Condition Assessment of Corroded Piping for a Power Plant in Africa

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The client requested ETD to conduct Conditional Assessment on corroded piping for its newly constructed plant. During the commissioning stage, the client found there were leakages on some piping which were rectified accordingly. Pin holes were also observed on piping and reject tank during this stage. As the commissioning progressed, the owner observed that the corrosion on most of the plant piping and some tanks were getting worse. 

The scope of the work included:

  • Visual and dimensional examination - This was performed on the samples in order to assess any obvious issues with the quality of internal and external surfaces of the pipes, or with any welds in the pipe samples, condition of oxide scale, corrosion damage, past repairs and any other signs of distress etc. and to select representative locations for more detailed investigation such as locations of the exact failed/ damaged areas or where the presence of deposits and/or corrosion has been detected.
  • Metallographic examination – This was carried out on sections through the wall of the pipe samples using optical microscopy. This was to enable the condition of the internal and external surfaces and assess the damage mechanism(s). The microstructure was examined for evidence of degradation (e.g. spheroidisation). Any evidence of cracking/micro-cracking or manufacturing defects was also noted.
  • Sand Analysis – A sample of the sand was sent to see the Chloride Level and any other corrosion issues like Microbiological Induced Corrosion or any live microbes etc. in the environment.
  • Report – A report (PDF copy) was issued detailing the findings with photographic records and test results. Furthermore, the report included the aforementioned results without discussing the mode of the failure and remedial action, as this is wasn’t a complete failure analysis study.

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