Hydrogen-induced cracking (HIC) continues to pose a significant threat to the integrity of pipelines, pressure vessels and steel infrastructure in the petrochemical sector. Dekra Industrial South Africa is responding with an advanced non-destructive testing (NDT) portfolio that sets new benchmarks for early detection and reliability in asset integrity management.
"With continuous investment in equipment and people, we are setting new standards for asset integrity in South Africa’s petrochemical sector,” says Bennie Groenewald, Business Line Manager, NDT/Advanced NDT at Dekra Industrial.
Unlike surface-level damage, HIC develops internally as atomic hydrogen diffuses into steel, leading to blistering and stepwise cracking. Early detection remains a complex challenge. Dekra Industrial addresses this with precision NDT techniques including:
- Total focusing method (TFM): high-resolution ultrasonic imaging to detect sub-surface defects as small as 200 microns.
- Time-of-flight diffraction (TOFD): ultra-low angle (ULA) methods for improved defect detection and sizing.
- Metallographic verification and destructive testing: for comprehensive characterisation when required.
These methods provide both qualitative and quantitative insights into HIC, enabling more accurate maintenance planning, repair decisions and improved operational safety.
Backed by Dekra Group’s global research and development expertise, the South African operation has invested in next-generation phased array ultrasonic testing (PAUT) units, advanced data-processing software, and internationally trained Level 2 and 3 NDT specialists. This combination ensures a high degree of accuracy, consistency and actionable results for clients.
Beyond HIC, Dekra Industrial also offers advanced detection of high-temperature hydrogen attack (HTHA) through techniques such as automated ultrasonic backscatter (AUBT) and advanced velocity ratio measurement (AVR). Remote Access Inspection (RAI) solutions—using crawler, camera and drone-assisted tools—will soon be introduced locally to enable safer, more efficient inspections in confined or hazardous environments.
“For a petrochemical refinery, a hydrogen plant or a remote pressure vessel site, our approach is always rooted in accuracy, safety and international best practice,” adds Groenewald. “We do not just find cracks - we help our clients to ensure asset integrity, and prevent potentially catastrophic failure.”
From petrochemical refineries to hydrogen infrastructure and green energy facilities, Dekra Industrial’s advanced NDT capabilities are set to play a pivotal role in safeguarding industrial assets across South Africa and the wider continent.
