Speak to one of our team now +44 (0)1493 653535
Speak to one of our team now +44 (0)1493 653535
The Brief
ASAMS was engaged by a global engineering and asset management organisation to investigate severe corrosion affecting multiple kiln pipe sections operating at unusually high temperatures (>800°C). We delivered a failure investigation combining destructive testing with external chemical analysis, XRD, SEM, and EDX. The programme was completed within seven weeks, identifying the most likely damage mechanisms and supporting mitigation planning.
The Challenge
Client & Asset Overview
A global engineering and asset management organisation supporting complex assets across the energy, chemical, and resources sectors. The client provides multidisciplinary engineering services throughout the full asset lifecycle, including design, construction, operation, and maintenance of high‑temperature process equipment.
The Challenge
Unexpected corrosion was identified on multiple kiln sections operating increased temperature conditions, raising concerns around asset reliability and the risk of repeated damage following repair. The client required a clear, independent understanding of the corrosion mechanisms involved to support effective remediation, minimise downtime, and reduce future operational risk.
Scope of Work
ASAMS delivered a comprehensive, end‑to‑end failure investigation, beginning with a transparent quotation that clearly outlined each test and the insight it would provide. The scope included charpy impact testing to ISO 148, detailed metallographic examination, and SEM/EDX and XRD analysis, all coordinated through ASAMS’ in‑house capabilities and trusted specialist partners to identify material embrittlement, microstructural degradation, and high‑temperature corrosion mechanisms.
Our Approach
On receipt, the kiln sections were catalogued, photographed and examined to preserve evidence and traceability. Testing was structured so subcontracted analyses ran in parallel with inhouse work, and results were consolidated into a single, evidence-based report to support decision making.
The Result
Results & Findings
Interpretation & Root Cause
The investigation indicated that prolonged exposure to unusually high operating temperatures promoted sensitisation and creep related degradation, increasing susceptibility to intergranular corrosion and embrittlement. Findings also suggested a contribution from high temperature coal related corrosion mechanisms, including reducing sulphidation and metal dusting, with the potential for local nickel sulphide related liquid metal embrittlement. Conclusions are based on laboratory examination of the supplied sections; wider operating conditions were not directly assessed.
Key Outcomes & Client Benefits
ASAMS provided a clear, evidence-based view of kiln condition and the most likely damage mechanisms, enabling informed decisions on repair strategy, mitigation options and future operation. Findings were issued in a single, clear report to reduce uncertainty and support confident asset management planning.
Services Provided by ASAMS
Need certainty on a materials or failure issue?
ASAMS provides accredited metallurgical, mechanical, and corrosion testing to turn complex failures into clear, actionable decisions. Speak to a metallurgist today about your investigation or qualification requirements.
