Applus+ conducts penstock integrity assessment, NDT inspection and corrosion evaluation for Sg. Perak hydroelectric plant in Malaysia

With more than three decades of continuous operation, the penstocks at Sg. Perak play a critical role in delivering high-pressure water to turbine systems. As part of the plant’s modernisation and life extension strategy, a detailed understanding of the current condition of these assets was required to ensure continued reliability under upgraded power generation capacity.

The inspection program presented several operational and technical constraints. The penstocks were large-scale assets with limited accessibility and confined working conditions. Long-term exposure to operational stresses had resulted in corrosion and material degradation in certain areas. In addition, inspections had to be completed within tight outage windows while maintaining strict safety controls for high-risk confined space environments.

The primary objective was to comprehensively assess the condition of the penstock systems, identify defects or weaknesses that could affect performance, and provide reliable asset integrity data to support safe operation under increased loading conditions associated with new generator installations.

Applus+ deployed a structured inspection methodology combining advanced and conventional techniques. Visual inspections were conducted across accessible areas of the penstock system, supported by confined space entry procedures and specialised access arrangements. All activities were executed in accordance with stringent safety protocols to ensure controlled inspection in high-risk environments.

The inspection program delivered a detailed condition assessment of the penstock systems, including the identification and characterisation of corrosion, defects, and potential failure points. Thickness measurement data and integrity readings were compiled to support structural evaluation. Weld areas were assessed for quality and discontinuities, and findings were consolidated into technical reports providing clear recommendations for repair, monitoring, or continued operation.

The findings enabled proactive maintenance planning and risk mitigation for critical hydroelectric infrastructure. The assessment supported the reliability of the water conveyance system under upgraded generator conditions and contributed to a structured life extension strategy for the plant. It also reduced the likelihood of unplanned downtime and helped operators strengthen long-term asset performance planning.

By ensuring the integrity of essential components such as penstocks, Applus+ supports hydroelectric operators in maintaining safe, reliable, and future-ready energy infrastructure.