pipe pads

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Metal corrosion can be a killer for piping systems, no matter how advanced they might be. In fact, metal corrosion costs the U.S. economy nearly $300 billion every year. While pipe pads won’t help from corrosion on the inside of pipes, they can do something about corrosion and damage from the outside. But first thing’s first, what are pipe pads, and how can they help?

What Are Pipe Pads?

Wear pads, also known as pipe pads, are pipe support pieces that help hold pipes apart, reducing metal-on-metal damage and potential corrosion. Pipe pads are made of a composite material that fits over the outside of a pipe. The pad then acts as the main contact point that the pipe rests on.

Why Do I Need Pipe Pads?

Unchecked corrosion can cause serious damage to even the best piping system. As corrosion weakens the pipes, they can begin to break down. Even beyond the immediate financial costs of repairs, severe corrosion can lead to shutdowns, damage to equipment, and even on-site injuries. Wear pads are one easy solution to help stop exterior pipe corrosion and boost the longevity of your piping system.

How Do They Work?

Pipe pads are designed to move with pipes, protecting them from dust and grit that may become trapped between other barriers and the pipes themselves. They also account for thermal movement. This allows pipes to move naturally, expanding and contracting as the temperatures change. Because pipes aren’t restricted, there’s no risk of point loading and damage from restriction.

As pipes move and shift over each other, the motion can wear on and even scrape off the pipe’s protective outer coating, allowing microbes a way in. Wear pads will absorb the surface impact caused when pipes rub against each other at crevices, putting a stop to crevice corrosion. They’re also easy to install — no welding required!

Wear pads are designed to help stop exterior pipe corrosion, extend the life of piping systems, and drive overall long-term performance. They’re simple to install and protect against a range of potentially damaging factors threatening your system’s functionality. While they won’t stop corrosion from the inside of pipes, they can be a great asset when it comes to corrosion from the outside, and other kinds of metal-on-metal damage.

pipe corrosion prevention

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Pipeline corrosion happens because metals are sometimes vulnerable to chemical reactions that weaken them. Once the metal is weakened, it becomes susceptible to rust and may form cracks and holes. This is a big problem because pipeline corrosion results in a $9 billion loss for the US economy each year alone.

Pipeline corrosion prevention is, therefore, crucial, especially because once corrosion begins, it will quickly spread to other piping and non-piping surfaces. Here are the pipeline corrosion prevention tips you need to know.

Monitor pH and Oxygen Levels in Your Water

The wrong type of water can cause corrosion. That’s because some metals like copper are weakened if the pH is too low, so the pipe’s lining will get damaged. Ideally, you want to make sure your water’s pH is as close to neutral as possible, which is why the EPA recommends a pH range of between 6.5 and 8.5.

The other thing is, your water’s oxygen level and temperature shouldn’t be too high as this facilitates corrosion.

Protect Your Pipes

A big part of pipe corrosion prevention is adding protective linings and coatings to all metals and other surfaces. Typically, this is done by adding a layer of corrosion-resistant zinc to metallic surfaces. Corrosion can have many entry points, so make sure your beams, joints, and bolts are also protected. Use a sealant to eliminate crevices where corrosive bacteria can hide.

Beware Corrosive Bacteria

Chemicals and high pH levels are not the only things that cause corrosion. Pipe corrosion can also be microbiologically induced. You can avoid this by keeping your pipes clean. Ensure that any fluids passing through the pipes are clean by using inhibitors or biocides or chemically treating your water and other fluids passing through your pipes.

Insulate Metal Piping

Corrosion happens when metallic surfaces get in contact with the wrong material. That’s why it’s best to install insulation, to prevent the chances of weakened pipes. You should especially watch out for galvanic corrosion which happens when the wrong types of metals are in contact.

One metal will “steal” electrons from the other, creating weakened sections that are susceptible to corrosion. By insulating your pipes, you prevent galvanic corrosion and extend the lifespan of your pipes.

Pipeline corrosion is a huge issue in most industries. Thankfully, these practical and helpful pipeline corrosion prevention tips will help you fight this issue, so you can avoid huge losses.

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The oil and gas industry heavily relies on thousands of miles of running pipelines to transport products that run the US economy. According to data from the US Department of Energy, the US maintains approximately 2.6 million miles of natural gas and oil pipelines across the nation. This infrastructure serves as a vital artery for the energy sector. It may necessitate constant maintenance to prevent any structural defects that can affect functionality.

Economic Impacts Surrounding Pipe Wear

Corrosion is the bane of most industrial complexes, including the oil and gas industry. The natural process leads to pipe erosion and deterioration, resulting in significant property damage, injury, or death. A study by NACE International showed that corrosion cost the US oil and gas exploration and production an estimated $1.4 billion in losses annually. Early detections and mitigation measures such as pipe wear pads are key to mitigate its impact.

Here are the impacts of corrosion that pipe wear pads can help you avoid.

1. Expensive Product Replacement

The economic losses attached to corrosion can be extensive. The continuously eroding pipe and joints may require replacement in an expensive repair process. Using corrosion protection methods such as a pipe wear pad can prevent vibrations and rust formation, common causes of pipe erosion. These measures can save your plant the massive costs attached to replacing pipeline components destroyed through corrosion.

2. Structural Breakdown Leading to Shutdowns

The gradual wear down of your straight pipes, flanges, gaskets, and other components can weaken your pipeline infrastructure. The structural breakdown may necessitate a pipeline shutdown to carry out the necessary repairs. Utilizing pipe protection measures can help extend the useful lives of your pipeline components and components while decreasing your expenditure on repairs and maintenance.

3. Loss of Valuable Product

Gradual pipe erosions, especially on your joints, can result in cracks in the pipeline. The crevices may result in oil or gas leaks that can result in the loss of valuable products. A pipe wear pad can reduce the mechanical wear on your joints, reducing your product loss from corrosion damage. Contamination of the product through the cracks formed due to corrosion may also decrease the value of the fluids transported.

4. Safety

According to the US Pipeline and Hazardous Materials Safety Administration, corrosion is responsible for 18% of pipeline accidents in the United States. Loss of pipe strength at the corroded location can result in splits that can result in workplace accidents. Stress corrosion cracks can result in the release of flammable products onto the environment, increasing the risk of catastrophic accidents in your oil and gas plant. A corrosion protection system can help prevent pipe wear that can result in accidents that destroy your assets.

5. Compliance Issues

Corrosion can also mean safety issues from non-compliance with federal regulations. These include pipeline inspections, reporting corrosion-related incidents, and filing accident reports. Failure to follow these instructions may result in hefty fines that can impact the profitability of your plant. A pipe wear protection system can help you meet compliance requirements without compromising on quality or production output. It ensures a smooth operation that preserves your assets and decreases the chances of accidents resulting from faulty corroded pipelines.

6. Environmental Issues

Oils spills resulting from damaged pipelines can contaminate the local flora and fauna. This can lead to several fines and penalties that may impact your assets and reputation as an environmentally responsible company. Environmental damage costs are also likely to increase insurance premiums, which affect your business’s bottom line. A pipe wear pad system can help reduce the loss or contamination of your valuable products through corrosion while protecting your plant from costly lawsuits related to spills and accidents caused by corroded pipes.

Looking at the economic impacts that arise from pipe wear indicates the importance of a corrosion protection system for your pipeline. A pipe wire pad in a critical section of your piping with joints can help you make cost savings for your oil and gas plant. To learn more about pipeline corrosion prevention tips, reach out to DynaGard.

pipeline corrosion protection

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Pipeline corrosion alone has the potential to cause more serious problems if ignored, making pipeline corrosion protection an important thing to consider. Corrosion occurs when old metal pipes corrode from years of use, causing a leak or a burst and leading to serious wastage of water. Here are some warning signs that can help you catch and repair a corroded pipe before worse damage occurs.

Discoloration of Your Pipes

If you notice areas on your pipes that have a different color from the rest of the pipe like blue or white, this may be a sign of pipe corrosion. Similarly, stains, flaking, and dimples may indicate a weak spot in your pipes. This weak spot could be at greater risk of failing.

Minor Leaks

If you spot wet areas near your pipe or discover a leak no matter how small, you should call in an expert to do a full inspection. Pipeline corrosion protection is important to prevent high water bills due to leaking pipes that ought to be replaced.

Smelly Water

If you start to notice a strange smell in the water coming from your taps, you have a potential corrosion problem. The smell may be metallic, like copper or iron, and this is a sign that you have corroded pipes that are transferring the corrosion to your water as it flows through the pipes.

Poor Water Pressure

When you notice poor water pressure in certain outlets in your house, like faucets or showers, this is a sign of corrosion. It occurs when a pipe has been corroded, leading to a buildup of corrosion that has breached the pipes and is now causing a partial blockage within them.

Discolored Water

If you have corroded pipes that have been breached by the corrosion, the water coming out of your taps may be discolored in the color of the specific metal that makes your pipes. This may be brown for steel or iron pipes, or blue-green for copper pipes. Water that has been sitting in your pipes for that long takes on the color of the corrosion when it starts to flow.

With pipeline corrosion costing the U.S. economy over $9 billion every year, it is a widespread issue that needs to be solved immediately when it’s discovered. Pipeline corrosion protection can save you a lot of time and money, as well as help you to stay healthy because consuming water with corroded elements in it can lead to serious diseases.

preventing moisture penetration

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One of the best ways to limit the occurrence of moisture in piping is to insulate the pipes. For this, professionals often use non-absorbent, fiber-free materials, which can help to avoid mold and its far-reaching consequences. Read on to find out other ways of preventing moisture in piping.

Identify the Sweating Water Pipes

If you keep having a moisture problem in your piping, chances are it’s not all the pipes that are causing the problems. Therefore, one solution can be to identify the sweating pipes. Unfortunately, it might not be easy to access these pipes directly, and without direct access, fixing this problem can be impossible. The first step should be to figure out a way to expose the pipes. Please note that you may need to cut into drywall or other finished coverings for this. Once you expose the pipes, you then find ways of preventing moisture penetration.

Eliminate Additional Moisture

After exposing the pipes, you will need to repair any issues that are causing moisture. You can even find that there are some leaky or dripping pipes. Depending on what’s causing the pipes to leak, you can correct the problem with simple measures like tightening a faucet.

Insulation

Insulating water pipes, ducts, and fitting is a great method of preventing moisture penetration. Without insulation, there will be a lot of condensation, which can lead to many problems. A great material to use for this is a closed-cell elastomeric foam material. Apart from preventing the occurrence of moisture, this material is also a great way to limit the growth of mold in the insulation.

Avoid gaps in Piping Systems.

You can use ArmaFlex 520 to seal all your seams and avoid gaps which will help in preventing moisture penetration. There are other materials you can use as well but ensure they are non-moisture-absorbing. You should watch out for this, especially if you are dealing with chilled water and refrigeration piping. With these kinds of pipes, condensation can easily become a problem.

Apart from dealing with the moisture problem, you might also want to take measures to ensure that your pipes are not attacked by corrosion. For this, you can use pipe saddles as a barrier from their supports.

These will eliminate the risk of pipe corrosion by ensuring that no moisture penetrates and that metals do not come into contact with each other. This can all be achieved without mixing chemicals, straps, or hot work.

pipe wear

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There are a lot of forces that threaten the integrity of pipe systems. Some of the forces that present as issues to engineers when designing pipe systems are heat and moisture. To prevent corrosion and wear from destroying your pipe system, you can use pipe wear pads. Wear pads can minimize the rate of corrosion and prevent unnecessary downtimes that come with pipe repairs.

What Is a Wear Pad?

A pipe wear pad is a support that is used to isolate pipes and to minimize metal-on-metal damage. This piece of equipment is made using a composite material that matches the diameter of the external pipe circumference. The pipe wear pad serves as the main contact between the pipe and its support system.

How do Pipe Wear Pads Work?

Even if you cannot see it, your pipes are constantly exposed to a lot of wear, tear, and corrosion. Apart from the financial loss, erosion can weaken pipes which might result in shutdowns and damaged equipment.

Wear Pads Reduce Metal-on-Metal Contact

Any time the metal in the pipes scraps the surrounding systems, there can be damage to either of the pipes in contact with each other. Pipe wear pads prevent this contact from occurring and therefore prevent the following problems:

Galvanic Corrosion

When metals of different compositions come into contact with each other, it can cause an electrochemical reaction known as galvanic corrosion. This reaction can damage metals and lead to ruptured pipes. Wear pads prevent this by acting as a physical barrier that prevents metal-to-metal contact.

Metal-to-metal wear

Even in cases where there are no chemical reactions, each time metals rub together; there will be significant wear that occurs. This is also true for pipes that rest on support beams. With changes in temperature, these pipes will expand and contract, and their outer coating will wear as a result of friction with the surface of the beams. Wear pads prevent this friction, thereby preserving the outer coating of the metal pipes.

They Stop Crevice Corrosion

When pipes move on support beams, the friction can create crevices that will let microbes in. Part of the microbe population includes corrosive bacteria, which can spread to other pipes and weaken them. Wear pads prevent the formation of these crevices by absorbing impact and preventing damage to the underlying pipe’s metal.

Pipes are constantly moving. While you might not notice this movement, it is significant enough to stop damage. Wear pads act as buffers that prevent damage from occurring due to the movement of pipes.

pipe pads

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Corrosion control remains a key pillar in supporting human scientific endeavors in technology, engineering, and material science. According to recent studies by the Battelle Institute, metal corrosion costs the U.S. approximately $300 billion annually. Oil, gas, and water companies spend over 6% of their total revenue combating corrosion.

Critical to the efforts laid towards corrosion control is preventative maintenance. Products such as pipe pads provide excellent solutions to external pipe wear, allowing companies to save thousands of dollars. Pipe erosion can quickly get out of hand. Here are reasons why you may need to protect your industrial piping system with DynaGard pipe pads.

1. Reduce Metal-to-Metal Pipe wear

Naked pipes are a huge problem for most industrial plumbing, especially on joints and supports. The bare metallic pipes grind against each other, wearing down the protective outer layer. This creates an opportunity for rust to set in. Worse, dissimilar metals may end up in contact, causing galvanic corrosion. Pipe pads have a rigid, composite shell that creates a barrier between the two pipes and support. Preventing the metal contact halts the disruptive process at the start.

2. Protect Your Pipes from the Elements

Industrial piping passes under a variety of harsh environmental conditions, which may accelerate the rate of depreciation. From salty sea air in marine environments to ice formation in cold lands, external elements can significantly damage your plumbing parts. Pipe pads act as a barrier between the harsh elements and your metal pipes, actively protecting them from corrosion.

3. Insulate Pipes

Heat and moisture are arguably the most notorious causes of corrosion in industrial piping systems. High heat or ice formation on the outer surface may cause the layers to chip away. Additionally, the frequent thermal expansion and cooling result in moisture accumulation on the surface, supporting rust formation. DynaGard wear pads cover your pipes underside, covering up the condensation cavities. The composite padding inhibits the formation of water droplets at your pipe joints and prevents moisture penetration to your metal piping.

4. Easy Installation

Traditional protective products require specific installation conditions, including surface preparation, set-up time, or heat for welding or glue sticking. Pipe pads are easy to fix, unlike other systems. You do not require any special skills. You only need to raise your pipe of the support, clean the underside, remove the adhesive liner, stick the pipe wear pad and lower your pipe to the support. The simple installation process makes it easy for any technician in your plant to manage corrosion.

5. Cost-Effective Investment

The goal of every business is to maximize its revenues while reducing its expenses. Corrosion protection systems such as pipe pads can increase your profit margins by significantly reducing corrosion impacts on your industrial plumbing. Experts estimate that using the available corrosion control practices; industries can save between 15% and 35% of the cost of corrosion. This is approximately $375 to $875 billion annually on a global scale. Pipe wear support is affordable and can help keep your pipe wear expenses low.

Corrosion is a huge menace for any industrial plant. Pipe pads can help you prevent corrosion while increasing the life of your metal piping. For more information on pipe corrosion prevention tips, reach out to DynaGard.

prevent pipe corrosion

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At some point in time, every material starts to wear and tear. That is also true for pipes. The laws of thermodynamics state that once work is put into making a pipe, its highly organized structure will only start to deteriorate. There are many forms of deterioration when it comes to pipes. For instance, the structure of pipes can be weakened by corrosion, fatigue, or even thermal stress.

Regardless of what is causing the wear and tear, the pipe structure will eventually fail. Let’s look at some of the factors that influence external pipe corrosion. External pipe erosion happens when the material that creates pipe walls thins out and weakens over a period of time. Here are some factors that influence external pipe corrosion:

Thermal Stress

Most materials expand and contract when they are heated and cooled simultaneously. Sometimes this stress might not be enough to destroy the structural integrity of a pipe, but when these forces are combined with others, they can have a significant impact on the structure of the pipe. This causes what we know as creep. Creep causes cracks which can then lead to corrosion of the exterior of the pipe. It is important to understand this concept in order to prevent pipe corrosion.

Contact with Other Materials

Another common cause of erosion in pipes is contact with different materials. For instance, a pipe can be placed on top of saddles that are designed to support its weight. While this is useful for support, constant contact with the saddles can result in wear and abrasion, which eventually leads to corrosion. The material on the outside of the pipe starts to get removed, which creates good enough conditions for rust to occur. This is probably the most common cause of exterior corrosion in pipes. To prevent pipe corrosion, you have to minimize metal to metal contact by using proper pipe saddles.

Moisture

Galvanic corrosion happens when a cathode and an anode are spaced out by an electrolyte. This happens when a pipe and its saddle are separated by drops of water. This is the corrosion that everyone else knows and is familiar with. If, however, pipes are padded and the saddles are designed properly and insulated, moisture will not get into the space between the pipe and the saddle, which will prevent galvanic erosion. Properly designed saddles and pipe wear pads will also prevent metal-to-metal contact. This is all achieved without chemicals, hot work, or straps.

There are several factors that can lead to external pipe corrosion. It’s important to ensure that pipes fitted with wear pads are properly saddled and insulated to prevent exterior pipe corrosion. It is also important to note that you can significantly prevent pipe corrosion with pipe pads.

pipeline corrosion protection

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Pipeline corrosion is a potential hazard for the oil and gas industry because it can affect the production and transportation processes. When pipelines are weakened over time, they can break easily and cause explosions and other equivalent dangers related to health problems for those nearby. This is why pipeline corrosion protection is an essential measure to curtail the effects thereof. This article will briefly highlight the causes of pipeline corrosion, signs to look out for, and effective measures to provide you with sufficient pipeline corrosion protection.

Common Causes

Pipeline corrosion can be categorized into internal and external corrosion. In internal corrosion, the contaminants are usually the materials that are transported within the pipeline such as chemicals and water. Whereas, external corrosion is mainly caused by the surrounding environmental conditions that can affect the coatings and cause them to disband. Other factors include poor workmanship during the pipeline installation process.

Detecting Corrosion

If you do not conduct regular maintenance on your pipeline system, then it will give you problems. If you are having trouble figuring out if your pipes are disintegrating or if the brown appearance is just soil, consider the following ways to detect corrosion.

  • Conduct a visual inspection to look for obvious signs of damage, including cracks or pitting.
  • Perform ultrasonic testing to identify thinning inside the pipeline walls.

Install high-tech equipment into the pipeline; as it moves through the line with the product (oil or gas, for instance), the equipment will detect potential problems.

Prevention

Pipe saddles are designed to insulate pipes and eliminate the risk of corrosion by preventing moisture penetration and metal-to-metal contact. They don’t require chemical mixing, straps, or hot work. The adequate protective coating is as essential as regular maintenance. Other preventative measures include using corrosive-resistant materials and cathodic protection.

The Bottom Line

Pipeline corrosion is a natural occurrence that you cannot fully prevent from happening. However, knowing what the causes are, being able to identify early signs, and utilizing measures to ensure pipeline corrosion protection as part of a regular maintenance process can benefit your business. If you suspect that your pipeline system may be in danger of corrosive damage, you should contact a professional who can determine the extent of the pipeline damage.

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The plumbing industry is a multi-billion dollar industry, and it is dependent upon metal pipes. Metal pipes are used beyond plumbing, however. Natural gas, oil, and water are all transported through underground metal pipes. These pipes are built to last for years, as it’s obviously extremely expensive and time-consuming to replace them. However, they are not immune to damage. Perhaps one of the main types of damage that these metal pipes can undergo is corrosion. Corrosion can occur when metal pipes are exposed to chemicals and water over time, and pipe erosion can get out of hand quite quickly. In fact, metal corrosion can cost the U.S. economy almost $300 billion each year.

It’s incredibly important for those in charge of pipe systems to invest in corrosion prevention methods. Perhaps one of the most significant types of corrosion prevention is the pipe wear pad. Pipe wear pads can make a significant difference for pipelines. But there is a lot of misinformation existing about this corrosion prevention tool. With that being said, let’s explore some of the advantages of using pipe wear pads.

1. They Prevent Friction

Perhaps one of the most significant benefits of using pipe wear pads is that they provide friction prevention. Friction occurs in pipelines due to vibration, especially at the connection points of the piping system. As this vibration shakes the pipes, the protective coating that prevents corrosion will gradually wear away. Metal on metal friction is created in the process. This results in long term damage, which potentially calls for repairs or even replacements.

The reason why this damage occurs in the first place is that condensation can collect on these metal on metal areas. This is where corrosion comes into play, and it can spread throughout piping systems fairly quickly. Pipe wear pads are some of the only types of prevention that are effective against this particular issue.

2. They Isolate the Pipe From Support

One of the main reasons why corrosion and wear occur within piping systems is that pipelines allow for too close a connection. Therefore, it’s all too easy for pipes to rub against each other and cause damage.

Pipe wear pads essentially separate the pipes from the support systems and isolate the pipes. This reduces the risk of friction, while also preserving the pipes for the long term. Additionally, these pads also can make it easier for repairs to do be done on individual sections of pipelines due to the isolation that it creates.

3. They Save Money

While it may initially be somewhat costly to add pipe wear pads if they were not already existing within pipelines, in the long term they save money. Corrosion and damage make it necessary for pipes to be repaired, often prematurely. These types of repairs can be prevented through the use of pipe wear pads.

Pipeline repairs are incredibly important, but they’re also quite expensive. They require unearthing pipelines and sending employees down to work on them, often for days at a time. The materials themselves are expensive, and the labor adds to that expense. Any way of preventing this issue is very much worth the cost.

4. They’re More Effective Than Alternatives

One of the main alternatives to pipe wear pads in terms of attempting to prevent pipe corrosion is the classic pipe half-saddle. However, this method often isn’t as long term as pipe wear pads.

Pipe half-saddles actually require changing out every support structure in a system. This is quite expensive, and they don’t always last as long as pipe wear pads. Therefore, it makes much more sense to invest in pipe wear pads outright.

There are lots of benefits to using pipe wear pads. What’s most important is that these pads can be relied upon for the long term, reducing friction and creating a more safe and stable environment for pipelines and those that rely on them.

preventing moisture penetration

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There are so many reasons why pipeline corrosion is a problem. On a practical level, pipeline corrosion can cause pipes to break or leak, potentially causing massive environmental damage over time. But on a financial level, the damage is severe as well. In fact, pipeline corrosion alone costs the American economy over $9 billion every year. But despite the fact that pipeline corrosion may seem to be inevitable to some, it can in fact be prevented through careful strategies and applications.

Perhaps one of the most important factors to consider when exploring pipeline corrosion prevention tips is understanding why pipelines corrode in the first place. There are actually different types of pipeline corrosion, and they can be dependent on what the pipes in question are made of, where they are located, and the materials the pipes are transporting.

What Types of Materials Are Used for Pipes?

As previously mentioned, the type of materials used to construct a pipeline can determine why the pipeline is corroding in the first place. Some of the most popular types of materials used include galvanized steel, copper, PVC, polybutene, CPVC, and polyethylene. Usually, the type of material chosen is selected based on the type of material being transported. Galvanized steel, for example, is usually selected to transport oil, petrol, and gas.

This should be considered heavily when preventing moisture penetration, for example. There must be a balance between ensuring that liquids are being transported efficiently and preventing corrosion.

What Are the Different Types of Pipeline Corrosion?

Different types of corrosion can occur depending on the conditions the pipeline is subjected to. One common type of corrosion is pitting corrosion, which occurs when a small hole or pit forms in a part of the pipe, slowly deepening over time. Microbiologically influenced corrosion can also occur, which is often dependent on the types of microorganisms the pipeline is exposed to. Though these organisms, which include fungi and algae, do not cause corrosion, they can speed up the corrosion process. Galvanic corrosion, in comparison, occurs when metal interacts through electrical contact with another type of metal.

The wide variety of different types of corrosion that can occur is why different types of pipeline corrosion protection strategies need to be considered. Preventing moisture penetration, however, should always be a priority for those responsible for pipelines. As moisture affects the pipelines themselves, it can cause oxidization and therefore rusting, which will gradually break down the pipes over time. It’s incredibly important that this type of corrosion, in particular, is prevented.

How Can Pipeline Corrosion Be Prevented?

There are several different strategies that can be taken to prevent pipeline corrosion. Perhaps one of the most common methods of preventing moisture penetration is the application of pipe wear pads. Pipe wear pads actually serve multiple purposes and are perhaps some of the best means through which contractors can protect pipelines.

One of the reasons why pipelines become corroded is that they vibrate and often rub against each other. This wears down protective coatings on the metal and eventually thins out the metal itself. Additionally, the metal is more susceptible to the effects of moisture when it is thinner, further emphasizing the need for pipe wear pads. Essentially, pipe wear pads are liners that are filament-wound and fiber-reinforced. They are fitted onto pipes themselves and act as cushions that isolate the pipes and keep them from rubbing against each other.

There are different types of pipe wear pads available. Some require epoxy in order for them to be attached to the pipes, while others are naturally easier to mold onto the pipes through stick and peel methods. Pipe wear pads should be resistant to condensation, chemicals and acids, and ultraviolet light.

Due to the fact that they can both safeguard the pipes against the effects of vibration and aid in preventing moisture penetration, pipe wear pads are among the best methods for preventing corrosion in general. They are cost-effective, fairly simple to apply, and generally long-lasting and effective. It’s crucial that pipelines are outfitted with this type of material in order to avoid the long term effects of corrosion.

pipe wear

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Pipe wear and corrosion are dreadful enemies that every industry has to deal with. Over the past half-century, different approaches to studying corrosion’s national costs show the equivalence of 3-4% of each nation’s GDP. Metal corrosion costs the U.S economy nearly $300 billion annually. Globally, the figure stands at a staggering $2.2 trillion.

Beyond the astronomical figures, pipe wear can also lead to catastrophic destruction, workplace injuries, and halted production processes. Even worse, the enemy is sneaky and slowly-creeping, hard to detect with the naked eye.

Corrosion Prevention Methods

However, pipe wear and corrosion don’t have to be scary. There are effective pipe protection systems that you can use to keep your pipeline safe and extend its life. Pipe pads are among the most popular solution for piping projects.

Pipe wear pads are composite liner membranes that provide a light coat of protective material for your pipes. The pads are placed under joints and metal to metal surfaces, acting like a protective layer. The composites prevent metal abrasion that results from pipes grinding against each other.

Still not convinced how pipe wear pads can extend the life of your metal piping systems? We’ve identified three ways you can use DynaGard pad systems for long-term pipe integrity.

1. Insulate Pipes

Heat and moisture are the two most common issues for engineers designing a piping network. Alternating cycles of rapid heating and cooling of the pipes cause pipe wear. The temperature changes cause metal pipes to expand, contract, and move. External cracks start to appear, which leads to leaks within the pipes. The moisture lining the outer surfaces leads to a build-up of rust, eroding pipes. Wear pads work in both extreme heat and cold conditions. The non-conductive composite reduces thermal movement, which contributes to longer-lasting pipe systems.

2. Reduce Friction Loss

Pipe wear pads provide a protective coating that prevents metal pipes from vibrating against each other. As the slurry flows within the lines, vibrations are inevitable. The slight movement of the piping system and its supports could lead to structural damage. The frictional forces may also cause pressure loss that results in operational constraints. The pipe protection pads reduce vibrational friction, thus assisting in extending the plumbing system.

3. Prevent Corrosion

Your industrial piping system is exposed to harsh corrosive forces. Pipe wear via corrosion occurs gradually over long spells, which eventually leads to erosion. As a plant manager, there are two common corrosion culprits you should be mindful of.

  • Galvanizing corrosion: Occurs where two dissimilar metals are in close contact. It kick-starts an electrochemical reaction that sees one metal pull electrons from the other less reactive one. A pipe wear pad insulates the pipes, forming a physical barrier that separates the metal surfaces.
  • Surface Pipe Wear: The constant movement and rubbing of metal pipes peel the protective paint layer present. Condensation on the surface leads to moisture build-up that results in rust. A pipe wear pad creates a buffer zone, preventing moisture penetration. Your piping system remains safe, having extended life.

Protect Your Plumbing

Pipe wear and corrosion can lead to substantial financial losses, on top of other risks. The DynaGard Pipe wear pad seeks to prevent the unseen enemy from creeping into your pipes. In the end, your plumbing systems remain strong, resilient, and can last longer.

pipe corrosion prevention

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Many factors can cause issues related to pipe corrosion. It all depends on the environment and the presence of variables that can deplete the quality of materials. If the conditions are right, corrosion will happen quickly, and you will start having issues with your plumbing.

Here are some issues you should keep in mind when planning for pipe corrosion prevention and repair.

Corrosion at Joints and Seams

It is not uncommon for corrosion to take place at the joints of your plumbing. That’s because the fluid gets stuck at the point where the pipes intersect. The liquid is also more likely to stagnate at the seams where there is a change of directions.

If there is a high amount of acids, it will erode the metal at a much faster rate in these areas. High pressure can also accelerate the process of corrosion. The pressure will increase the chances that the liquid will get stuck around the seams.

Pitting Pipe Erosion

Pitting is the formation of small holes resulting from corrosion along the pipe. It often occurs when there is the presence of corrosive elements such as chloride or bromide. Sulfides and a variety of other compounds may also be responsible for pitting on pipes.

Several different factors may cause pitting. Pitting has made it complicated for engineers to design effective pipe corrosion prevention strategies. The holes may be elliptical, wide, narrow, or long. The pits are also localized and are hardly ever evenly distributed. So it may be hard to spot without routine monitoring and inspections.

External Pipe Corrosion

External corrosion is often the result of environmental variables. It is prevalent in coastal regions where the humid and saline moisture can accelerate rusting. External and chemical factors within the industry may also settle on the plumbing will, over time, cause corrosion.

Fortunately, you can prevent pipe corrosion with metal coatings, pipe wear pad, and other appropriate treatments. Since the coating can also deteriorate, the plant should inspect and treat the piping as per manufacturer recommendations.

Water Problems

When devising a pipe corrosion prevention plan, you need to understand the role of water. In industrial plants, the chances are that the fluid contains chemicals that can diminish the long-term pipeline integrity. The temperature may also speed up the process of metal erosion.

The velocity of the water can also cause turbulence, which acts as a catalyst for corrosion. The defects may be more prevalent at those points where the piping turns abruptly.

Source of Inefficiencies

Corrosion can cause inefficiencies across the industrial plant in a variety of ways. First, minerals can buildup around the heating elements of appliances reducing their capacity to heat water. The flow rate and pressure will also go down as erosion eats away the walls of the metal piping.

Corrosion can cause many problems with the plumbing within the plant. It also comes with substantial financial implications that cost the economy more than 300 billion annually. It is, therefore, advisable to be aware of the factors that can accelerate the process before installation. You also need to make monitoring and inspections part of your pipe corrosion prevention strategy. It is easier to detect erosion than when performing repairs.

pipe pads

Posted by & filed under Pipes.

Metal corrosion costs the United States’ economy up to $300 billion annually. Bare or insulated piping that rests on structural steel will have corrosion problems that cause the pipe to leak. Bare piping just cannot rest on structural steel in a manner that doesn’t allow water to become trapped. Even protective paint cannot withstand corrosion over time. Typically, a paint system isn’t designed to withstand immersion service anyway. It will soften over time with the influence of water that has been trapped being one of the main causes of pipe erosion. This is what causes protective pipe coatings to have a corrosion problem and fail when the pipe moves and exposes parts of the steel surface leaving it bare.

Sometimes protective coatings just are not applied correctly during piping installation too. When this happens, a crevice can collect moisture that causes an accelerated rate of corrosion. It doesn’t matter if the support and pipe are made from the exact same material like carbon steel. The metallurgical difference provides the tiniest potential difference which can cause the formation of corrosion cells. Crevice corrosion, as well as any other type of corrosion, can lead to a hazardous situation for any piping system.

 

Pipe Pads Are the Solution

When you want long-term pipeline integrity, it takes the use of pipe pads. One of the top pipeline corrosion prevention tips is to utilize adhesive bonded, non-metallic pipe pads. Pipe protection of this sort keeps crevices from even forming. Pipe pads, otherwise known as wear pads, are adhesively bonded to pipes to create a continuous seal that is easily maintained around the pipe cradle to prevent crevices from forming. Pipe pads are easily installed and provide superior protection making them a cost-effective product for protection from corrosion for pipes.

 

Get Specially Designed Protection

A pipe wear pad from leading manufacturers is specially designed to insulate a pipe from its support while also swiftly eliminating the risk of corrosion via prevention of moisture penetration as well as metal on metal contact. When you use pads without chemical mixing, hot work, or straps you are assured a simple way to install adhesive liners that prevent damage otherwise caused by movement due to expansion, moisture penetration, and metal on metal abrasion with a pipe wear support.

 

Use Uniquely Designed Pipe Wear Pads That Are Cost-Effective

You don’t want to use just any pipe wear pads to protect your pipes. It takes fast, cost-effective, and easy protection that doesn’t require any training or special tools to install. The adhesive should be a very high bond strength to encourage a long-lasting and secure hold. Get superior protection as well as easy installation using pipe pads that help the gas, petrochemical, and oil industries reduce costs while preventing corrosion in conduit systems.

Posted by & filed under Pipes.

Naked or uninsulated pipes pose a risk to the structural integrity of your piping system. The potential for pipe corrosion and damage is significantly high. The industrial piping systems naturally carry corrosive products. When combined with stress, humidity, and excessive pressure, the pipes eventually weaken and give in.

 

The damage can be devastating. Every minute that your production unit is not functional, the company is bleeding money. The weakened and eroded parts can turn into ticking time bombs that may result in worksite injuries and completely ruined projects. Currently, corrosion costs the US economy approximately $300 billion every year, with the global figures standing at $2.2 trillion.

 

What Are Pipe Wear Pads?

 

Maintaining an industrial or commercial piping system involves an endless battle with a subtle, slowly-creeping enemy. Corrosion occurs gradually over the years, eventually eroding your metal pipes.

 

Again, high vibration levels can scratch off your protective coating, exposing the metal pipes to the elements. Condensation that occurs on the exposed metal leads to rusting, which corrodes and weakens the pipe.

 

Pipe pads are composite, fiber-reinforced polymers that are attached to a pipe. The liner padding insulates the pipes at support joints, acting as a cushion to isolate the metal piping. The isolator works as a buffer that protects against vibrations and corrosion to your pipes.

 

Here are the benefits of using wear pads

 

1. Reduce Pipe Abrasion

 

The constant movement of pipes rubbing against each other can gradually wear them down. As the naked pipe vibrates, it shifts and slides across the surface, leading to mechanical chipping and ruptures. Wear pads can reduce friction by eliminating metal-to-metal contact.

2. Helps Insulate Pipes

 

One of the major causes of pipe erosion is galvanic corrosion. The exchange of electrons between dissimilar metals can accelerate the destruction of your piping system. Composite pads insulate pipes, preventing them from touching against each other. The buffer helps to keep the surfaces from rusting by electrically isolating the piping from other metallic structures.

 

3. Prevent Moisture Buildup

 

Wear pads use a fiber-reinforced liner that has excellent resistance to condensation. It inhibits the formation of water droplets at your pipes’ joints that later cause corrosion. You can easily prevent moisture penetration by utilizing the composite padding.

 

4. Improve Energy Efficiency

 

Flowing through your piping system is an invisible, yet costly force; energy. Corrosion of your piping systems causes energy to seep out, resulting in wastage of money. Metal, as a good conductor, can be an easy gateway for energy to escape in the form of heat. That’s why you need to insulate pipes effectively to prevent energy loss. Wear pads do not absorb heat and can withstand extremely high temperatures.

 

5. Lengthen the Life of Your Pipes

 

Pipe wear pads can drastically cut down on abrasion, insulate pipes, and prevent condensation on your joints, which in the end increases the durability of your pipes. The corrosion protection system reduces the wear and tear on the underside of the metal piping, making your pipes last longer.

 

Controlling pipe movement and corrosion is at the heart of safeguarding your industrial piping. Wear pads insulate pipes, eliminating friction and galvanic corrosion at the points of support. For more information on how pipe pads can transform your commercial piping, feel free to contact Dynagard.

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Industrial pipes, as durable as they are, are still susceptible to corrosion just like any other traditional pipe systems are. Eroding pipes are costly to repair and often require replacement; pipes can corrode and erode from the inside out.

The only way to truly do pipe corrosion prevention is to install certain pipe wear support materials on the outside of the pipes to keep corrosion from beginning. Since metal corrosion costs around $300 billion yearly to the American economy, it’s important to learn ways you can prevent eroding pipes and how a pipe wear pad is beneficial.

Prevention is Less Costly Than Repair

It’s far cheaper to prevent pipe erosion than it is to repair it, so create a prevention plan over a restoration plan if you can. A pipe wear pad is one way to prevent pipe corrosion and will allow the pipe to be free of rusting and other erosion from the outside.

Prevention Creates Longer Lasting Pipes

In order to make the most profits for your business, your pipes have to last. Replacing worn and eroded pipes is a cost to your business and slows down your future profits. Preventing moisture penetration by installing a pipe wear pad is key to helping your industrial pipes last longer and be more profit-producing for your company.

Prevention Makes for Better Production

When you have healthy and durable pipes that are free of corrosion, you have an industry that can remain ongoing and current with production. The last thing you want is to have to halt production to make way for pipe repairs, so make sure to begin a pipe wear pad installation process to keep all your exposed and susceptible pipes from damage.

The best way to make sure your pipes work well for your business is to keep them from corroding in the first place. A wear pad for pipes is one of the many, and one of the most effective, ways to keep your pipes in great condition. Speak to a supplier about the ways you can prevent pipe erosion in the future once you have your pipe pads installed. Costs vary for the pipe pad installations, depending on how many you need and where the pipe wear pad supply you get will be placed.

Posted by & filed under Pipe Corrosion.

Each year, oil, gas, and water companies use approximately six percent of their total revenue to combat corrosion. Despite vast investments in corrective maintenance, pipeline corrosion continues to cost the American economy close to nine billion dollars annually.

 

The best approach to tackle the corrosion problem is by adopting a preventive maintenance approach. Corrosion protection systems need to be replaced more often than people do. Are you interested in these preventive systems? Below are some of the features to look out for in potential providers.

 

Effectiveness

 

Moisture and heat are some of the most notorious causes of pipeline corrosion. A standard refinery has alternating heating and cooling processes that are likely to bring corrosion problems. The instant interchange between hot and cold material causes pipe erosion, which primarily occurs in the form of external cracks.

 

With this problem in mind, any material you choose not crack easily. Whether it is a water company or an oil refinery, pipe protection has to be a top priority.

 

The protection begins by preventing moisture penetration. The presence of water particles can easily erode the external surfaces of exposed pipes. In most cases, firms opt for painting as an approach to curb pipe erosion, an approach that is only useful in the short-term.

 

In the long-run, you will need better corrosion protection systems, and the use of pipe wear pads is one of them.

 

Easy to Install

 

An effective corrosion protection system is easy to install. Unlike other complex systems, pipe pads are external components of the pipeline and are easy to fix.

 

The installation process should not require any special skills. In most cases, the protection systems do not need any form of welding. Additionally, they have no effects on the media being transported through the pipes. Instead, these systems insulate pipes that prevent contamination of the content.

 

In cases where special attention is required in the installation, the manufacturers must offer much needed support. Always obtain corrosion protection materials from reputable dealers who provide after-sale services.

 

Even when the materials are perceived to be easy to install, ask for an installation manual. Use this manual as a guide. In areas where you can’t understand, your dealer is only a phone call away.

 

Low Costs

 

The primary goal of each business is to generate enough revenues and have a wider profit margin. The presence of leaking piping systems does not contribute to these goals in any way. A corrosion protection system comes in to lower these costs.

 

The cost-effectiveness should play out in the sense that the installed system should be long-lasting. Unlike ordinary installations, a high-quality system should serve you for years, depending on the intensity of use.

 

Positive Reviews

 

Every problem in the world presents a new business opportunity. In the recent past, there has been an influx of new entrants into the corrosion prevention market. While some are genuine, the majority of them are out here to take advantage of desperate firms.

 

Any reputable pipeline corrosion protection firm must have an established and secure online space. Additionally, their website should have a reasonable number of genuine reviews. If anything, these reviews will inform the decision you make.

 

Newly established firms can hardly offer long-term pipeline integrity solutions. The experience of the company in the sector will, therefore, be a crucial part of the decision you make.

 

Quality Customer Service

 

Customer service is part of the pipeline corrosion protection process. How did the firm treat you from the first encounter? How often have they been communicating? Any flaws that manifest in the early encounters are likely to be replicated in the final product.

 

Firms that do not value their customers can hardly meet the corrosion protection system requirements. Look for companies that offer customized products since not all pipe pads are similar.

 

Final Word

 

Apart from the lost revenues, leaking gas and oil pipes pose a significant environmental risk. Firms must, therefore, be ready to experiment with the available corrosion protection methods and retain what works best for them. In this case, no prevention approach beats the use of wear pads. For more information on an effective corrosion protection system, contact us today.

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Pipe wear is something every pipeline company has to deal with. There are steps that you can take to slow down pipe wear. While no pipe will be impervious to pipe wear, addressing the main causes of pipe erosion can slow things down greatly.

 

Over 300 billion dollars each year is spent because of metal corrosion. Cutting that cost starts with taking the steps that are necessary to help slow down the effect of eroding pipes.

 

Causes of Wear On Pipes

 

Pipe wear occurs not only because of exterior factors but because of interior factors as well. For example, sand, grit, element exposure all play a role in the wear and tear on pipes, but what is flowing through that pipe also plays a role.

 

The temperature of the fluid and the content of the fluid can all cause wear and tear on the pipes. Piping is attacked from both inside and outside. The right corrosion protection system can help ward off a large part of the wear on your pipes.

 

A Worthy Investment

 

A corrosion protection system that includes a wear pad is a preventive system that can help to slow the pipe wear down to a manageable and affordable level. Pipe pads and pipe protection designed to insulate pipes and protect them from the elements is a good way to get the ROI on your piping that you should expect.

 

When it comes to piping an ounce of prevention truly is better than a pound of cure. Controlling pipe erosion can mean having the reliable piping system that you need for longer with less worry, it can also mean that you can save on costly repairs and replacements.

 

Investing in preventing a corrosion problem using the right corrosion protection methods will help to protect your larger piping investment. It is the smarter way to do business and get the return on your piping investment.

 

The Right Source

 

To get all the protection that you need to help slow down pipe wear, you have to turn to the right source. Long-term pipeline integrity starts with the right supplier. The right source will have the products that can help with preventing moisture penetration, corrosion resistance, and wear.

 

Laying your pipeline without the right protection systems in place is a risky game. You can connect with a leader in pipeline protection and get the materials you need to ensure that your investment delivers the best return possible.

pipe pads

Posted by & filed under Uncategorized.

Pipes play an essential role in the functioning of any industrial company. Everyday use exposes pipes to extreme conditions which often leads to deterioration of pipes in the long run. Even the slightest neglect could lead to large-scale damages, so it’s important to shield your pipes against such damages. That’s where pipe pads come into play.

 

Pipe pads, also known as fiber-reinforced polymer (FRP) pads are made from a liner material that’s reinforced with fiber and a filament winding around it. The liner is then fitted directly onto the pipe to act as a cushion. Given that the plumbing industry raked in over $107 billion in revenues in 2018, it would make sense for industries and oil companies to protect their pipes to maintain profitability. Here are a few reasons why you should invest in pipe pads.

 

Minimize Corrosion Problems

 

Heat and moisture are two of the most common issues that industrial pipes face. Alternating cycles of heating and cooling cause the pipes to expand and contract which often leads to external cracks and leaks that cause pipe wear. The heat coupled with moisture in the air often leads to a build-up of rust.

 

A lot of industries resort to painting their pipes but paint tends to peel off after a while, leaving the pipes exposed. Pipe pads help to prevent pipe corrosion by providing an extra layer of piping that protects against the effects of heat and moisture. Preventing moisture penetration lowers the wear and tear in your pipes and maintains the structural integrity of your pipes for a lot longer.

 

Save on Costs

 

The essence of any business lies in making a profit. Eroding pipes are never a good sign and call for immediate replacement. The high-grade nature of the pipes and their premium build translates to high purchase costs. Therefore, replacing industrial pipes calls for a substantial investment that would eat into your profits.

 

Using pipe pads significantly lowers pipe erosion. Less pipe erosion goes a long way in ensuring the health of your pipes. Healthier pipes translate to fewer long-term replacements and as a result, fewer operational costs.

 

Control Vibrations

 

As pipes transport fluids, vibrations become an inevitability. Too many vibrations could lead to some structural issues. Pipes may be knocked off their support structures or flanges could start leaking, resulting in pipe fatigue and pipe failure.

 

Pipe pads help control the effects of vibrations by absorbing the resulting energy. Rotating equipment such as compressors and pumps create significant excitation forces as they operate. Other forces such as mechanical resonance also build up forces that could get destructive. Lower vibrations in your pipes ensure your pipes maintain the highest level of performance without the risk of continuous breakdowns.

 

Lower Friction

 

Piping systems have a variety of components such as bends, valves, fittings, and expansion joints. Any change in the direction of these components can create friction forces resulting in pressure loss. A reduction in pressure in your piping system will create several operational issues.

 

Pipe pads are designed to lower vibrational friction created by moving parts of the piping system. Lower friction ensures that piping pressures and rates of fluid flow remain optimal at all times. Additionally, by lowering friction, pipe pads maintain your pipes’ protective coating by preventing parts from rubbing against each other.

 

Easy Installation

 

Pipe pads are very easy to install. The pads are directly fixed to the pipes using a highly effective epoxy adhesive to ensure a secure seal. The epoxy is flexible and features high peel strength, ensuring it remains in place.

 

Installation of the pipe pads doesn’t require any welding and is a fairly straightforward exercise. The pipe pads can be installed before or after you add paint to your pipes as well as during the fabrication process.

 

Pipe pads are an effective way to protect your pipes by ensuring they remain in excellent shape. The pads save a lot on time and resources. In addition, they give you a guarantee that your pipes will keep functioning optimally.

preventing moisture penetration

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Protect pipes from the outside with the right pipe saddle products that offer superior protection, easy installation and effective moisture penetration that will prevent moisture from damaging your pipes. Not every pipe saddle is the same although they all have common attributes. A pipe saddle is designed to insulate a pipe from its support, eliminating the devastating risk of corrosion by keeping moisture from penetrating as well as the contact of metal on metal with the added benefit of no chemical mixing, hot work or straps. Installation is easy when you use superior pipe saddles made by distributors that have put a lot of care into preventing moisture penetration.

 

Invest in Cost-Effective Corrosion Prevention

 

Pipes are the main flow for many industries and they necessitate protection. Pipeline corrosion protection should insulate pipes from their supports. A pipe saddle is precisely what will protect pipes by eliminating corrosion as well as moisture penetration. Being able to keep pipes impenetrable means that your business remains streamlined. Preventing moisture penetration will keep you from having to replace eroding pipes which can slow up business and put a halt to it altogether.

 

A wear pad with an adhesive liner can give the precise corrosive-resistant composite shell that isolates pipes and stops damage that is due to moisture, the movement caused by expansion, and metal contacting metal at a pipe support. When you want to establish and keep long-term pipeline integrity, you need an effective, easy and fast defense. Don’t settle for a normal pipe wear pad, choose pipe pads that go above and beyond to thoroughly shield your pipes.

 

Preventing Moisture Penetration Calls for a High Bond Strength Adhesive

 

Being able to keep pipes impenetrable reduces overall maintenance costs and increases productivity for the petrochemical, gas, and oil industries. The less wear and tear pipes endure, the better your conduit system will flow. Taking care of pipes was not always an easy task. Typical pipe wear pads are difficult to install. Now there are better choices available from top manufacturers that offer pipe saddles that require no training or special tools for installation. It takes a very high bond strength adhesive when it comes to preventing moisture penetration. A lasting and secure hold gives the superior protection you want with the ease of a simple installation.

 

Use Unique Solutions for Preventing Moisture Penetration

 

Exactly how does a corrosion protection system work for a pipeline? The right saddle products isolate pipes from their supports. A composite shell that’s rigid offers fitted corrosion resistance using an adhesive liner. The abrasion that comes with movement or vibrations within pipes wears away any protective coating over time at the point where pipes come into contact with their support. If there is no protection, the direct contact of metal to metal creates a corrosion cell where water or moisture will collect at the crevice or contact point and accelerates corrosion. Then pitting will occur, or some other type of loss of steel, creating the potential for many types of hazards and leaks.

 

Superior wear pads can help guard pipes against this type of corrosion. Pipes need to be isolated from their supports. However, you want to be able to install wear pads without all of the steps it takes using traditional pads. Your cost is increased as well as work times. Besides, traditional pads do not have the necessary physical properties needed to withstand environmental and mechanical stresses.

 

Use Wear Pads That Are Easy to Install

 

A traditional wear pad has to be glued or welded into place. Using revolutionary pads with industrial-strength adhesive takes just minutes to install. Peel off the protective release liner then just stick the pad on the pipe. Simple, easy, and ideal fortification doesn’t get any better or easier than that. Make sure that you follow all of the installation instructions for the perfect installation. Protecting pipes keeps your business running smoothly longer without increasing costs.

corrosion protection methods

Posted by & filed under Pipe Corrosion.

Metal corrosion is the bane of most industrial piping systems. Every year pipeline corrosion costs the US economy about $9 billion. Globally, the figure stands at a staggering $2.2 trillion. That is about 3% of the world’s GDP.

Corrosion does not cause financial problems only. Corrosion eats into metal pipes, causing them to be weak and brittle. Eroding pipes can be hazardous for your employees who may even sustain injuries from pipe collapse. The impact of pollution from pipeline oil leaks to the environment is immeasurable. Luckily, in most situations, metal corrosion can be managed, slowed, or even stopped using proper corrosion protection methods.

What Is Corrosion?

Corrosion is the deterioration of material when exposed to environmental factors. It is caused by a reaction between moisture, a metal surface, and an oxidizing agent. These reactions lead to the formation of oxides, sulfides, and chlorides, which effectively weaken the metal structure.

There are various corrosion protection methods that you can use to keep your pipeline safe. They include:

Protective Coating

This method involves placing a protective barrier between the metallic pipe and external environmental factors such as moisture. A paint coating is one of the most common forms of protective coating. It is a cost-effective method that prevents the transfer of electrical charge to the metal underneath the paint. This inhibits the acid solution from chipping the steel away.

Additionally, you may opt for dry powders to form a powdered protective coating. The most common powdered compounds include:

  • Acrylic
  • Polyester
  • Epoxy
  • Nylon
  • Urethane

The powders are poured on a clean metal surface then heated to fuse with the metal forming a smooth, broken film. You can use the powders to fill cracks and crevices on the piping, thus preventing further leakages.

Sacrificial Coating

This process involves the layering of your metal pipes with another metal of a different type. This corrosion prevention method works on the principle of oxidation, where the coating metal is likely to be oxidized compared to your metal pipeline. This technique ‘sacrifices’ the coating metal over your base metal.

The sacrificial coating is achieved in two ways:

  • Cathodic protection which involves coating your steel pipes with zinc in a process commonly referred to as galvanizing. Zinc is more reactive than steel and is oxidized faster, thus protecting the steel surface from being eroded.
  • Anodic protection involves coating your metal piping systems with tin, which is less reactive than steel. The tin will not corrode, thus prevents pipe corrosion.

Corrosion Inhibitors

These are materials that line the surface of metals, thus protecting them from moisture and other corrosive environmental factors. One of the most common protective linings is the pipe wear pads. These wear pads provide a light coat of protective material, usually a composite that acts as a protective layer.

The pads keep moisture out, thus preventing rusting. The protective coating insulates the pipes preventing them from vibrating against each other, which may cause abrasion. The pipe wear pads are cheap and easier to install compared to other corrosion protection methods.

In Conclusion

Most metal corrosion can be prevented using effective corrosion protection systems. You may opt for galvanization, protective coatings, or metal pads. Pipe wear pads offer a cheaper and more effective method to deal with pipeline corrosion.

corrosion prevention

Posted by & filed under Pipe Corrosion.

America’s economy loses an estimated $300 billion annually due to metal corrosion. This is a figure that can keep anyone with an engineering project awake at night. Apart from the heavy costs, corrosion comes with risks such as putting employees’ life in danger, causing injuries, and even halting important projects. The fact that corrosion is difficult to see with the naked eye doesn’t make things any better.

Even so, pipe corrosion shouldn’t be a death sentence to your project. There are ways that can help keep this irksome metal punisher at bay and save a generous amount of cash. Keep reading to learn what pipe corrosion is all about and how to stop it in its tracks.

Pipe Corrosion

Have you ever come across a metal pipe that has rusty spots? These sections will in most cases seem worn down or eaten away. If yes, that was most probably pipe corrosion. Corrosion is a culprit known to cause the caving-in of metal pieces without any warning.

What causes pipe corrosion? This happens when metal comes into contact with elements such as grime, oxygen, water, and even other metal. After interacting with such elements, the metal loses electrons and becomes weak in the process. In the end, the metal becomes prone to other harmful reactions known to cause issues like holes, cracks, and rust.

The situation gets worse when it comes to pipes, because the corrosion self-perpetuates. This is simply to say the corrosion keeps going a notch higher if pipe protection interventions like pipe wear pads get overlooked. Fortunately, there is something you can do to avoid pipe corrosion from becoming a menace. Here are pipeline corrosion prevention tips you need to know.

1. Avoid Metal-to-Metal Contact

When it comes to the piping world, all metals do not get along–one might draw electrons from the other and cause galvanic corrosion. The loss of electrons will in most cases leave the metal weaker than it was before, thus compromising your structure. Insulating the metal is the best means of pipeline corrosion protection as it helps avoid metal-to-metal contact. Some of the best insulation methods in the market include pipe shoes and pipe wear pads. Pipe wear pads and other insulators work by creating a buffer zone between corrosive prone metals.

2. Structures Should Always Be Stable

Activities such as bouncing and jiggling, as well as friction, can take a toll on metals. Corrosive triggers find their way in whenever openings begin forming and it doesn’t take long before crevice corrosion sets in. Using a restraint is among the best ways to avoid crevice corrosion. The use of clamps, straps, and U-bolts can help scale down vibrations that could result in corrosion.

3. Pipe Cleaning

Any metal exposed to corrosive bacteria becomes prone to MIC (Microbiologically Induced Corrosion). Cleaning your pipes from time to time will avoid corrosive bacteria build-up, more so for pipes that frequently interact with sulfides. Biocides and other microbial inhibitors are a good way of keeping pipes clean.

4. Keep an Eye on Your Water

Particularly in copper pipes, water is a major cause of corrosion whereby low PH levels damage pipe lining. The best way to avoid pipe lining damage is by using water whose PH lies between 6.5 and 8.5.

5. Add Metal Protection

Special coatings and protective linings help prevent pipe corrosion. Bolts, joints, and beams will also benefit from such protection. Galvanization, for example, helps prevent pipeline corrosion by adding a zinc layer on iron, steel, and other metal surfaces. Using a sealant also inhibits corrosive bacteria from accessing crevices and joints.

6. Monitor Water Pressure

High water pressures and immense pipe stress go hand-in-hand. Subjecting pipes to a big deal of stress edges them a step closer to corrosion. This means that any inconsistent or high water pressure issue needs to be addressed as soon as possible.

Summing Up

Corrosion is a problem that no one should overlook. In order to keep corrosion at bay, always have these tips in mind. However, if this is a problem that seems to have gone overboard, seeking the help of a professional is wise. Piping experts are more conversant when it comes to corrosion mitigation methods such as pipe wear pads.

pipe wear

Posted by & filed under Pipe Corrosion.

If you’re working on a complex engineering project, chances are the dread of pipeline corrosion keeps you up at night. And that’s valid — every year, corrosion problems in industrial pipelines cost the U.S. economy more than $9 billion.

And cost isn’t the only downside. Causes of pipe erosion and corrosion can lead to halted production and work-related injuries. Worst of all, it’s difficult to see with the naked eye until it’s too late.

However, pipe wear through corrosion doesn’t have to be scary. You can fight back against this phenomenon, keep pipe wear minimal, and save everyone time and money with these tips.

What is Pipe Corrosion?

Other than being the sworn enemy of many pipe installers, pipe corrosion is when pipeline materials begin to break down because of environmental factors.

If you’ve ever run into rusty sections on pipes and other metal pieces, you know what corrosion looks like. And it doesn’t just look bad, this kind of pipe wear can lower the structural integrity of piping and metal structures, which could lead to expensive damage and even injuries later.

What Causes Pipe Corrosion?

Simply put, the main cause of pipe corrosion is contact. When metal comes into contact with water, oxygen, grime, or even other metals, corrosion can occur. While any one of these things can be a cause of corrosion, they cause it for different reasons.

More technically, corrosion is a chemical reaction that involves a loss of electrons in the metal. Electrons are encouraged to leave by electron-greedy materials like water. This results in rust, cracks, and holes in the weakened metal. Perhaps worst of all, corrosion is self-perpetuating, which means it only gets worse once it begins.

Fortunately, there are things you can do to prevent corrosion from creeping into metal surfaces. The following are a few tips you can use to prevent corrosion.

Watch Out for Water

As noted already, water is a significant cause of corrosion. When water’s pH levels are below about 6.5, it can cause damage to a pipe’s lining, especially in copper pipes.

Besides monitoring the pH levels in your water, you might also want to monitor oxygen levels. Because oxygen leads to corrosion as well, having water that’s high in oxygen all over your piping can be twice the problem.

Finally, water temperature also comes into play. The warmer water is, the more corrosive it tends to be. If you can keep water temperatures towards the cool end, that will be ideal for avoiding corrosion.

Keep Pipes Clean

Corrosion can also occur with exposure to certain bacteria. Called microbiologically induced corrosion, or MIC, this happens when metals become exposed to corrosive bacteria. The way to avoid this is straightforward: keep your pipes and other metal pieces clean, especially if they come into contact with sulfates on a regular basis.

You may also choose to use inhibitors or biocides for keeping everything free of bacteria. Another option is to use special chemical treatments for the water or liquids used in your pipeline system.

Protect All Metals

Some types of metal get along fairly well together, while others can cause significant corrosion when they make contact. Protective linings, special coatings, and pipe wear pads can prevent corrosion from happening between pipes and other surfaces. Beams, joints, and bolts are made of metal, just like pipelines themselves, so using wear pads and other liners to separate them is a good strategy for avoiding corrosion caused by contact with metal.

Galvanization is one such method, in which a layer of zinc is added to metal surfaces to prevent any metal touching them from corroding.

It’s also a good idea to use a sealant for preventing corrosive bacteria from settling in between joints and crevices.

Keep Everything Stable

A lot of movement tends to take place in industrial environments, even without heavy equipment being transported. Friction, bouncing, and jiggling caused by manufacturing and construction processes can cause significant wear on metal over time. When openings in metal begin to form, corrosive material can make its way in, leading to crevice corrosion.

To prevent crevice corrosion, try using restraints such as U-bolts, clamps, and straps to limit movement. Methods like this minimize vibrations that might lead to corrosion.

Metal corrosion may cost billions in damage annually, but you don’t have to fall victim to it. By putting those tips into action, you can minimize pipeline corrosion.

pipeline corrosion protection

Posted by & filed under Pipe Corrosion.

Did you know that metal corrosion costs the U.S. economy nearly $300 billion every year? This is a problem many homeowners or business owners may face if they do not have pipeline corrosion protection already implemented in their pipe system. But what is pipeline corrosion, and how can you protect the outside of your pipes?

What Is Pipeline Corrosion?

Pipe corrosion refers to a process your pipes undergo when they begin to deteriorate. Eroding pipes can be caused by a number of factors, including external temperature, accumulated moisture, contact with other metals, microbes, and stress caused by mechanical vibrations. This can cause your home or business to develop a foul odor, make your water heater inefficient, and cause your entire pipeline to fail in extreme cases. This can cost you thousands of dollars in repairs, so you shouldn’t wait to address this problem.

What Are The Warning Signs Of Pipeline Corrosion?

In order to make a pipe corrosion prevention plan, you need to know the warning signs of pipeline erosion. These can include frequent clogs in your pipes, discolored water, or water that doesn’t taste how it should.

How Can Pipeline Corrosion Be Prevented?

Pipeline corrosion protection is easy to accomplish with pipe pads. These pads prevent moisture from causing pipe erosion and can protect the piping from developing cracks caused by vibrations. These pads are also extremely easy to install and can save you money as they do not need to be welded or glued like traditional pipeline corrosion protection methods.

What Else Can Be Done To Prevent Pipeline Corrosion?

To help prevent internal corrosion, the first thing to check is the ph level of your water. If the ph is above seven, you may need to lower it depending on the type of pipes you have. If you have pipes that carry something other than water, make sure the chemicals don’t negatively interact with piping material. If the material is moving too quickly through the pipes, this can damage them as well. If you aren’t sure which prevention method to take, a specialist will be able to help you determine the necessary pipeline corrosions methods you should be using.

Final Thoughts

Pipe pads are an easy and cost-effective way to prevent external pipe corrosion. They can keep moisture off of your pipes, insulate pipes that may rest on one another, and keep your pipes’ temperature at an appropriate level. This can save you thousands of dollars in repairs and keep your home or business operating smoothly without needing to halt your daily routine.

long-term pipeline integrity

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Engineering involves the balancing of competing interests. For example, heavier pipes may be more durable and less prone to failure, but heavier pipes cost more and require more robust supports. Adding more supports or stronger supports requires more labor to build and install and more construction materials.

One factor that is often missed in all of this balancing is the effect of those additional supports on the pipe itself. There is a trick question that is raised in engineering statics classes about whether it is better to support a pipeline with two supports (one at each joint) or three supports (one at each joint and one in the middle). In theory, three supports distribute the pipeline’s weight more evenly, with each support carrying less load in a three support system than a two support system.

But in the real world, the middle support adds a stress point to the pipeline. Moreover, the interface between the pipeline and the pipe support can cause pipe erosion and other effects that may result in pipeline failure. Here are three ways pipe supports can compromise long-term pipeline integrity and how pipe pads can prevent it:

Pipe Supports Wear Pipes

One of the primary causes of pipe erosion is a metal-to-metal interface that causes the outer surface of the pipe to wear. When pipelines are exposed to the elements, pipe erosion can be aggravated by dirt, sand, or other abrasives that get between the pipe support and the pipeline. Over time, long-term pipeline integrity can be reduced as the pipeline’s walls narrow and weaken. Abraded pipelines can leak or burst when pressurized.

Furthermore, when the walls of the pipeline weaken, the weight of the pipeline and the fluid inside can cause the walls to deform. This could cause the pipeline to bend at the pipe support.

Pipe wear pads, however, adhere to the surface of the pipeline. This prevents abrasives from getting between the pipeline and pipe support. By reducing abrasion and wear, pipe pads ensure the long-term pipeline integrity.

Pipe Supports Facilitate Exterior Pipe Corrosion

Not only can abrasives get between the pipeline and pipe support, but water can also leak into the interface. This can lead to galvanic corrosion as electrons are exchanged through the moisture trapped between the pipeline and pipe support. Galvanic corrosion will convert iron, which makes up anywhere between 80% and 98% of steel, into iron oxide — the scientific name for rust.

Rust, like wear, can weaken and narrow pipeline walls. As the full weight of the pipeline rests on the pipe support exactly where the wall has been weakened by corrosion, the support can punch through the wall, rupturing the pipeline. For an oil or chemical pipeline, it can be catastrophic when the long-term pipeline integrity is reduced by corrosion.

Galvanic corrosion requires three elements — an anode, a cathode, and an electrolyte. When the iron making up a steel pipeline corrodes, the iron acts as the anode, water acts as the electrolyte, and the pipe support acts as the cathode.

Pipe pads eliminate the electrolyte and the cathode. That is, the pipe pad adheres to the exterior surface of the pipeline. This seals out the water acting as an electrolyte. However, even if the adhesive does not seal the surface of the pipeline from moisture, the pipe pad itself is non-conductive. This means that the pipe pad cannot act as the cathode necessary for galvanic corrosion.

Stated differently, pipe pads electrically insulate pipelines from their supports. This eliminates corrosion by preventing both moisture penetration and metal on metal contact. Because the pipe pads are held in place by adhesive, no chemical mixing, straps, or hot work is required to secure them to pipelines.

Pipe Supports Can Become Stress Points on Pipes

Although it happens slowly over time, land moves. Soil and sand can erode, subside, and sink. This geologic action can be translated through pipe supports to pipes. As a result, pipes can sag, bend, and twist. Combined with abrasion, wear, and corrosion, these stresses can reduce the long-term pipeline integrity.

However, pipe pads can act as a shock absorber to reduce the stress translated from the pipe supports to the pipe.

Pipe pads can be essential to long-term pipeline integrity because of the stresses, wear, and corrosion that occurs between the pipeline and pipe supports.