Why Verifying Impact Sensors Before Shipment Matters More Than Ever

6 October 2026

A small device with potentially major consequences

The safe transportation of large electrical equipment such as power transformers, gas-insulated switchgear (GIS), and other critical long-lead assets is essential to the successful delivery of major energy and infrastructure projects. While these assets are designed to withstand the demands of transportation, they remain vulnerable to hidden damage caused by excessive mechanical shock during transit.

Internal winding displacement, movement of core components, loss of clamping force or active-part damage can occur without visible external signs. In many cases, such damage may only become apparent during commissioning, testing or even after energisation, when the operational and financial consequences are significantly greater.

To help manage this risk, manufacturers routinely install impact or shock recorders that monitor acceleration events throughout the transportation process. These devices provide valuable data on shocks experienced by the equipment, creating a time-stamped record that can be reviewed by project owners, OEMs, insurers and risk engineers.

However, the effectiveness of this control depends entirely on one critical factor: the recorder must be operational throughout the entire journey.

The growing challenge of transit risk in the Middle East

Recent disruption to regional shipping routes, including those passing through the Red Sea and the Strait of Hormuz, has resulted in longer voyage durations, increased port dwell times, additional trans-shipment activities and more frequent handling of project cargo.

These conditions increase both:

The likelihood of impact events occurring during transit
The duration over which monitoring equipment must remain powered and operational

As transport routes become more complex, ensuring the continued functionality of impact sensors becomes increasingly important. A discharged battery, incorrect configuration or failure to initiate logging before departure can leave project stakeholders with an incomplete record of the equipment's transportation history.

Without reliable monitoring data, assessing whether damage occurred during transit becomes significantly more challenging.

Why missing data matters

The consequences of a failed impact recorder extend far beyond the cost of replacing a battery.

Where monitoring data is unavailable or incomplete, project teams may face:

Additional testing requirements

Owners and contractors may need to undertake supplementary testing beyond the planned Site Acceptance Testing (SAT) programme to establish the condition of the equipment. This introduces additional cost, resource demands and programme risk.

Delays to commissioning and startup

Uncertainty regarding the condition of critical equipment can delay energisation activities while further inspections and testing are completed.

Insurance and liability challenges

When damage is discovered after delivery, impact recorder data often provides key evidence for determining where and when a loss occurred. In the absence of this information, allocation of responsibility between carriers, contractors, suppliers and insurers can become significantly more complex.

Potential Delay in Start-Up (DSU) exposure

In the most serious scenario, an undiscovered impact event may not be identified until startup, potentially resulting in equipment failure, replacement requirements and substantial Delay in Start-Up (DSU) losses. Given the long manufacturing lead times associated with large transformers and other critical electrical assets, the financial consequences can be considerable.

Case study: Transformer delivery in Saudi Arabia

A recent project in the Kingdom of Saudi Arabia highlighted the importance of maintaining reliable impact monitoring.

Several Generator Step-Up (GSU) transformers arrived at site with impact recorder batteries either discharged or no longer functioning. As a result, the project team had incomplete evidence regarding the conditions experienced during transportation.

While no actual transit loss was identified, the absence of reliable monitoring data prompted the site's quality team to adopt a precautionary approach. To increase confidence before energisation, they elected to repeat the full Factory Acceptance Testing (FAT) programme on site.

The additional testing successfully provided assurance regarding the condition of the transformers. However, the situation demonstrated how a relatively minor issue involving a small monitoring device can have significant implications for project schedules, resources and risk management processes.

Strengthening controls before shipment

One of the most effective opportunities to manage this exposure exists before the equipment leaves the manufacturer's facility.

At this stage:

The equipment remains accessible.
OEM personnel are available.
The transportation process has not yet begun.
Verification activities can be completed with minimal effort.

Prior to shipment, project teams should consider confirming that:

Impact recorder batteries are fully charged or newly installed.
Devices are correctly configured.
Monitoring thresholds have been established.
Data logging has commenced.
Operational status has been documented and recorded.

For projects involving extended transit routes, multiple transportation legs or route diversions, consideration should also be given to obtaining verification evidence at key transfer points throughout the journey.

Considerations for insurers and marine warranty surveyors

Although verification of impact recorder functionality isn't always a formal insurance requirement, it represents a practical and low-cost control that can provide considerable value.

Where marine warranty surveyors are already attending loading operations or reviewing shipment documentation, confirmation of recorder functionality can often be incorporated into existing pre-shipment procedures without creating additional project burden.

Independent verification that a recorder:

Has adequate battery life,
Is correctly configured, and
Has commenced recording,

provides stronger evidence than relying on post-delivery confirmation should an issue later arise.

As project cargo routes continue to evolve, insurers may wish to consider incorporating this control into broader risk management expectations for high-value and DSU-sensitive equipment.

A low-cost control against a high-consequence risk

In an environment where project schedules are under pressure and logistics routes remain unpredictable, maintaining confidence in the condition of critical equipment has never been more important.

Verifying impact recorder functionality before shipment is a simple and cost-effective measure that can significantly reduce uncertainty following a suspected transit incident. For project owners, EPC contractors, OEMs and insurers alike, this small step can help avoid substantial downstream costs, programme delays and disputes.

As the Middle East continues to invest heavily in energy and infrastructure development, reinforcing this basic control represents a sensible approach to protecting some of a project's most critical assets.

Stephen Scott

Divisional Director - Head of Risk Advisory

Dubai

Disclaimer

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