage tanks, pipelines, and separators.

Our team deployed advanced inspection techniques to mitigate risks associated with aging infrastructure, ensuring DPOC’s uninterrupted operations and regulatory adherence.

Impact & Legacy

This project set new benchmarks for asset integrity management in the region.

Leveraging state-of-the-art NDT technologies such as Acoustic Emission Testing (AE) and Phased Array Ultrasonic Testing (PAUT), Esnad delivered actionable insights that extended the lifespan of DPOC’s assets while minimizing downtime.

Beyond technical excellence, Esnad invested in local workforce development. Our training initiatives empowered local talent, built sustainable capacity, and left a lasting positive impact on South Sudan’s oil and gas sector.

Key Challenges & Solutions

1. Pandemic Disruptions

Challenge: 15-month delay due to COVID-19 lockdowns and travel restrictions.
Solution: Implemented rigorous health protocols and adapted schedules to safeguard teams and maintain productivity.

2. Remote Operations & Environmental Risks

Challenge: Hazardous conditions and limited infrastructure in remote locations.
Solution: Distributed team structure across Khartoum, Juba, and on-site teams ensured continuity.

3. Complex Project Scope

Challenge: Inspection of over 1,300 piping systems and 69 tanks, including in-service assets.
Solution: Applied AE testing for tanks in operation, eliminating the need for shutdowns.

4. Budgetary and Partnership Dynamics

Challenge: Initial withdrawal of JV partner and scope expansion increased project costs.
Solution: Strategic project management kept the final project value at a viable USD 3.19M, demonstrating financial prudence.

Advanced Technologies Deployed

Ultrasonic Testing (UT): Measured wall thickness and detected internal flaws.
Radiographic Testing (RT): Inspected welds and structural integrity.
Magnetic Particle Inspection (MPI): Detected surface and near-surface cracks.
Dye Penetrant Inspection (DPI): Verified surface defects.
Acoustic Emission Testing (AE): Enabled real-time tank inspections without operational disruptions.

Measurable Outcomes

Technical Excellence

100% inspection coverage of critical assets.
Critical issues like corrosion under insulation and weld integrity risks identified.
Actionable recommendations for immediate repairs and future monitoring.

Safety Achievements

Over 104,920 safe man-hours with zero Lost Time Injuries (LTIs) or fatalities.
Effective COVID-19 risk management kept operations safe and efficient.

Financial Success

Despite scope increases, the project was completed within the revised budget.
Resource efficiency and innovative solutions delivered maximum value for investment.

Conclusion

This project with DPOC exemplifies Esnad Supplies’ commitment to excellence, innovation, and resilience.

By integrating advanced NDT methods, strategic project management, and local capacity building, we not only delivered exceptional technical outcomes but also strengthened the future of energy operations in South Sudan.

Esnad continues to set industry benchmarks, proving that with the right expertise and dedication, even the most challenging environments can achieve operational excellence.