Overview

An engineering team for a major oil and gas services company was tasked with finding a technology solution to coordinate the high-pressure workflows related to flange management (i.e., a systematic approach to ensure the integrity and reliability of flanged connections in piping systems). Typically covering inspection, disassembly, and reassembly of flanged joints. With tight timeframes and high compliance requirements, they needed a smarter way to manage risk, visibility and execution quality. By adopting Inspectivity’s digital inspection platform alongside live Power BI dashboards, the client transformed how flange management work was planned, tracked and controlled. This resulted in faster decisions, fewer delays and enhanced QA traceability.

Background

Flange management is a critical operational process in energy and infrastructure maintenance. Whether carried out during periodic asset overhauls, ongoing field maintenance or dedicated intervention campaigns (shutdown/turnaround), the integrity of flanged joints directly impacts plant safety, equipment reliability and schedule adherence.

Previously, flange maintenance activities were managed through manual paperwork and spreadsheets. This made it difficult to capture inspection data in the field, track work against defined packages and produce accurate, timely reports. Documentation was often inconsistent, fragmented across teams and tools, and not easily auditable.

To improve visibility and consistency, the client sought a digital-first approach capable of standardising flange workflows, capturing key data points at source and surfacing insights instantly.

The Challenge

Teams needed a solution that could:

• Capture joint-specific data in the field with structured formats.
• Provide traceability for flange components, inspection results and technician credentials.
• Deliver real-time dashboards that guide decisions during active operations.
• Accommodate planned, unplanned, and witness joints within a unified framework.
• Enable filtering by boundary or location representing work zones or scopes.

A major requirement was live visibility. Teams had no immediate way to assess which joints required intervention, what stage each task was at or why progress was stalling.

The Inspectivity Solution

Structured Templates for All Scenarios

Leveraging Inspectivity Professional Services, our team delivered five purpose-built digital inspection templates covering diverse flange activities and joint types. These templates standardised the capture of:

• Flange specifications and joint dimensions
• Component materials and part numbers
• Initial flange condition, such as damage or corrosion
• Torque and tensioning method details
• QA steps and technician competency

Each joint managed is tagged with one or more boundary identifiers. This allows dashboards to aggregate and filter data by zone or scope.

Digital at Source, Integrated at Scale

Inspection data is captured in real time using mobile devices. Every data point, from flange class to tightening pressure, is synchronised with the Inspectivity platform and made available for downstream reporting.

All templates share a common structure. This allows seamless integration into Power BI dashboards that surface:

• Joint status such as Assembled, Disassembled or Repair Required
• Machining outcomes, such as Repair Completed versus Required
• Joint type categorisation including Planned, Witness and Unplanned
• Aggregated joint counts by boundary

Process-Oriented Dashboards

Three dashboards are configured to represent different flange activity phases:

• Preparation Phase: Disassembly and readiness checks
• Execution Phase: Inspections, machining and repairs
• Completion Phase: Reassembly and final verifications

Each dashboard includes interactive filters by boundary or scope, visual summaries of joint statuses and detailed asset-level insights. These tools helped managers identify issues early and intervene quickly.

What’s powerful about this implementation is that it reflects the client’s vision for digital workflows, executed rapidly using our no-code platform. The configuration itself becomes the client’s intellectual property, capturing their unique approach to flange management. Our role is to provide the digital foundation and flexibility so they can build, adapt, and scale with confidence.

Paul Eddison, Inspectivity co-founder

Results & Benefits

Inspectivity provided the ideal platform for a flange management environment where accuracy, visibility, and speed were essential.

• Asset-Centric Data Model: Every data point is linked to a flange asset and its lifecycle.
• Mobile and Offline Support: Field teams capture data on location regardless of connectivity.
• BI-Optimised Architecture: Inspection records and status flow directly into dashboards.
• Flexible Configuration: The platform adapts quickly to reflect new scopes and user roles.

The implementation of Inspectivity’s platform delivered measurable improvements across all aspects of flange management. Supervisors gained continuous oversight of joint activities, while engineers accessed live dashboards to make faster, more informed decisions. With every inspection and QA step digitally recorded, the process became fully traceable and audit-ready. Manual reporting was eliminated, replaced by structured, mobile-first data capture that ensured consistency and reliability at scale.

About Inspectivity

At Inspectivity, we’re revolutionising the world of asset management with our cutting-edge digital inspection software. Our platform is a versatile mobile and cloud solution, designed to simplify engineering inspection and asset management, all within a single, user-friendly tool.

Trusted by many tier 1 operators and service providers across a variety of sectors, we’ve harnessed technical expertise and industry-specific workflows to create a digital inspection solution that’s a game-changer.

If you’re ready to take your inspection processes to the next level, we’re ready to provide the ideal solution for you.