Corroded Conduit replacement

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California
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Associate EE
I have a corroded conduit at a waste water treatment facility. Any Ideas on replace/adding new conduit without having to disconnect and pull the wires back. these wires feeds many loads and we can not shut theses equipment's down any time soon. Thanks Everyone

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Hi, WoW

My first thought was this is probably not the only place the issue exists at your site.
Odds are there are other similar issue locations, unless you know exactly what caused the corrosion and therefore why the problem might be just in this one spot.

To your question: (In my Root Cause Analysis education/training it is heavily geared to Defining the Problem, specifically)
With much respect I would suggest taking a Big Picture look at this situation in a regulated environment.

First, is the issue Acute or Chronic. In other words is this an immediate Safety Issue requiring An immediate Shutdown or a Problem that needs resolution.

This is the path I would suggest
Contact Management, describe the finding, indicate you will be speaking w/ your Safety Department
Discuss the Hazard and possible injuries to individuals and damage to assets
Quickly determine what needs to be done immediately, cordon off area, signage, determine a safe way to cover the exposure (a hut?)
Inspect the rest of the facility, similar areas (underground), Is this systemic across the site or local to just here
Depending on findings
Systemic: You need help, it would be a huge undertaking to fix, electrical contractors, Digging Excavation contractors
Local: I believe at some point you will have to shut down. So do everything possible to make the time period as short as possible. Possibly create a parallel path(s) for the circuit(s). Installing junction boxes either side of the effected area. Wire box to box in prep. Prepare landing points for Old Wires to connect into New Junction Box Circuit, Once everything new/parallel is prepped safely, and a proper, safe, orderly shut down is performed, the switch over would hopefully go quickly.

Just my 2Cents
 
I have a corroded conduit at a waste water treatment facility. Any Ideas on replace/adding new conduit without having to disconnect and pull the wires back. these wires feeds many loads and we can not shut theses equipment's down any time soon. Thanks Everyone

View attachment 2568809
Would not recommend what we did many years ago while an apprentice and the electrician that I worked under would do anything to get out of working overtime. When three phase lines had to be relocated due to new equipment or walls be removed if there was enough space in a pull box or through we would run new conduits then tape off one end and tie it into energized conductors that were never color coded. Then we we measure voltage to see what wire went to what phase then tie it in hot. Then cut old wires .You might want to install the gray coated heavy wall conduit that even has a protective red coat of paint on interior wall to prevent corrosion. Only used it once maybe 40 years ago.
 
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