Using Strain Gauge Testing to Validate Pipework Under New Operating Conditions

Strain Gauge Testing for Pipework

Changes in production, flow rate or equipment configuration can alter the forces acting on connected pipework. Before new operating conditions are introduced, engineering teams may need evidence that the system can perform safely without creating damaging vibration-induced stresses.

AVT Reliability’s Asset Integrity Division supported an offshore project where a new well was being brought online. The customer needed to understand how increasing production would affect the connected pipework and whether the resulting stresses could increase fatigue risk.

Measuring behaviour during commissioning

AVT Reliability engineers installed high-temperature strain gauges connected to a 64-channel data acquisition system. Machine Sentry® technology was also used to collect vibration information throughout the commissioning process.

More than 50 hours of strain data and 15,000 vibration measurements were captured as operating conditions changed. This allowed the engineering team to assess how the pipework responded under real production loads rather than relying solely on assumptions or static calculations.

Assessing vibration-induced fatigue risk

The measured data was reviewed against the Energy Institute Guidelines for the Avoidance of Vibration Induced Fatigue Failure and BS 7608.

By working closely with the control room team, AVT Reliability helped identify operating conditions that supported increased production while maintaining confidence in pipework integrity.

Evidence for safer engineering decisions

Strain gauge testing can support the validation of new installations, plant modifications, commissioning activity, fatigue assessments and investigations into pipework vibration.

Measuring actual structural response gives engineers a clearer basis for deciding whether an asset can operate safely under revised conditions. It helps replace uncertainty with evidence and can identify where further analysis, reinforcement or operational controls may be required.

For critical infrastructure, the ability to balance production objectives with asset integrity is essential. Strain measurement provides the data needed to make that balance with greater confidence.