Pipeline Corrosion Protection Methods

Posted by & filed under Pipe Corrosion.

Corrosion is a terribly annoying byproduct of metal pipelines. A recent study found that the global cost of corrosion to float somewhere around $2.5 trillion.

That’s nearly 3.4% of our planet’s global GDP.

If you own a factory or plant that houses pipelines and other metalworks, you probably already know what a cursed affliction corrosion can be. But if you’re trying to make your profit margins as wide as possible, you need to try your best to win in this battle against mother nature.

Below, we’ll detail 3 pipeline corrosion protection methods you can use to protect your hardware.

1. Cathodic Protection

Cathodic methods of corrosion protection are by far the most complicated, but it’s very effective. Cathodic protection works by creating an electrical current around the pipe using anodes and cathodes. Simply put, this system repels corrosive molecules away from the pipe.

In a sacrificial cathodic protection system, the cathodes begin to corrode instead of the more important metal pipes.

This method protects against galvanic corrosion. Galvanic corrosion happens when two metals are placed closely together in a corrosive environment – i.e. salty seawater or wet soil.

2. Metal Selection

In addition to cathodic protection, you can also select metals and other materials that are less susceptible to corrosion when creating your pipelines. No metal is truly immune to corrosion. What once came from the ground will have to return in death, but some are better than others.

Materials such as stainless steels, plastics, and special alloys can greatly extend the life cycle of a pipeline. Nickel, stell, or titanium alloys are particularly good at preventing corrosion. This is especially true when coupled with a different protection method like cathodic protection.

It’s also important to monitor the surface of the materials once you’ve put them to use. Cracks, chips, and fissures from general wear-and-tear in the pipeline can rapidly increase the rate of corrosion.

3. Environmental Modification

Since it takes two to tango when it comes to corrosion, you can also try to change the other end of the equation: the environment itself.

Corrosion occurs when the metals of your pipeline come into contact with the corrosive liquids and gasses in its environment. So you can also reduce corrosion by trying to get rid of or reduce the corrosive elements in your environment.

You can do this simply by limiting the metal’s contact with rain and other water by shielding it with some form of insulation, thus changing its environment.

You can also use different methods to reduce the amount of sulfur, oxygen, phosphorous, or chlorine in the soil or water the pipe is submerged in.

Need Help With Your Pipeline Corrosion Protection Methods?

Hopefully, this brief rundown of pipeline corrosion protection methods has given some ideas on how to limit the rate of corrosion at your factory or plant.

If you’d like material assistance in further preventing corrosion, you might want to check out our products. We make padding you can apply to your pipeline with a simple peel-back adhesive that will guard your pipes against corrosion.

cathodic protection system

Posted by & filed under Pipes.

Haven’t taken the necessary steps to secure the safety of your pipes? Then it’s a good thing you’re here.

Corrosion is a natural occurrence, but it’s not one that you want to happen at your business or your home. Protecting your pipes should be of utmost importance.

There are two safe cathodic protection systems that are proven to extend the life of your pipes. Read on to find out more – and to learn which system is right for you.

Galvanic Cathodic Protection System

There are two types of cathodic protection systems: the galvanic protection system and the impressed current protection system.

The galvanic protection system works when sacrificial anodes are fixed to the piping during the manufacturing phase. This requires special wiring for an inspection station to be installed near the surface of the ground.

Galvanic systems have a limited lifespan that depends on the life of the sacrificial anodes, which will continue to degrade as they protect the piping. Once the sacrificial anodes fail, the pipes will start to corrode.

This form of protection is the more common of the two since it’s much easier to set up and maintain. But it doesn’t hold up as well as the impressed current system.

Impressed Current Cathodic Protection System

The impressed current protection system takes a different (and perhaps more complex) route.

The impressed current system has a rectifier that allows it to convert an alternating current to a direct current to slow the formation of rust.

In other words, it uses an external power supply to drive continuous current through the pipes, minimizing the amount of corrosion.

Because of this, the impressed current protection system usually provides a much longer lifespan than the sacrificial anodes of the galvanic protection system.

If needed, the current can also be modified to be stronger or weaker, and the greater amount of control does drive people to choose this option over the galvanic system.

That being said, the impressed current system is considerably more expensive than the galvanic system, and it’s much more permanent – meaning once it’s installed, there’s really no going back.

Make sure to think hard before you go for this option.

So What’s the Best Choice?

Both the galvanic system and the impressed current system do the job (to varying degrees of power and longevity) so the best choice is really based on your personal preference.

Most companies tend to choose the galvanic system because it’s easy to buy and install the necessary parts. Plus, replacement parts are easy to come by, and its a cinch to switch them out.

The impressed current system makes sure that the job is done right for a much longer period of time, but replacing the parts will not be an enjoyable task.

Both systems are safe for the environment, so it all comes down to your needs – and your wallet.

Give Us a Call

No matter what system you choose, you need to make sure it’s done by the pros.

Find out more about how we do business, as well as tips to get the most life out of your pipes.

Still have questions? Send them our way. We’ll look into it and get back to you with factual answers you can trust.

We look forward to hearing from you.

corrosion of pipelines

Posted by & filed under Pipe Corrosion.

America transports goods and other forms of material through 2.4 million miles of pipelines.

Crude oil, natural gases, sewer, and most importantly, water travels through these pipelines, which is why the need to understand the environmental factors that cause corrosion of pipelines is important.

Corrosion of pipelines is the leading cause of tank and pipeline failures. The United States spends $7 billion per year to monitor, replace, and maintain pipelines.

Billions can be saved if more knowledge regarding the factors that cause corrosion of pipelines was made more readily available.

Here are 4 environmental factors that can speed up the corrosion of pipelines.

Soil Resistivity and Corrosion of Pipelines

Soil Resistivity is an environmental factor that has to do with the amount of soil that resists the circulation of electricity through it.

The electric current that’s determined by soil resistivity promotes pipeline corrosion.

In a 12-month study on the relationship between soil resistivity and corrosion, the Journal of Corrosion Science and Engineering concluded that soil resistivity not only affects metals–of which pipelines are made of–but serves as an early indicator for the growth rate of corrosion.

Humidity

Humidity is a form of dew point corrosion that causes environmental corrosion in pipelines.

Dew point corrosion has to do with the damage that arises when the air rises to a certain temperature and the rate of its evaporation and condensation are at the same pressure.

Corrosion in steel pipelines happens in places where the humidity is very high. In Florida alone–which is a tropical state– there are over 31,177 miles of pipelines, 531 of which carry hazardous liquids.

Tropical states carry humid temperatures year round, a dangerous environment for pipelines. Corrosion is imminent.

Saltwater

Saltwater is another environmental factor that causes pipelines to corrode.

Steel pipelines that are exposed to saltier bodies of water like sea water corrode much faster than those near fresh water.

Salty water must be considered when making an attempt to prevent or manage pipeline corrosion.

Sulfur Dioxide

Environmental gases affect the rate of corrosion of pipelines as well. Sulfur Dioxide is one of them.

Sulfur Dioxide, usually found on the back label of most dried, packaged fruits, is a loud-smelling chemical compound.

Though harmless when it’s coated on a batch of apricots, sulfur dioxide turns to sulfuric acid when it’s combined with water and air.

Sulfuric acid is corrosive to steel.

In Summary

Miles of the American underground is inhabited by pipelines, underlying all fifty states.

Almost 200,000 of them transport hazardous liquids, while more than 300,000 haul different gases. These liquids and materials pass directly under our homes and businesses.

The United States could save billions of dollars if environmental factors were a consistent focus. These environmental factors–soil resistivity, humidity, saltwater, and sulfur dioxide–corrode pipelines, destroying the life and health of them over time.

Protecting pipelines against environmental factors that disrupt the safety of transporting hazardous materials is imperative. There are benefits to pipeline protection.

Check out our blog to find out more information and helpful hints about pipeline corrosion and the benefits of pipeline protection.

corrosion of pipelines

Posted by & filed under Pipe Corrosion.

The influential National Association of Civil Engineers (NACE) Cost of Corrosion study estimated a $276 billion in direct costs annually associated with metal corrosion in 2002. In the production and manufacturing sector alone, this is a cost of $17.6 billion every year.

Corrosion is a natural occurrence and the costs associated cannot be eliminated entirely. The NACE study notes that 25%-30% of annual corrosion costs can be saved by using optimum corrosion management practices.

To prevent and control corrosion, consider the specific material to protect. What product is transported or processed? Are there environmental concerns such as saltwater or soil to consider?

Need to figure out the correct corrosion inhibitors for your pipeline? Read on to learn more.

Don’t Let Corrosion Begin

Corrosion is the primary cause of failure of pipelines and tanks. Up to 80% or $4.5 billion of the annual cost to maintain, monitor and replace these assets is due to corrosion. Corrosion inhibitors are part of the annual maintenance of your pipeline, and while costly, the alternative is much more expensive.

Selecting the correct materials for your pipeline is the first step. Take into account the material to be transported, the distance and the environment.

Corrosion requires two dissimilar metals and a current-conducting medium between the two. Preventing contact between the metals and the electrolyte medium is the goal of any inhibitor.

Four Types of Corrosion Inhibitors

A corrosion inhibitor is a material that attaches to a metal surface, providing a protective barrier against a corrosive reaction developing.

Types of corrosion inhibitors:

Anodic inhibitors react with oxygen to form a thin film on the surface of the metal. They reduce the corrosion potential of the material by oxidizing a surface layer that is less reactive to corrosive elements.

Cathodic inhibitors slow the cathodic reaction itself or limit the diffusion of reductive elements such as hydrogen or oxygen to the metal surface. Examples are cathodic poisons such as arsenic and selenium ions which slow the reaction or oxygen scavengers such as sulfite ions which limit the diffusion of oxygen.

Mixed inhibitors are compounds that form a film or precipitate to reduce both the cathodic and anodic reactions. Sodium silicate and phosphates used in domestic water softener salts to prevent rust water are examples.

Volatile corrosion inhibitors are compounds delivered to the site of corrosion in a closed environment. They form a protective film only a few molecules thick. For example, in boilers, volatile compounds such as morpholine or hydrazine, are transported with steam to prevent corrosion in condenser tubes.

In shipping, wrapping metals in volatile corrosion inhibitor-coated paper is a common short-term protection against corrosion during transit. The chemicals in the paper continuously vaporize and fill the airtight package to protect against moisture and humidity.

Engineers Evaluation

Corrosion protection is a necessary part of asset maintenance for pipelines and tanks. Professionals develop specific protection strategies using some or all of these types of inhibitors as appropriate to their environment.

For more information about pipeline corrosion protection, tips and techniques, read our blog or ask questions below.

pipeline corrosion protection methods

Posted by & filed under Pipe Corrosion.

What do you do about your pipes? Most homeowners install pipes and forget about them.

When they experience damages such as leaks, they just patch up their pipes or install new ones. But practicing pipe safety will save you money and time in the long-term.

Pipe corrosion is one of the worst problems that can occur with metal pipes. Corrosion eats away at the surface of your pipes, causing leaks. They often go undetected, and you don’t notice corrosion until it’s too late.

Corrosion prevention sounds difficult. But once you get in the habit, it becomes fairly simple. Use these 3 pipeline corrosion protection methods and prevent pipe damage.

1. Apply a Primer

Applying a primer or finished coating is one of the easiest pipeline corrosion protection methods. Primers act as a barrier between the steel of the pipes and the corroding elements. Primers also prevent moisture from reaching the pipes.

When there’s a coating on your pipe, it takes longer for water and oxygen to diffuse. This slows the rate of diffusion to the metal of the pipe.

Depending on the primer you use, the primer can contain anti-corrosive properties. This helps develop a high electrical resistance and absorbs moisture. Primers protect both pipe surfaces and the underlying area of the pipes.

2. Regular Cleaning

When you perform spring cleaning, don’t forget your pipes. The key to pipeline corrosion prevention is regular cleaning. Cleaning prevents corrosion; in case corrosion does occur, clean pipes minimize the corrosive effects.

You should always use suitable chemicals to thoroughly clean your pipes.

These should be applied to the inside and outside of your pipes. The moisture first targets the outside of your pipes, but debris and contaminants stick to the inside of your pipes.

To effectively clean your pipes, use chemicals and wash off debris with a brush.

For thicker deposits such as wax, use a blade.

3. Choose Specific Materials

The best way to prolong pipeline life is by choosing appropriate materials. Metal is the most common chosen pipeline material, but it can be an easy victim of corrosion.

When installing your pipeline, choose corrosion-resistant materials. These include stainless steel, plastic, and other special alloys. If you prefer to have a metal or steel pipeline, consider adding one of these materials to your pipes.

However, keep in mind these materials largely depend on the environment of the pipes. Metal is often chosen because it can survive in several environments.

Always ask your pipe installer for advice.

Use These Pipeline Corrosion Protection Methods

If you don’t monitor your pipeline, your pipes will eventually deteriorate. One of the most common pipeline problems is corrosion. Corrosion weakens the integrity of your pipes, resulting in issues such as leaks.

When this occurs, you need to reinstall your pipe system.

Simple monitoring prevents spending lots of money on a new pipe system. Common pipe protective methods include consistently cleaning your pipes and using a primer or corrosion-resistant material.

Are your pipes weakened by corrosion? We can fix any pipe leaks.

pipeline maintenance

Posted by & filed under Uncategorized.

If you’re a plant owner or operator, there’s nothing more concerning than the C word. C, of course, stands for corrosion.

But pipes that don’t corrode are non-existent. Okay, plastic pipes don’t corrode. But they degrade, which means they’re also not perfect.

The good news though is there’s a way to avoid pipeline failure. And it has everything to do with pipeline maintenance and protection.

What is Pipeline Maintenance?

As you can gather from its name, pipeline maintenance means maintaining the integrity of a pipeline and all of its components. This is not a do-it-once-and-forget-about-it kind of thing.

You want to be as thorough as possible with maintaining your pipes if you want to keep them safe for life. This involves careful inspection, leak detection, and making sure the inside of the pipeline is clean as can be.

How to Protect Your Pipes

Since corrosion is the number one enemy of a pipeline, it makes sense to invest in corrosion protection. As we’ve said before, there are five ways to do this.

First is regular cleaning, which usually involves pigging and chemicals. Clearing the area around the line is also part of this process. Remember that any new vegetation growth could impede the proper functioning of the pipe.

Other corrosion protection methods are cathodic protection, use of corrosion inhibitors, as well as coating and linings, and abrasive blasting.

The Cost of Not Doing Maintenance for Your Pipes

$2.2 trillion. That’s the annual global cost of corrosion according to the World Corrosion Organization. But it’s not just about money. Corroded structures including pipelines can and do cause injury and death.

Corroded water pipes, for example, don’t just cause premature failure of plumbing systems and fixtures. Anyone who ingests corrosive water is in danger of exposure to heavy metals such as lead.

As you may already know, long-term exposure to lead has been linked to diseases including cancer, high blood pressure, stroke, seizures, and behavioral disorders (in children).

As for corroded oil and gas pipelines, there are other dangers to consider aside from hazardous materials leaking into the environment. Oil and gas are flammable, which means these lines are very much susceptible to explosions when exposed to heat or flame.

Plus, there’s the fact that replacing aging pipelines isn’t always practical. According to the National Association of Corrosion Engineers (NACE), oil and gas companies spend more than $7 billion annually to repair or replace corroded pipes. That’s a considerable amount compared to investing in fast, easy, and cost-effective pipe corrosion protection.

Prioritize Pipeline Maintenance and Protection

Now that you know the importance of maintaining and protecting the integrity of your pipes, it’s time to think about your options.

If you’re considering the most cost-effective solution, you can’t go wrong with DynaGard pipe saddles. Our products are designed to quickly eliminate the risk of pipe corrosion through prevention of moisture penetration and metal on metal contact.

Plus, they’re easy to install. If you have any questions about DynaGard products, please don’t hesitate to Contact Us. We would be more than glad to answer any concerns you may have.

corrosion prevention

Posted by & filed under Pipe Corrosion.

How can you implement a corrosion prevention plan for your pipelines? It’s not easy since corrosion is a part of nature’s process to break down materials.

It’s also the main cause of pipeline and storage tank leaks and breakdowns. These breakdowns cost up to $17 billion, according to NACE International.

Are you looking for ways to protect your pipelines from corrosion and economic catastrophe?

Read on for ways that proper corrosion prevention can save your pipelines.

What Causes Corrosion?

To understand how to best protect against corrosion, we have to first look at the underlying causes of corrosion.

Most pipelines are made from galvanized steel and coated with protective paint. Looking at steel at the cellular level, there are 4 components: an anode, cathode, electrolyte and a connected electronic path. These components make a galvanized cell.

Corrosion happens when the protective paint is compromised and the steel is exposed. These four components come into contact with soil or water. When exposed to the elements, the anodes and cathodes carry an opposite polar charge, connected by the electronic current.

The anodes then break down at a fast pace, causing corrosion. The corrosion then spreads throughout the pipeline, causing a tremendous amount of damage.

One of the main areas where corrosion occurs is around pipe supports. Pipe supports have a tendency to rub against the pipes, which can cause the protective paint to wear down. Water can also be trapped between the pipe and support. This combination can initiate the process of corrosion.

Once corrosion begins under pipe supports, it’s virtually impossible to inspect and maintain.

Wear Pads for Corrosion Prevention

There are multiple ways to protect your pipelines from corrosion.

Most pipelines have some sort of protective coating. The thing to understand about corrosion is that if one small area of the coating is cracked, that small area becomes vulnerable to the elements and corrosion.

That small area can make your entire pipeline vulnerable to corrosion.

By using wear pads in conjunction with pipe saddles, you can prevent metal to metal contact and prevent moisture from building up around the joint.

The thing is that not any wear pad is sure to protect pipes from corrosion.

Wear pads that separate the pipes from the support beam can prevent the direct contact. That would prevent the protective paint from breaking down.

The other critical piece is to have a wear pad that prevents moisture build up. Dynagard’s wear pads have a high-bond strength adhesive liner to prevent moisture from penetrating the support area.

Leave Corrosion Prevention to Professionals

Are you still concerned about the potential damage caused by corrosion? It’s easy to understand why, given how much economic and infrastructure damage can happen as a result.

Corrosion prevention requires a professional and experienced firm to diagnose and resolve potential hazards.

At DynaGard, we have over 15 years of experience working with the largest oil companies to protect their pipelines from corrosion, saving them time and money.

Contact us today for samples of our pipeline products. Our team is available to answer your questions.

corrosion protection methods

Posted by & filed under Uncategorized.

Pipelines are critical for infrastructure in the modern world. There are over 2.4 million miles of pipeline in the United States alone. Unfortunately, all these pipelines are susceptible to corrosion.

Corrosion protection methods are very important because corrosion can make water unfit to drink. It can also expose the environment to harmful materials.

Are you looking for some ways to ensure your pipeline stay free or corrosion? Maybe you already have a problem and need help on what to do?

Don’t worry, keep on reading for five easy methods to handle corrosion in any pipeline.

1. Protection & Cleaning

When thinking about corrosion protection methods, cleaning and protection should be at the top of the list. In combination with a Dynaguard corrosion protection system, regular cleaning will help to prevent corrosion. This can help you avoid having to deal with getting rid of corrosion down the road.

Have your pipelines cleaned regularly. This usually involves pigging and chemicals. Depending on the severity of your corrosion problem, different tools and materials may be used.

Another part of pipeline upkeep is clearing the area around the line. Pipelines will only function correctly if their path is not interrupted.

During the planning phase, be sure to remove all nearby tree roots. Monitor the area afterward for any new vegetation growth that could affect the pipe. Keeping the area clear will also make any needed repairs easier.

2. Cathodic Protection

This method of dealing with corrosion uses an electrical current. This controls the corrosion from becoming worse by neutralizing it.

Cathodic protection is used frequently with pipelines that are underground or in water. If done with a new pipeline, it can actually prevent corrosion from forming at all.

3. Corrosion Inhibitors

One other option for corrosion protection methods includes corrosion inhibitors. This method involves adding compounds to pipelines.

They can prevent corrosion from occurring on the inside by creating a thin layer of product.

Corrosion inhibitors are a popular choice because they are cost effective. Take one small step can help prevent costly pipeline issues down the road like oil spills.

4. Coatings and Linings

Using coatings are one of the easiest ways to protect your pipes against corrosion. Coatings and linings can be used on pipes that are above or underground. They frequently are used in combination with cathodic protection.

Some materials that are used to add defense to your pipelines include epoxy and zinc. Sometimes urethane is also used.

These materials must be properly applied and cured to be effective.

5. Abrasive Blasting

Corrosion is tackled by abrasive blasting through use of a high powered machined. The machine throws a certain material at a pipeline.

One benefit of abrasive blasting is that you can control and remove any current corrosion. It is often used first and then followed by another treatment to prevent further corrosion.

Choose Your Corrosion Protection Methods

You are now equipped with five ways to fight corrosion in your pipelines. By following these steps, you will ensure your pipelines remain corrosion free and safe for everyone.

Interested in talking about your particular situation with a professional? Contact us and we will help you with your needs.

cathodic protection

Posted by & filed under Pipes.

Plant managers and industrial pipeline workers should be aware of all the threats of pipeline corrosion.

About 85% of all steel is under threat of oxidation and galvanic corrosion because it is carbon-based.

Controlling corrosion involves implementing cathodic protection; this utilizes a process of electrochemical reactions, which suppresses oxidation inside a galvanized cell at the anode.

Pipeline managers must have a cathodic protection plan in place.

Cathodic protection applied during the initial construction or installation can extend operation for more than 30 years past the average lifespan.

It’s time to start protecting infrastructure and reducing maintenance costs.

Types of Cathodic Protection

All pipelines and tanks made of steel are subjected to the environment’s harsh elements. You must be proactive before signs of failure show up and it’s too late. Protection is prevention.

Cathodic protection can be applied in two fundamental ways, but they both achieve the same goals of avoiding the oxidation process.

Galvanic Cathodic Protection

Galvanic corrosion involves a system of sacrifice, where two metals are bonded by electrical current, with one metal being substantially more susceptible to corrosion than the other, thereby forcing it to take on all the corrosion.

It’s a very effective way to protect large structures and pipelines made out of metal because the sacrificial anode does not have to be equal in size, just enough to provide a place for the electrochemical process to happen.

Galvanic anodes can be utilized in underground, underwater, indoor, and outdoor applications. There is no additional equipment to buy and no additional power source needed.

Impressed Current Systems (ICCP)

ICCP is most commonly used on large metal buildings and structures, where the coverage is expanded by a process called impressed current cathodic protection.

In this scenario, when electrolyte resistivity is too high, an anode is enhanced through the use of an external DC power supply.

Sometimes an AC transformer is used to provide the DC power, that way the ICCP can stay efficient through the use of solar, wind, or eco-friendly generators, keeping costs low and consistent.

Cathodic Protection Design

To be the best and most efficient, cathodic security frameworks must be comprised of smart design and smart planning.

The best cathodic protection is a tested design that includes:

  • A comprehension of the ecological conditions and the structure to be shielded from erosion
  • Audit of cathodic protection installation for the structure or application
  • Determination of which major cathodic type (Galvanic or ICCP) is appropriate.
  • Finish the cathodic assessment using exhaustive tests and illustrations using the most recent drafting technology.

Contractors must have experience in working with and installing cathodic protection and dealing with corrosion, otherwise a simple mistake can leave you completely vulnerable.

Dynagard’s pipe wear pads are a great alternative for those looking for an affordable solution to protect pipes from wear and corrosion.

Getting the Job Done Right

You have to start your pipeline protection at the beginning of its life, preferably.

Utilize Dynagard’s pipe wear pads during the installation or you might be fighting an uphill battle against corrosion.

Providing protection isn’t just one-and-done, either. You must continue inspecting and maintaining it for the rest of its life.

If you want to learn more about protecting your business, you should contact us. Our wide selection of Dynagard pipe wear pad solutions guarantees that you’ll never be at the mercy of the elements.

pipeline maintenance

Posted by & filed under Pipe Corrosion.

Are you a plant owner or general manager looking for ways to maintain your pipeline?

According to the Pipeline Association for Public Awareness, government statistics show that “a common cause of pipeline incidents is improper or unauthorized digging near a pipeline.” 

Other major causes include “mechanical failure, human error, and corrosion.”

How can you ensure that you’re doing your part to prevent these kinds of incidents?

With pipeline maintenance, of course.

Read on to learn 5 maintenance tips for your pipeline system.

1. Right-of-Way Clearing

An important aspect of pipeline maintenance is right-of-way clearing. This is because a pipe needs a clear path of travel in order to operate the most efficiently and uninhibited.

During right-of-way clearing, trees and roots are removed so that the land near pipes is free of the threats of these conditions.

It’s also important that the right-of-way remains clear so that in the event of an emergency with your pipeline, it’s easily accessible for repair.

2. Hydrostatic Testing

To ensure the strength of the pipes in a pipeline, hydrostatic testing is recommended before and during their use. 

Hydrostatic testing is a procedure where the pipes you will use in your project are connected to one another. They are then filled with water at a higher rate of pressure than they will normally be. 

These high pressures help you see how well your pipeline will perform under heavy use.

Besides doing this before pipes are put in the ground, hydrostatic testing is also used to measure the strength of pipelines over time.

3. Identifying Corrosion

A way to help extend the life of your pipeline is by monitoring your pipes for any evidence of corrosion.

Protecting your pipeline against corrosion begins long before your pipes are put in the ground. Depending on the material your pipes are made out of, you should ensure you’re using an anti-corrosive coating. 

But even then, you still can’t protect 100 percent against corrosion. 

This is because natural conditions and accidents create a threat to your pipes. 

For example, a leak, emergency or natural disaster can cause serious damage. This means you should monitor how these substances impact your pipes. 

One way to address corrosion concerns is to use “pigs”. These are devices used to identify corrosion. They also repair certain issues without losing production time. 

4. Maintain Complete Records

When it comes to maintaining your pipelines, you should keep accurate records.

By doing this, you’ll give others a complete record of the life cycle of your pipeline. Besides keeping a database of site plans and pipeline product guides, you should also take lots of pictures.

This helps when it comes to showing the condition of pipes at installation. It will also serve as an important baseline to determine how quickly your pipes are corroding. 

5. Perform Regular Inspections

Regularly inspecting your pipeline is a great way to stay on top of maintenance issues that may arise.

This means being proactive and using an experienced crew who knows what to look for and what to do based on their observations.

If you’re not performing regular inspections, you put yourself at a greater risk for an emergency situation.

This can be dangerous for your employees and costly to your business – especially if the situation causes your operation to be offline for an extended time.

Wrapping Up: The Importance of Pipeline Maintenance

Pipeline maintenance begins at the planning stages of your operation. It also continues throughout the life of your business.

For more than 15 years, businesses have turned to Dynagard when it comes to corrosion control products. Contact us today to learn more about how we can help protect your pipelines!

pigging

Posted by & filed under Pipes, Uncategorized.

Pigging is a great way to protect your pipes without hurting your activity. Chances are, you’ve used “pigs” in the past.

But did you know there is a smarter way of fighting corrosion?

Intelligent pigging is taking the pipeline world by storm, and for good reason. It is by far the smartest method of finding corrosion and keeping you in business. But what is it, and what do you need to know?

Corrosion Is The Enemy

If you work with pipelines, you know corrosion is the root of all evil.

It makes water unsafe to drink or use and has killed more than 500 people since 1986. It’s a scourge upon our businesses, families, and communities.

In the United States, it’s a real problem. With so many pipelines over 50 years old, we are losing $300 billion per year to old metal.

So fighting corrosion should be priority number one for anybody who works with pipes.

But how do you do it without stalling your business? You can’t shut your pipes down and lose revenue, and wait until the problem happens and becomes more costly.

This is why pigging was invented. This procedure involves checking pipes with devices known as “pigs” to maintain the pipe.

Pigs can be used for a variety of tasks: cleaning, preventing leaks, and avoiding cross contamination with other pipes are all applications of this process.

Pigs have made fighting cross-contamination easier. But intelligent pigs are more than just a convenience: they are a blessing.

Intelligent Pigging

Intelligent pigs are one of the newest innovations in corrosion protection.

As the name implies, these technological wonders are no ordinary swine. Once launched in, they can inspect for deadly corrosion and leaks without interrupting your production cycle.

The techniques are mind-blowing. The old pigs were useful but performed only basic cleaning operation. Smart pigs are far more advanced.

Intelligent pigging can save you from corrosion by using things such as magnetic testing and sound to check for leaks, corrosion, and instability.

Knowing the signs of corrosion is an important way to protect your pipes, home, or business. But that may be easier said than done: if you’re worried about this in the home, you may not check your pipes all that often. And even if you are working with pipelines at a professional level, by the time you see the signs could be too late.

Smart pigs can get a lot of people out of a jam because they can find signs invisible to the human eye.

Conclusion

If you’re worried about the damage caused by pipe corrosion (and as we’ve said, you should be,) then smart pigs will absolutely save you and your business from future costs.

But don’t just trust anybody with this delicate procedure: it’s a complicated matter that requires professional work and equipment to get the job done.

If you want to keep your pipes safe, check out our store and contact us to work with the pros.

Your pipes (and wallet) will thank you.

 

 

pipeline corrosion

Posted by & filed under Uncategorized.

Corrosion is any pipe line’s enemy, but ignoring the warning signs can cost you more than just money.

Lives are also at risk. These ‘ticking time bombs’ have killed more than 500 people and injured over 4,000 since 1986.

The United States has over 2.4 million miles of pipe, making it the largest network of energy pipelines on Earth.

But here’s the problem: Over 50% of these pipelines are now over 50 years old. With age playing a large role in this corrosion, it’s now more important than ever to take action.

So, where does one start? Keep reading to find out everything you need to know about pipeline corrosion.

What is pipeline corrosion?

It is when the metal of the pipeline reacts to elements such as soil and water. Naturally, it will begin to rust over time, leading to corrosion.

What causes it?

Pipelines can corrode due to any of the following causes:

  • The pH level of the water
  • Water temperature
  • Certain minerals in the water (i.e. high levels of calcium)
  • Too much or too little oxygen in the water
  • Velocity of the water traveling through pipes
  • Exposure to sunlight
  • Underground soil and debris
  • Installation issues
  • High carbon environments (i.e. synthesis gas which causes metal dusting)
  • Impurities in the pipeline (such as impure gas, solids, or liquids)

The warning signs of pipeline corrosion

Be on the lookout for corroding pipelines by being aware of the following warning signs. If you notice any of these, immediate action is vital.

  • Discolored water, particularly brown.
  • Leaks, as they can indicate when a corroded pipe can no longer hold water. If left untreated, leaks can spread and cause more corrosion.
  • Strange-tasting water, which is the result of oxidation. This is the leading cause of corrosion in pipelines and oxidation can be dangerous to your health.
  • Clogged pipes, as this means there is a buildup in the pipeline which could cause an explosion or burst.

What are the effects of corrosion in pipelines?

Chemicals such as copper and lead can enter the water-flow when a pipe is corroded. Both of these can have serious health effects if the problem is not fixed quickly.

Health problems due to copper contamination include gastrointestinal problems. More serious contamination can lead to liver and kidney damage.

Lead contamination can cause kidney problems and high blood pressure in adults. In children, however, it can lead to physical and mental development issues.

Corroded pipes can also greatly affect businesses and the safety of employees. Aging pipelines cause major accidents such as explosions due to ruptures.

Additionally, corroded pipelines can cost companies a fortune. Each year, metal corrosion costs the U.S. economy almost $300 billion.

In 2010, a pipeline accident in Michigan caused 840,000 gallons of crude oil to leak into the Kalamazoo River. This pipeline spill alone cost $800 million to fix.

Don’t let that happen to your company!

Prevent pipeline corrosion with DynaGard

Get in touch with DynaGard today to find out how our DynaGard pipe protection products can help you.

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Commercial pipes burst for various reasons. Some bursts are as a result of negligence and others just accidental. But mostly, bursting of pipes is easy to avoid if only the right precautions are taken. Sometimes it only needs pipeline corrosion protection services to guard against bursting of the pipes.

These are 5 reasons why pipes would burst and cause untold water damage and loss.

1. Excessive water pressure

It’s a common cause of water pipes bursting and results from build up of pressure to a point the pipe cannot handle. The excess pressure is often caused by pipes clogging and letting only a little water through. Since more and more water is being pumped from the source, the pressure created has to find a way out and, it eventually leads to a burst.

A warning sing for this kind of danger would be taps that suddenly start to trickle water at unusually low pressure. If this happens, there’s a high chance that there’s a blockage somewhere and very soon a pipe burst will occur somewhere, usually at a point where the pipeline is weak.

2. Freezing weather

Cold winters usually cause pipes to burst. Water in the pipes starts to freeze. Freezing causes the water to expand, and when the pipe cannot take in the expansion, it bursts. This can be prevented by having insulation all around pipes to prevent the water inside ever reaching freezing point. Pipes that are exposed to the weather are, especially, vulnerable.

3. Exposure to weather and other activities

Pipes that are not laid underground are prone to damage both from natural factors and human activities. They’re exposed to the sun and other weather elements which cause them to deteriorate over time and in the long run cause them to corrode and crack. Pipeline corrosion protection methods such as insulation against the weather would go a long way to prevent damage and eventual loss.

Activities like construction can also lead to accidental bursting of pipes, especially if the pipeline is not conspicuously a labeled.

4. Poor quality pipes

Pipes that are manufactured out of poor quality materials or which were faulty at the time of leaving the factory are a disaster in waiting. Before laying them in the pipeline, they should be adequately inspected for quality and faults. It’s better to prevent than to have to do costly repairs.

5. Tiny cracks in the pipes

Cracks that a tiny and almost invisible are a cause of future pipe burst. They enlarge over time and when the start to let water enough to allow the pressure of the water to vent through the pipe bursts. This is why pipes should be inspected for cracks, right from the initial installation to during routine maintenance inspections. Neglecting a small crack can lead to expensive and inconvenience causing major repair, not to mention the damage the leaked water may have caused.

Burst pipes cause water damage to property around the area the burst happens. It can lead to costly water damage restoration. It is easier and better to prevent it; most of it is caused by not taking adequate prevention measures. Knowing the possible causes is the first step toward it. And taking action is the next.

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corrosion controlMeasuring in at over 2.4 million miles, the United States alone has the largest energy pipeline in the world. This includes over 72,000 miles of crude oil pipeline that connects regional markets across the country.

And while many companies, communities, and consumers recognize the corrosion issues associated with all this pipe they miss one major factor.

Beyond the commercial reasons for corrosion control safety is a huge concern with aging pipelines.

In fact, addressing the issue as fast as possible can save lives.

Let us show you how vital controlling corrosion is to safety:

The Leading Cause of Spills

A recent explosion killed 2 people and sent 2 others to the hospital in Colorado. The sad truth is many knew the risks surrounding the pipeline that ruptured.

As a result, the new state pipeline engineer in Colorado investigated accidents. They found that nearly half the pipeline failures in the state were a result of corrosion.

And Colorado isn’t alone. There are other parts of North America where corrosion is the leading cause of accidents.

With lives and injuries on the line, it’s more important than ever to address corrosion.

Safety Risks Are Increasing

As corrosion is the culprit in so many so many safety issues it is a necessity to address the concern fast. Critics remind all of us that as pipelines age the dangers will continue to grow.

While pipelines have been likened to the safe operations of airplanes, the comparison begins to fade as you consider the age of pipelines.

Unlike airplanes, pipelines aren’t maintained at the same level. As pipes age, the concerns grow.

Corrosion Can Act Fast

Aging pipelines aren’t the only culprit in major accidents. A recent pipeline blast in Pennsylvania was the result of miscalculations on the part of engineers.

During 2012 inspection officials noticed corrosion. But they anticipated the corrosion would grow at a rate of 2 to 3 percent annually.

The line corrosion increased approximately 5 times faster than expected.

The resulting blast burned 40 acres of land as well as a homeowner and his home.

Protect The Environment With Corrosion Control

Personal safety isn’t all that is at risk when pipelines suffer from corrosion. Corrosion led to a pipeline rupture in Santa Barbara last year that sent over 140,000 gallons of oil into the ocean.

The spill killed 204 birds and 106 marine animals.

Monitoring Isn’t Enough

In the case of the Santa Barbara oil leak the pipeline monitoring system had been turned off at the control center.

Unfortunately, inspections and monitoring aren’t enough when it comes to implementing safety controls. Lives are at stake.

We Can Help

With over fifteen years of experience, Dynagard offers the best in composite-based, corrosion control products. Major oil companies worldwide save money every day by protecting their steel pipes from corrosion using Riserclad solutions.

We can help you address your vital safety needs too. Don’t wait to save money and reduce your risk of liability. Let us help you with your corrosion control issue today.

Contact us now and we will answer your questions or provide samples of our DynaGard Pipe Protection Products to help you achieve your safety goals.

corrosion control

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Pipelines are some of the most incredible man-made objects you can find. They have to be planned, built, and maintained, which takes the effort of numerous people. Considering how many there are, pipeline corrosion protection is essential to good energy production. Now, with that in mind, let’s look at the 10 longest pipelines in the world and be wowed.

1. West-East Pipeline Project (5410 miles)

Started in 2002, this pipeline officially began to supply natural gas three years later. It’s so long that it travels through almost seventy cities in China, and is used for electricity. Further, there are plans to make this line more efficient by allowing it to transport more.

2. GASUN Pipeline (3100 miles)

This line is due to be completed by 2026. While still a ways from being done, this pipeline is geared to begin in Brazil and bring those north of the Amazon the gas they need.

3. Yamal-Europe Pipeline (2607 miles)

This pipeline provides gas to Russia, Belarus, Poland, and Germany. This project began in 1994, and first began its production in 2006. Its capacity is 32.9 billion cubic meters, with each of the countries having a different part in its flow.

4. Trans-Saharan Pipeline (2565 miles)

In 2009, the planning for this project began. Its makers hoped to give options to people in Nigeria, Algeria, and Niger. The line was also meant to keep one source from being overused.

5. TransCanada Pipeline (2005 miles)

This is Canada’s longest pipeline, going through to Quebec and other places from Alberta. In 1951, Canada found a great need for better gas supply. This led them, along with the United States, to begin planning and financing for this pipeline. Oh, and it used to be the longest in the world!

6. Rockies Express Pipeline (1678 miles)

Commonly known as REX, this pipeline supplies up to 2.6 billion cubic feet of gas per day. Its services range from Colorado and Wyoming into Indiana. It was made even better (reaching its 2.6 billion cubic feet) after the Zone 3 Capacity Enhancement project came into action.

7. Transcontinental Pipeline (1671 miles)

This one is a real whopper! Reaching from West Texas to New York City, this main line is a vital source of natural gas to numerous people. It provides 12 million dekatherms every day (or about 12,000,000,000 cubic feet).

8. Trans-Mediterranean Pipeline (1610 miles)

The main purpose of this pipeline is to provide natural gas to Italy through Algeria. Though its building was finished in 1983, it was recently improved to carry even more gas, in 2012.

9. Northern Border Pipeline (1391 miles)

This pipeline supplies natural gas from both Canada and U.S.-owned companies. It carries a good supply of this gas through many of the western states, and is operated by TransCanada.

10. Nord Stream Pipeline (759 miles)

Going from Russia to Europe via the Baltic Sea, its pipes were constructed in 2 years (2010-2012). This took 23.5 million hours of hard work for 200,000 pipes. Wow!

These pipelines are a good example of the incredible things that can be achieved through hard work and effort. They also reveal the importance of corrosion protection. Imagine the damage that could be caused if any of these pipes corroded!

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All kinds of items made from metal undergo some form of corrosion over time. When this happens, the usefulness of the items decreases. Excessive corrosion can lead to complete damage of any metal, necessitating replacement. When it comes to economically useful metal appliances like pipelines, the damage can lead to significant losses. Thus, protecting the surface of the metal is critical. There are many benefits of pipeline corrosion protection. Here are 4 urgent reasons why all pipelines should have corrosion protection.

To increase the lifespan of the pipeline

The longevity of metal is increased significantly when it gets adequate protection. Naturally, metals react with common gases and liquids found in the atmosphere. Oxygen is especially essential in the process of forming rust. This means that there is always a huge probability that any metals left in the open will corrode over time. Other substances like various types of acids can also contribute to corrosion. Depending on where the pipeline is being used, the level of wear and tear can vary. The best preventive measure is therefore to use proper corrosion safeguards before putting pipelines to use.

To ease the process of repair

Pipelines carry all sorts of fluids from oil to water. Over the course of any set of pipelines, there are several connections. This means that repairs become necessary from time to time. The frequency of repair and maintenance thus makes it imperative to have the process as simple as possible. It is no secret that corroded metal is very difficult to work with. To ensure that maintenance routines do not become unnecessarily cumbersome, therefore, it is important to protect pipelines from corrosion in advance.

To prevent future costs

Repair and maintenance is a costly process which is inevitable. The costs associated with this work always vary depending on the condition of the affected appliance. To minimize these costs, most people put up several measures that enhance the condition of their appliances. This is also the same treatment that metallic pipelines get. One of the foremost measures in this regard is to put corrosion protection. Protecting pipelines, especially those that carry fluids under high pressure, is the most economically sound thing to do. The process is inexpensive and definitely increases the lifespan of the pipeline. This translates to fewer repairs and replacements in the long-run.

For aesthetic purposes

The appearance and looks of any construction project really do matter. While aesthetics are not directly targeted in the process of corrosion protection, the aspect of beauty can also be achieved by the same process. Most common methods of protecting pipelines involve coating them with some sort of paint, tape, metallic spray or other possibly colorful substance. Even in cases where concrete is used, the goal remains possible. This means that the same process of enhancing the sturdiness of pipelines can also serve as a way of achieving the desired look. Most companies and clients are already cognizant of this fact and often plan ahead when considering to have the pipelines worked on.

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Pipes are often subject to failure, especially if they have been in use for a long period of time. They often deteriorate with time, making them vulnerable to failure. It is essential to buy the right kind of pipe fit for service. Pipe failures need to be thoroughly investigated with care to ensure that future failures are prevented. Down below are 4 common reasons as to why pipes usually fail:

  1. Too much exposure to sunlight: When your pipe is exposed to the sunlight for a very long period of time, disasters can happen. This is because the ultraviolet rays produced from the sun usually break down the material of the pipe, making it become more brittle over time. Thus, if for any reason you need to make use of a pipe above ground, make sure that you have a certain kind of covering for it or paint it so as to avoid it from becoming brittle. You also need to make sure that whoever you purchase pipe from is storing it properly, protecting it from the sun. Otherwise you’ll have to deal with pipes that have already been damaged.
  2. Velocity of the water: If water travels way too quickly in the pipe, it can lead to problems such as water hammering. which may develop surge pressures. Both of these have the power to wear down your pipe over time, regardless of how durable the material may be. If you are using pipes for irrigation purposes, you need to make sure that the flow of water is at the right pressure to prevent any kind of mishaps from occurring. buy pipes that will help you make use of the velocity of water you need.
  3. Soil and debris: Usually when pipes are fitted underground, we think that they are not exposed to any damage. However, this is not true. Underground soil and debris may create friction that can in turn damage the pipes. This is why it is a necessity to remove as much debris as possible before installing a plumbing system. At times, when the soil has too many rocks, you might even need to make use of a chain trencher to pulverize the rocks. Soil movement is another reason why pipes usually fail. All pipes have a breaking point that will be reached at some point in time. Freezing and thawing can cause the pipes to keep moving and as a result get damaged completely.
  4. Problems with installation: It is extremely important to install the pipes properly. Pipes that haven’t been installed properly have high chances of failure well before their breaking point. When the pipe needs to be cut, the contractor should be careful about removing any debris that can later lead to the accumulation of residue. The outer edges of the pipe needs to be very smooth so that they join together easily and the cement can bond properly. Otherwise, it may lead to leaks. Another installation problem is known as “short insertion”. This occurs when the contractor doesn’t push the pipe all the way into the filling. This can cause the accumulation of contaminants, thus causing the pipe to fail.

Thus, these are the common causes of pipe failures. If these reasons of failure are kept in mind, we can avoid the failure of pipes at an early age. Often times, pipeline corrosion protection is used in order to protect the pipes from corroding away. This is one measure that must be taken by every pipe contractor to ensure that pipes don’t fail due to corrosion.

Corrosion's impact in the gas and oil industry

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Fuels and gases can be a bit destructive. A tragic accident involving gases — like an explosion — can cause a huge loss of lives and property. This is the reason why the best means of transport for fuels, gas and vapor is pipelines, usually underground. However, some of the fluids transported in pipelines can have corrosive properties or elements in them.

This means that after a period of time after a fluid has been transported for a while using pipelines, They start to corrode the pipelines which can eat up the material from which the pipeline has been created and in turn cause a leak in the pipeline. A pipeline leak can be very devastating. It can be a bit difficult to find the source of the leakage and repair it. Repairing a pipeline will require that you stop the flow of the fluid inside the pipeline at a certain point so as to allow either replacement or reinforcement of the pipeline.

You will need to implement pipeline corrosion protection methods when a pipeline fails. In order to do that effectively, you will need to install valves at certain points in the pipeline. Valves are very helpful at maintaining a pipeline. There is a wide range of valves that can be installed on a pipeline.

1. Ball Valves

Ball valves are very easy to operate. They also require just a little amount of motion to completely shut off the flow of the fluid in the pipeline. All that needs to happen is a simple 90 degree turn and the pipeline is either completely closed or completely opened. This is very essential when there is a need for emergency pipeline corrosion protection methods. The valve is able to do this using a simple ball shaped disk that either opens or closes to control the flow of the gas. The small disk has small holes on it. When they stay in line with the inlet allowing for passage, the ball valves are most commonly used for gas, air and liquids.

2. Butterfly valves

Butterfly valves are a very common type of valve. They are implemented in most pipelines because of their efficiency and simplicity and light material. They operate almost the same as ball valves. This is because they are also easy to operate and take a short time to completely open or close the pipeline. Butterfly valves have a simple metal plate which is supported at the middle by a strong and rigid metallic rod. When the plate is turned through an angle of 90 degrees, the metal plate stay parallel to the flow of the fluid in the pipeline hence opening the pipeline.

3. Gate valves

Gate valves are also very easy to operate. They are also used to either close or open the pipeline and allow for flow of the fluid in the pipeline to allow for implementation of pipeline corrosion protection methods. The gate valves can however not be used to regulate the amount of fluid passing through them. They either open or close the pipeline. This means that they cannot be partially opened as it would destroy the metal plate.

4. Globe valves

Unlike gate valves, butterfly and ball valves, the globe valves have the ability to regulate the flow of the fluid in the pipeline without being damaged by the pressure of the liquid. The only disadvantage, however, is that the globe valves require a longer time to operate than the ball and butterfly valves. The amount of fluid flowing through the valve is determined by the amount of distance left between the valve plug and the valve seat.

5. Diaphragm valves

The way the diaphragm valves operate is very simple. They operate in the same way as applying pressure in the middle part of a flexible pipe to stop flow of the fluid in the pipe. The one disadvantage involved with diaphragm valves is their inability to last for a long period of time while still functioning perfectly. A diaphragm valve requires constant replacement and/or repair. Diaphragm valves are most common with liquid transport. A diaphragm valve contains a simple diaphragm-like plate which can be either be pulled down away from the floor of the pipe to open or pushed down towards the floor of the pipeline to close and stop flow of the fluid.

What materials impact pipeline corrosion?

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Corrosion refers to the tendency of metals to return to their natural condition and the deterioration of material due to chemical and electrochemical reactions. Pipeline metals corrode when exposed to certain elements or materials. This is a natural process which can be halted if the conditions are changed or treatment is applied. If, however, there is no change in conditions or no treatment applied, the metal will continue to corrode until it disintegrates. So what are the main elements that impact pipeline corrosion?

1. High temperatures

High temperatures can cause corrosion in pipelines due to the increased temperature of the metal. If the metal is in contact with heat that contains oxygen or compounds chemicals such as sulfur, the metal will begin to oxidize. There is, however, a plus side. Oxidization can help protect many metals by providing a naturally protective layer, which prevents a further atmospheric attack on the surface. So some oxidization such as the green patina seen on bronze can be beneficial for the longevity of the metal.

2. A high-carbon environment

This causes metal dusting and occurs when metals are exposed to high carbon environments, such as synthesis gas. These gasses and high-CO environments wear away at the pipeline metals, causing them to break down into a powdery substance. Metal dusting is one of the most significant forms of pipeline corrosion.

3. Microorganisms

Microbiologically-influenced corrosion (MIC) occurs when metal is attacked by microorganisms which eat away at the metal, usually in localized areas. These organisms (usually chemoautotrophs) produce hydrogen sulfide which can cause the metal to oxidize and crack. MIC is most commonly found on metal which is immersed in sea water.

4. Atmospheric air

This leads to crevice corrosion to pipelines, a localized corrosion which occurs in areas where the metal has little access to air. Areas such as metal seams and between parts and spaces become filled with deposits and begin to eat away at the metal.

5. Low oxygen concentration

Low levels of oxygen or high levels of chloride can interfere with the structure of pipelines. The metal, when under attack, will show signs of localized erosion in the form of pitting. If not treated, the erosion will continue. Pitting corrosion is one of the most common forms of metal corrosion damage.

6. Impurities

Impurities such as impure gas, solids, or liquids can wear pipelines down. Though plenty of contaminated gasses do not damage metal in dry form, they can form harmful corrosive droplets if exposed to moisture. An example of such impure agents is hydrogen sulfide.

Pipeline Corrosion Protection

Pipelines can be treated to help prevent or halt corrosion from happening or advancing. There are many innovative corrosion management treatments around to stop corrosion from damaging the metal material. Some metals are naturally resistant to corrosion, such as stainless steel. However, most metals can incur erosion problems. In some cases, corrosion is removed using a chemical process. In other cases, it is removed by removing some of the surface metal. The best way, however, to deal with pipeline metal erosion is to treat the metal in the first place before erosion occurs.

There are many surface treatments and applied coatings that can be used on metal to help protect it from erosion. These treatments and coatings provide a barrier between damaging environmental factors and the metal structure. Most metals today are coated with a surface treatment to help preserve the metal, and then re-coated again at intervals over the years. Alternatively, some metals are painted to protect the surface. Painted metal coatings are easy to apply and provide an anti-corrosive protective seal on the surface.

Coatings will differ on the kind of metal involved along with the kind of corrosion being prevented. For instance, coatings made from aluminum and zinc are beneficial for preventing galvanic corrosion in steel alloys and iron. Large components like energy windmills and bridges can also benefit from these coatings. On the other hand, a thin layer of cadmium can be helpful for iron and steel fasteners and bolts.

If you notice any metal material or the pipeline metal under attack from these elements and rectification is difficult, you can call up a corrosion consultancy company to have a corrosion inspection carried out.

Pipe corrosion protection tips

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Pipeline corrosion is one of the most common problems faced in the industry. There are various innovative steps that have been introduced for corrosion protection. However, due to many reasons, these effective and innovative steps have been proved to be a failure in the long run.

For proper management and passage of uninterrupted gas supply along the chain, it’s necessary to understand corrosion mechanisms that occur at the top of the line as the result of dewing.

Apart from the maintenance in production and transport of gas along the chain, this strategy would ensure long-term pipeline integrity for maintenance of the chain. The prediction of corrosion in the system is challenging, for the type of corrosion varies based on the nature of iron sulfide scales that form over the pipelines as a result of temperature ranges and condensation rates.

Corrosion inhibitors, on the inner sides of the pipe line, help in preventing internal corrosion. But it’s hard to prevent corrosion on the outer sides of the pipeline. ‘Spray pigs’ that have the capacity to bypass flow and create a venturi effect are being used now. They help to protect the pipes against corrosion by sucking liquids containing corrosion inhibitors from the bottom of the pipe and spray them onto the top of the pipe. However, if you do not remove the corrosion causing agents like debris and deposits from the individual pits, corrosion inhibitors will not be effective on the top or bottom of a pipe.

To help remove the debris and deposits, we could use self-cleaning equipment like cleaning pigs that have sprung brush bristles that are capable of aggressively removing deposits. To remove stronger corrosion causing agents, the use of bypass flow features seen in certain upgraded pigs are used to certify good prevention and remediation against corrosion.

Keeping the System Clean: Regular Cleaning

Prevention is always better than cure. Always ensure that your inner pipelines are regularly cleaned, for it prevents and minimizes corrosion. Cleaning is made effective with the use of pigs with the inclusion of chemicals.

1. Advanced Cleaning:

If you haven’t cleaned the inner portions of the pipe for quite a while, you may have to use an advanced cleaning program. To begin with, you may have to use very non-aggressive pigs that give out low density foam. On doing this repeatedly, you can remove small debris and contaminants.

In the case of very thick deposits, a smaller pig is the tool of choice. Start with that and then later you’ll be able to work up to the regular size.

Cleaning Requirements Based on Types of Contamination:

  • Black Oxide: discs, brushes
  • Ferrous debris: magnets
  • Liquids: multi-lip sealing cups and/or discs
  • Microbes: pit-cleaning / wear-compensating brushes, discs
  • Scale: wear-compensating brushes, pit-cleaning brushes, studs
  • Sand: discs, brushes
  • Wax (hard/soft): blades, discs, self-cleaning/wear-compensating brushes

To ensure even more effective cleaning, it’s better to use chemicals in the cleaning procedures.

When you clean the systems, it’s important that you maintain a regular cleaning regime to prevent corrosion from occurring again. Maintenance pigging along with chemicals is one way to ensure a proper cleaning strategy. This cleaning regimen should involve regular removal of corrosion cells and prevent future formation of them. Depending on the type of problem, special purpose pigs are to be employed.

2. Bypass:

This technique is of major importance, for it increases the effectiveness of the work carried out by the pigs. It helps in the cleaning procedure by:

  • Preventing debris from piling up, that may hinder the functioning of the pig
  • Regularly cleaning and clearing debris from the cleaning elements on the pig
  • Reducing the amount of debris removed during the cleaning procedure
  • Prevents the debris from coming in contact with the pig
  • Allowing the pig to slowdown and perform its task better in high-velocity pipelines

3. Pigging Cycles:

As the point was already brought up earlier, it’s very important that the pigging procedure is carried out frequently and effectively. In the absence of pigging, the occurrence of corrosion would be high, and repetitious efforts of pigging would have to be carried out.

To have a safe and sound running of the system, it’s always better to have the pigging cycles at the maximum, using the right type of pig and cleaning elements, with a very good debris removal system to have a line free from corrosion.

Ways to prevent burst pipes

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Burst pipes in a home can be caused by different factors. The most common cause for this plumbing issue is freezing conditions. Pipe failure can also be caused by usual wear and tear or old age, misuse, and intense physical damage because of great pressure.

Burst pipes are one of the most chaotic plumbing problems any household can undergo. This particular plumbing issue will cause damage to a property and put people out of homes for a number of days. It can also leave people without water and homes for a long period of time.

The first step to avoid having burst pipes in your home is to use pipeline corrosion protection methods. Below are some useful tips for preventing the occurrence of this plumbing problem:

1. Have outside taps and piping insulated. When doing this, don’t forget to include the drain pipes for heating and overflow pipes. Lagging or foam can do a good job of insulating these fixtures, however, it is necessary to make sure that you do not leave any joints, bends or taps uncovered. If you have taps outside, you can insulate them with fitted covers. 

2. Make sure the pipes buried in the ground outside such as pipes that lead to garages or sheds are buried deep enough.

3. Make sure that pipes in unheated areas such as lofts, basements, and garages are lagged with good quality pipe lagging.

4. Before the cold season comes, fix all dripping taps or existing leaks since they can cause pipes to burst. This will prevent pipe corrosion that inevitably happens during wintertime.

In the instance that some pipes have already burst your home, here are some tips you can follow to minimize its effects and the damage they can bring:

Unfortunately, not every burst pipe is characterized by a torrent of water from the ceiling. Damp patches on walls, ceilings, and floors can also be signs of a burst pipe. A decrease in water pressure, unusual noises in the system, and even electrical faults can also indicate burst pipes.

If you think you have a burst pipe, immediately isolate the water from the stopcock. Make sure the stopcock is completely closed. The next thing to do is to open all taps to remove the water from the system.

Move any furniture and belongings immediately from the affected area so that they won’t get too wet.

Do not use electrical devices. Also, keep away from light switches and sockets as they can cause electrocution.

Call an emergency plumber immediately. A qualified plumber will be able to determine if your plumbing issue is really a burst pipe. The plumber will also be able to quickly isolate the burst pipes, identify the cause, and find the ideal solution to the problem.

If you are traveling during the winter months for an extended period of time, one of the first things to do is make sure your heat is set to 55 degrees. Always have a neighbor check on your house to make sure the furnace is working and the heat remains at 55 degrees because if it goes below freezing, you run the risk of a broken pipe.

If you do experience a broken pipe, you must act quickly to prevent further water damage to your home or business. The first thing you must do is shut off the water immediately. Know where the water shut off valve is located and make sure all members of the household are aware of its location and how to shut it off.

If you experience water damage from a burst pipe, contact a local reputable water damage repair company right away. They can advise you on the proper steps to take to clean up and restore your home or business. Taking care of the problem right away can prevent the need for mold remediation later.

If the house will be unoccupied for an extended period of time during winter months, it is a good idea to shut off and drain the water system prior to leaving to prevent frozen pipes. To do this simply turn off the main shut off value, then turn on all the faucets throughout the house. Leave the faucets on until all the water is drained from the pipes, then it is all right to turn them off. If the house will only be unoccupied for a day or two, leave the furnace on low and open all of cupboard doors where water lines are located.

If there is a pipe is suspected to be frozen, do not take any chances, and call a plumber immediately. In the case of a burst pipe shut off the nearest shut off valve, if there is not an isolated valve for that area of piping, shut off the main valve. Call someone offering emergency plumbing services immediately. Failure to do so could result in greater costs and damage.

Signs of pipe corrosion

Posted by & filed under Pipe Corrosion.

Due to a combination of factors such as oxygen, leaks, and what not, your pipes will begin to corrode over time. This corrosion takes on a number of forms such as leaks, increased pressure, and ultimately bursting pipes if the situation is not identified and corrected early enough. For that reason, getting to know what causes pipes to corrode and observing the warning signs early enough can ensure that you are protected as well as healthy since corroded pipes can usually infect water, thus leading to health complications. The following signs should be able to tell you where and when the pipes are getting corroded so as to take preventive measures and avoid a disaster in advance.

1. Discolored Water

If you start to notice brownish looking water flowing out of your pipes in a dense manner, then this is a sign that your water system has been compromised by the corrosion. The discoloration often happens as a result of the water crapping off the oxides that have been broken down from the water and thus causing the water to be colored in a strange way. However, a corroded pipe is not always the case as the water could turn brown after a routine maintenance where pipes have been replaced. The duration that this water stays brown should be able to indicate the severity of the situation and whether you need to do something about it or not.

2. Strange Taste

Oxidation, which is a leading cause of pipe corrosion in water supply systems, can often result in the water taking up too many minerals and as a result, taking on a strange taste which is sometimes too strong for the person tasting the water. This is a sure sign that there is something wrong with the water, which could prompt you into checking with the water supply to see whether the water is safe for your health and if it will get clean anytime soon. A health inspection at this point could prove to be life-saving as it will determine whether the water is safe for human consumption or not.

3. Leaks

As pipes begin to wear down due to corrosion, you will find that leaks start to pop out all over the place. By doing an inspection of your piping system, you should be able to determine whether the leaks are spread out all over the pipes or just concentrated around one place which then indicates the degree of damage. A leaking system is usually a warning sign that your corroded pipe is unable to support the water supply any longer, thus this should be a cause for alarm whenever you begin to notice it. Additionally, leaks can spread the damage to other areas of the building such as the roof and floors, which then causes mould and, ultimately, respiratory infections. Leaks are also quite tricky to identify as they happen in small stages and over time spread to a greater area, causing even greater damage to your infrastructure.

4. Clogged Pipes

Corrosion often leads to a buildup inside the pipes, which causes the pipes to narrow down. As this happens, they happen to be clogged which can cause a pressure build-up and ultimately an explosion or a burst of the pipe. This would be an even greater disaster than the leaks, which can be patched easily as compared to replacing a whole length of the piping system.

Whenever you suspect that you have pipe corrosion in your system, getting into contact with the professionals can often prove to be the best course of action. This will ensure that a thorough inspection and damage estimation of the piping system has been done as well as determine the manner in which these pipes should be replaced and the cost involved. Corroded pipes often pose a health risk to the people involved and can lead to an escalation of costs where you have to take someone to the hospital as a result of infection by the leaking water or its consumption.

At the end of the day, corroded pipes pose an obvious health risk and as such, you need to ensure that it is looked into to avert a disaster.

Materials of pipes used in the oil and gas industry

Posted by & filed under Pipes.

Many countries across the globe now rely on oil and gas for a variety of everyday needs, such as heating and transportation. Therefore, it is no surprise that demand for fossil fuels remains high, especially considering the onset of cleaner-burning fuel sources like diesel and compressed natural gas. Things such as different types of materials are often used in the oil and gas industry.

Oil and gas companies must do all they can to ensure a steady supply of product to distributors and consumers. An infrastructure of pipes that carry oil and gas across the country and around the world is, therefore, essential. Parts such as piping materials, pipe shoes, and wear pads, must be durable and resilient, so maintenance and repairs do not interrupt the supply of product.
There are both inside and outside piping issues such as corrosion, heat, and pressure both inside and outside piping to contend with. Thus, choosing the right materials for pipes and pipe supports will make a world of difference. Here are just a few of the most common different types of materials used in the oil and gas industry.

Steel

This is easily the most important material used in the oil and gas industry. It is a strong and reliable metal. Virtually every element of oil and gas production, from harvesting and refining products to shipping them across the globe, uses it.
Steel is especially important for distribution. It is the main material used for piping and external parts because it is strong and resistant to wear. Consequently, steel is often paired with small percentages of other materials to enhance strength, durability, or other desirable traits.

Steel Alloys

Steel, combined with any number of other materials, produces improved alloys. For example, when paired with carbon, molybdenum, or nickel, steel becomes stronger and more resistant to corrosion. Thus, it is a common problem in the oil and gas industry.
Sometimes, steel alloys include chromium. Not only does it strengthen the steel but also it helps the metal to resist the effects of carbon dioxide and hydrogen sulfide, and high temperatures. Titanium is a popular additive because of its strength and durability. It is also resistant to a variety of substances, including seawater.

Copper

Copper and copper alloys are for special usage within oil and gas operations. These materials are often used for valves and seals. This is due to properties like electrical and thermal conductivity that help to transfer heat and cold without warping, cracking, or failing otherwise.

Corrosion's impact in the gas and oil industry

Posted by & filed under Pipe Corrosion.

Petroleum products like gas and oil come from reserves located below the surface of the Earth. These reserves are tapped into by various means (mining, fracking, etc.), after which raw materials are harvested and refined to make the gas and oil products that we use in our homes, automobiles, and so on.

In order to get these products from inside the Earth and into the hands of consumers, so to speak, a vast transportation network is used. In some cases, products are transported by tanks that are moved around on all types of vehicles.

More often, however, gas and oil are transported by pipes, including pipelines that transport mass quantities across the globe, as well as those that transport smaller amounts to homes and businesses. As you can imagine, this requires miles of piping, pipe supports, and so on.

Corrosion, both inside and outside of pipes, is a major cause for concern. Piping may be located below or above ground, and both scenarios entail challenges where potential corrosion and other types of deterioration are concerned. How does pipe corrosion impact the gas and oil industry?

Threats from Inside

Natural resources and refined gas and oil products alike can carry impurities that are corrosive, including carbon dioxide, hydrogen sulfide, and even water. These agents can react with the internal metal of pipes and begin to eat away at them until enough breakdown occurs for leaks to form.

The velocity of materials being transported through pipes could play a role in how slowly or quickly corrosion occurs, as could temperature and other factors like the integrity of the metal. Corrosion can eventually compromise any surface if not addressed.

Outside Threats

The elements tend to account for the greatest threat to the exterior of piping where corrosion is concerned. Certain environmental factors like temperature are also pertinent. Again, the quality of metal used and the use of peripheral products like pipe wear pads could also make a difference.

Solutions

The gas and oil industry naturally prefers to prevent corrosion as much as possible in order to save money and ensure the flow of product to customers. There are various methods of preventing corrosion, and many are under constant development in order to improve existing techniques and products.

For example, most pipes are coated internally to prevent known types of corrosion. In addition, traditional metal alloys for pipes are being replaced by corrosion-resistant alloys. Using matching metals for pipes, pipe fittings, pipe saddles, and so on is also common. Corrosion can be a very expensive problem in the gas and oil industry, which is why so much effort is made to prevent it.

Pipe erosion

Posted by & filed under Pipe Corrosion.

Like the aqueducts of old that were used to bring water into towns and early piping designed to reduce contagion by carrying effluent away from civilization, pipes have long provided a safe and convenient means of transporting liquids, gases, and even some solids. These days, pipes are many and varied, supplied for a variety of uses.

As such, there are many factors that could lead to pipe failure, and specifically, pipe erosion. It may depend on the piping materials and the contents moving through them. It could be related to environmental factors or whether or not proper pipe supports and wear pads were used.

In addition, erosion could occur both inside and outside of pipes. Regardless of the cause, however, no business wants to find itself dealing with the damage and cost that could result from pipe erosion. Here are a few potential causes you should be aware of and how you can prevent and treat them.

Pipe Materials

Certain materials may be more prone to erosion, especially when exposed to certain corrosive elements, or elements that create a chemical reaction. For example, certain metals are much more likely to suffer from rust when they come into contact with water or steam or if they are located outdoors.

Others may transport chemicals and undergo some type of erosion over time. It’s important to make sure that you select products, including pipes and pipe wear pads for example, that are designed to work properly in your environment and with the items being transported.

Heat

Some pipes will be subject to extreme temperatures as hot liquids, gases, or steam pass through, especially at high velocity. In such situations, it’s not uncommon to see erosion, particularly at joints where accelerated substances slam into a junction before rounding the bend and continuing forward. This scenario requires businesses to keep an eye out for wear and tear so that repair and replacement can occur before a fiasco develops.

Chemicals

Any number of chemicals can cause corrosion in and around pipes. Even something as seemingly innocuous as water can lead to chemical reactions with certain pipe materials or external elements like pipe shoes. Research is imperative to ensuring that you pair proper pipe materials with the substances that will come into contact with the pipes. Otherwise you could end up with corrosion, erosion, leaks, damages, and even injuries or fatalities.

Prevention

Your best efforts may not be enough to stave off pipe erosion completely. There are, however, steps you can take to prevent erosion, such as selecting appropriate pipes and looking for products that have been coated for additional protection.