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.

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.

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!

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.

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.

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.