Corrosion Survey & Integrity Assessment
A comprehensive corrosion survey was recently carried out at a major RO Desalination Plant on the western side of Saudi Arabia. The inspection campaign combined visual examinations, non-destructive testing (NDT), metallurgical analysis, ferrite testing and other NDT techniques to evaluate the condition of critical process equipment.
Scope of Work:
- Sea Water Intake (SWI) System – Assessed for structural soundness, corrosion, and leakage issues.
- Pre-Treatment Filtration Units – Inspected for coating failures, rust accumulation, and valve performance.
- Sea Water Reverse Osmosis (SWRO) Section – Focused on pipes, valves, and pumps, where localized corrosion, gasket degradation, and leakage were key concerns.
- Post-Treatment & Auxiliary Systems – Examined for chemical exposure effects, environmental corrosion, and sealing integrity.
- Metallurgical Studies – Replica metallography confirmed that no detrimental microstructural phases were present; however, ferrite distribution indicated localized susceptibility to stress corrosion cracking.
Key Findings:
- Localized corrosion and surface scaling at several joints and valves.
- Evidence of leakage at couplings and flange connections in the RO brine headers.
- Antiscalant and chemical dosing systems showing crystalline deposits and sealing inefficiencies.
- Pumps and auxiliary systems generally intact but requiring preventive maintenance.
Recommendations:
- Immediate repair of leakage points and replacement of degraded gaskets.
- Regular cleaning of corroded surfaces and reapplication of protective coatings.
- Laboratory failure analysis for critical components to strengthen long-term reliability.
- Implementation of enhanced maintenance protocols to mitigate operational risks.
Impact:
This study highlights the importance of proactive corrosion management in desalination facilities. By identifying degradation at an early stage, corrective actions can be applied to ensure plant reliability, protect water security, and extend asset life in one of the most challenging operating environments.
For more information email us at info@petromaster-sa.com or speak with us directly at +966-13-896-7124.
