• Tube Failure Analysis

  • Our Introduction

    AMCO Integrity Pty. Ltd is an independent company registered in Australia. It is a highly innovative engineering and consulting company engaged in state of the art R&D and product development in the energy sector, including renewable and small scale energies, and in high temperature plant issues in general…

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  • EDSE Technology

    The Electric Discharge Sampling Equipment (EDSE) was developed by our UK based partner in collaboration with international partners to aid in the condition and life assessment of components. The sampling of in-service components has long been seen as an effective way of determining actual material properties and sub-surface material

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  • Portable SFM Technology

    The Portable Scanning Force Microscope (Integrity-Scanning Force Microscope) has been developed for early stage damage detection such as creep cavitation (especially in P91 & P92 steels) which will not be found using traditional replication techniques.…

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  • Obikou

    Obikou is an on-site service for power, process and other high temperature plant and has shown to achieve creep life extension by a factor of about 4. It simply involves quickly reinforcing a potentially vulnerable or creep damaged pipe with multiple layers of thin high-temperature alloys strip that is wound/wrapped around a pipe thus halting/ reducing the development of creep damage….

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  • Research & Development

    AMCO has excellent expertise through its in-house R&D, plant service/technical
    consulting and project management experience and links with plant manufacturers,
    plant operators, service providers and researchers from around the world.

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AMCO Integrity tube failure services can help plants people to improve boiler tube reliability and avoid costly outages.

AMCO’s expertise and experience can determine the root cause of tube failure with both in situ and laboratory analysis – and provide the remedial action and recommendations to solve tube failure.

Our applicable capabilities include, but are not limited to root cause analysis, metallurgical analysis, visual inspection, deposit weight density determination, chemical composition, wall loss determination, scale thickness measuring, pit depth measuring, mechanical failure analysis, and more.

Our assessing process determines failures by corrosion, stress ruptures, erosion, fatigue and/or maintaining quality control. As a preventative measure potential failures may be identified to avoid costly repairs and lost production.

Tube analysis and evaluation includes:

    1. Metallurgical evaluation plan
    2. Visual, non-destructive testing and as-received photo documentation
    3. Dimensional measurements on ring samples
    4. Material verification
    5. Metallographic specimen evaluations
    6. Hardness testing
    7. Internal scale and deposit characterization
      • Steam-cooled tubes – determine steam side scale thickness and morphology
      • Water-cooled tubes – determine the chemistry and deposit weight
    8. Analysis of data and report
    9. Conclusions
      • Cause of tube failure
      • Remaining creep life
      • Current tube conditionRemaining creep life


    1. Operational change
    2. Water chemistry changes
    3. Chemical cleaning
    4. Tube replacement
    5. Design changes
    6. Additional analysis

Prevent failures before they occur:

Tube assessment isn’t just a case of waiting for failures to happen.

AMCO can help identify key areas and develop inspection programs. Regular condition assessments can help identify potential problems and eliminate them before failure can occur.

Our unique expertise in probabilistic assessment means that you would need to inspect, check and repair or replace lesser number of tubes than under a deterministic assessment which is what most consulting companies or OEM’s will be able to offer you. This will of course help you with saving costs and increasing profitability.

At AMCO’s, we keep up-to-date with the latest research into damage mechanisms and new materials, so our clients receive the most accurate evaluations of problems and the best possible solutions that meet their requirements.

Our partner is one of the European leaders in specialist areas such as application of defect and probabilistic assessment of plant integrity. They wrote a detailed guidelines on Boiler Tube Failure (BTF), please feel free to contact us if you need this guidelines.