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Detecting Underground Threats with Guided Wave Technology4

Detecting Underground Threats with Guided Wave Technology4

by | Mar 24, 2026 | Case Studies

Detecting Underground Threats with Guided Wave Technology

Underground piping failures can pose significant risks to industrial facilities, from costly repairs to disrupt-ing operations. Addressing these hidden issues requires advanced technology and skilled expertise. XCEL was approached by a Midwest refining client to tackle an issue involving their underground piping sys-tems, ultimately preventing catastrophic failures and setting a new standard for inspection programs.

Challenge

In 2019, the client experienced a piping failure at a road crossing within their plant, exposing vulnerabili-ties in their underground systems. Seeking an effective solution, the client contacted XCEL. The challenge was to identify defects in the underground piping, particularly at road crossings and piping supports.

  1. After a thorough evaluation, XCEL personnel determined Guided Wave Technology was the optimal method to detect the defects in the underground piping. A team was de-ployed to conduct immediate inspections at several road crossings.
  2. Guided Wave Technology was utilized to scan and assess the piping condition, especially at critical piping supports.
  3. The XCEL team identified multiple areas with significant underground corrosion that had gone unnoticed. XCEL performed excavation and directly assessed the affected areas. This confirmed the presence of severe corrosion, with several areas being at or near failure.

Outcome

XCEL’s intervention addressed the immediate issue but also led to the client implementing more long-term preventive measures. The client established a full-time underground piping inspection program. This program now utilizes two Guided Wave units, operating daily by two two-man inspection teams.

Thanks to XCEL’s advanced methods and insights, the client mitigated risks, enhanced the reliability of their underground piping systems, and prevented costly failures.

CTA

XCEL leverages cutting-edge technology to deliver proactive solutions for facilities around the coun-try. Learn More about how our trusted inspection services can protect your assets and safeguard your facility.

Simplifying CUI Inspections and Maintaining Compliance

Simplifying CUI Inspections and Maintaining Compliance

by | Mar 24, 2026 | Case Studies

Simplifying CUI Inspections and Maintaining Compliance

Corrosion Under Insulation (CUI) is a persistent challenge for industrial facilities, often requiring resource-intensive methods for identification and mitigation. XCEL, being the primary service provider at a large chemical facility in the Gulf Coast, provided a solution, which streamlined CUI inspections and enhanced operational efficiency.

CHALLENGE

The facility’s CUI project depended on Digital Radiography (DR) to inspect areas where long strips of insulation had to be removed. While effective, this process was time-consuming and labor-intensive, creating inefficiencies for the client. The challenge was to meet industry-standard inspection requirements while minimizing disruption and using resources effectively.

SOLUTION

After discussions with the client to understand their needs, XCEL recommended the use of Real Time Radiography (RTR) for targeted inspections. This approach provided several advantages:

  1. Reduced Effort: RTR eliminates the need to remove insulation, saving time and resources while still fulfilling procedural requirements.
  2. Efficient Screening: RTR allowed the client to quickly identify suspect areas, so they could focus efforts on actual problem points without exhaustive insulation removal.
  3. Compliance: Both RTR and DR solutions aligned with the facility’s operator procedures.

Over the years, XCEL’s innovative techniques have become a standard part of the facility’s CUI inspection processes.

OUTCOME

Implementing RTR and DR resulted in measurable, long-term benefits for the Gulf Coast facility. The facility experienced:

  • Streamlined inspections by enabling CUI detection without insulation removal where possible.
  • A more proactive approach to CUI management with better screening solutions.

CTA

At XCEL, we design solutions that simplify inspections, achieve compliance, and deliver results. Contact Us Today to learn how we can help optimize your integrity management processes

Achieving Swift and Successful Refinery Turnaround with Expert NDT

Achieving Swift and Successful Refinery Turnaround with Expert NDT

by | Mar 24, 2026 | Case Studies

Achieving Swift and Successful Refinery Turnaround with Expert NDT

Turnaround and shutdown periods at major refineries are essential for ensuring safety and operational readiness. For the CHS Inc. refinery in McPherson, Kansas, their 2025 spring turnaround required a vast scope of non-destructive testing (NDT) to validate the facility’s readiness for reinstatement into production.

CHS entrusted XCEL to execute thorough NDT testing over a rigorous 24/7 operational schedule.

CHALLENGE

Refinery turnarounds present unique challenges due to their scale and complexity, and the spring turnaround for CHS was no exception. The project’s requirements included a comprehensive range of NDT services, from basic techniques like Liquid Penetrant Testing (PT), Magnetic Particle Testing (MT), Ultrasonic Thickness Testing (UTT), and Radiographic Testing (RT), to advanced methods such as Guided Wave Ultrasonic Testing (GWUT) and Phased Array Ultrasonic Testing (PAUT).

Adding to the complexity, the scope of work had to be executed continuously over a five-week duration on a 24/7 schedule. Staffing for such an intensive project presented a significant challenge, requiring 100 skilled personnel sourced from XCEL’s locations all across the United States.

SOLUTION

To ensure the success of the turnaround, XCEL implemented a robust plan, leveraging its expertise in large-scale inspection projects.

Key actions included:

  1. Comprehensive NDT Service: A full suite of NDT services was deployed to meet the extensive inspection requirements, ensuring weld quality and detecting equipment anomalies before the facility’s reinstatement into production.
  2. Quick Mobilization: A team of 100 personnel was mobilized from all XCEL locations nationwide, matching the project’s extensive manpower demands to ensure uninterrupted operations during the 24/7 inspection schedule.
  3. Task Management: The intricate scheduling and execution of inspection activities were carefully managed to ensure quality and adherence to the client’s timeline.

XCEL’s ability to deliver advanced inspection services while adhering to a strict structure was key to addressing the unique demands of this turnaround.

OUTCOME

Through XCEL’s efforts, CHS’ McPherson refinery received comprehensive data to confirm the integrity of its critical assets and validate the facility’s readiness for production. For XCEL, the success of the project, despite the small timeframe, made it one of their most impactful inspection efforts in recent history.

CTA

XCEL is your trusted partner for large-scale NDT and inspection services, preserving integrity even under the most demanding conditions. Contact us today to learn how we can help optimize your facility’s safety and safeguard assets.

Partnership to Deliver Turn-Key Solutions

Partnership to Deliver Turn-Key Solutions

by | Mar 24, 2026 | News

Norman, OK — XCEL NDT LLC (“XCEL”), a leading provider of non-destructive testing (NDT) and industrial services, today announced the acquisition of Integrity Assessment Group (IAG). The combination expands XCEL’s service portfolio and industry reach—most notably into Power Generation—and sets the foundation for a long-term partnership focused on delivering turn-key solutions for customers.

“Bringing IAG into the XCEL family is about building something stronger together,” said Cole Morehead, Chief Executive Officer of XCEL. “IAG’s business model and momentum complement ours, and we see clear, immediate opportunities for synergies and cross-selling. Their Pipeline Maintenance & Cathodic Protection (CP) group will continue to operate under the Integrity Assessment Group entity, enabling a turn-key sales strategy. That’s a win for customers who want fewer handoffs, faster execution, and clear accountability.”

The acquisition adds service lines not previously offered by XCEL and broadens coverage into additional industrial markets, with minimal client and geographic overlap between the two companies. Customers will benefit from expanded manpower, specialized equipment, and senior technical leadership, with a disciplined integration plan that prioritizes safety, quality, and continuity of service.

About XCEL NDT LLC
XCEL NDT LLC provides NDT services to mission-critical customers across the United States. The company’s expansive team of experienced technicians utilize an array of conventional and advanced equipment to ensure critical infrastructure is functioning reliably and safely, and to help customers maintain compliance with stringent regulatory and insurance requirements. Learn more at xcelgrp.com.

About Integrity Assessment Group
Integrity Assessment Group delivers inspection and NDT services across multiple industrial markets and operates a Pipeline Maintenance & Cathodic Protection (CP) group that enhances turn-key delivery for customers. Learn more at www.int-grp.com.

Taking a Turnkey Approach to CUI Inspections

Taking a Turnkey Approach to CUI Inspections

by | Feb 11, 2026 | Case Studies

Achieving Swift and Successful Refinery Turnaround with Expert NDT

Turnaround and shutdown periods at major refineries are essential for ensuring safety and operational readiness. For the CHS Inc. refinery in McPherson, Kansas, their 2025 spring turnaround required a vast scope of non-destructive testing (NDT) to validate the facility’s readiness for reinstatement into production.
CHS entrusted XCEL to execute thorough NDT testing over a rigorous 24/7 operational schedule.

Challenge

Refinery turnarounds present unique challenges due to their scale and complexity, and the spring turnaround for CHS was no exception. The project’s requirements included a comprehensive range of NDT services, from basic techniques like Liquid Penetrant Testing (PT), Magnetic Particle Testing (MT), Ultrasonic Thickness Testing (UTT), and Radiographic Testing (RT), to advanced methods such as Guided Wave Ultrasonic Testing (GWUT) and Phased Array Ultrasonic Testing (PAUT).

Adding to the complexity, the scope of work had to be executed continuously over a five-week duration on a 24/7 schedule. Staffing for such an intensive project presented a significant challenge, requiring 100 skilled personnel sourced from XCEL’s locations all across the United States.

Solution

To ensure the success of the turnaround, XCEL implemented a robust plan, leveraging its expertise in large-scale inspection projects.

Key actions included:

  1. Comprehensive NDT Service: A full suite of NDT services was deployed to meet the extensive inspection requirements, ensuring weld quality and detecting equipment anomalies before the facility’s reinstatement into production.
  1. Quick Mobilization: A team of 100 personnel was mobilized from all XCEL locations nationwide, matching the project’s extensive manpower demands to ensure uninterrupted operations during the 24/7 inspection schedule.
  1. Task Management: The intricate scheduling and execution of inspection activities were carefully managed to ensure quality and adherence to the client’s timeline.

XCEL’s ability to deliver advanced inspection services while adhering to a strict structure was key to addressing the unique demands of this turnaround.

OUTCOME

Through XCEL’s efforts, CHS’ McPherson refinery received comprehensive data to confirm the integrity of its critical assets and validate the facility’s readiness for production. For XCEL, the success of the project, despite the small timeframe, made it one of their most impactful inspection efforts in recent history.

CTA

XCEL is your trusted partner for large-scale NDT and inspection services, preserving integrity even under the most demanding conditions. Contact us today to learn how we can help optimize your facility’s safety and safeguard assets.