Investigation and Condition Assessment of P91 Large Bore Piping for a European Power Plant

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The client required an independent technical review of all their P91 material following the discovery of some cracking in the manufactured welds. Therefore, ETD were approached to submit a proposal with the objective of assessing the condition/ suitability of the piping system for safe start-up and long-term use.

Required work included:

  • Welding Procedure Specification (WPS) and Weld Procedure Qualification Records (WPQR);
  • Weld and parent metal microstructures (reports including microstructure images supplied by the client);
  • Mechanical test results for full section weld sample;
  • Metallographic reports on surface breaking and detected subsurface defects;
  • Fitness for Service (FFS) study reports;
  • Contractors consultant report on weld condition;
  • Extent and type of NDT carried out on completed welds.

The final report included the results of documents review and the recommendations of any additional actions/testing considered necessary to ensure the integrity of the piping system.

For more information on our condition assessment services, please click here.

On-site LFET Inspection and Condition Assessment for Boiler Furnace Hopper Tubes at a Asian Power Plant

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ETD was approached to submit a proposal on condition and damage assessment of furnace hopper tubes of a boiler by performing on-site LFET (Low Frequency Electromagnetic Technique) inspection, analysis and assessment of the tubes.

The objectives and scope of the work to be carried out were:

1.  Review the drawings of furnace hopper tubes of the boiler to be studied and identify accessible test locations for on-site LFET inspection;

2.  Perform on-site LFET (Low Frequency Electromagnetic Technique) inspection of furnace hopper tubes for the quantity;

3. Analysis the on-site LFET inspection data:

  • To detect internal tube thinning/gouging due to the hydrogen damage. 
  • To determine the internal wall thinning. 
  • To determine the active and dominant damage mechanism and level of degradation.

4. Review & analysis previous failures, inspection and maintenance data for the furnace hopper tubes;

5. Perform assessment of hydrogen damage and/or other damage(s) and current condition of furnace hopper tubes based on the findings of all above investigations.

6. Prepare a full report including results of on-site inspections, analysis results of damage & condition assessment study and make recommendations for any further actions to be taken for safe and reliable operation of the boiler.

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Condition Assessment of Corroded Piping for a Power Plant in Africa


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.

For more information on our condition assessment services, please click here.