Advanced XRD Profiling of Residual and Total Stresses in Penstock Pipelines for Enhanced Structural Integrity

Abstract:

Penstock pipelines in hydroelectric power plants are critical components whose structural integrity is paramount for reliable operation. However, they are subjected to severe operational conditions generating complex stresses, favoring low-cycle fatigue crack initiation, particularly at critical weld zones. This is exacerbated by anomalous operational cycles like repetitive emptying and filling. This study presents a comprehensive methodology combining X-ray Diffraction (XRD) with other Non-Destructive Testing (NDT) techniques to assess residual stresses and their impact on pipeline integrity. XRD quantifies net stress under empty pipeline conditions, determining superposition between intrinsic residual stresses (manufacturing, welding, service-induced) and non-hydrostatic loads (self-weight, geomechanical forces). Diffraction pattern analysis yields crucial stress distribution data [1-5], identifying critical concentration zones prone to fatigue [6-10]. Complementary NDT techniques reveal morphological discontinuities influencing material mechanical behavior. Correlating XRD and morphological findings establishes cause-effect relationships between structural state and measured residual stresses. This integrated methodology offers significant predictive maintenance advantages, providing quantitative assessment of current pipeline state and projecting future performance.

• Periodical: Key Engineering Materials (Volume 1036)
• Pages: 101-114
• DOI: https://doi.org/10.4028/p-GHi8PI
• Online since: December 2025
• Authors: Sebastian Acuña, Camilo Seifert, Daniel Hincapie, Andres Felipe Duque, Alejandro Morales-Ortiz*
• Keywords: Hydroelectric Power Plants, Non-Destructive Testing (NDT), Penstock Pipelines, Residual Stress, Structural Integrity, X-Ray Diffraction

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