Corrosion in Pipelines and Underground Structures: Prevention Techniques

Corrosion in pipelines and underground structures poses significant threats to infrastructure integrity, safety, and operational efficiency. Understanding the causes, types, and prevention techniques is vital to minimizing the risks and costs associated with corrosion.

What Is Corrosion?

Corrosion is the gradual degradation of materials, usually metals, due to chemical reactions with their environment. In pipelines and underground structures, corrosion is accelerated by factors like moisture, soil properties, chemicals, and stray currents.

Types of Corrosion in Pipelines

• Uniform Corrosion: Even material loss across the surface.
• Localized Corrosion: Includes pitting, crevice, and stress corrosion cracking.
• Microbiologically Influenced Corrosion (MIC): Caused by bacteria and microorganisms present in soil or transported medium.​
• Galvanic Corrosion: Occurs when two dissimilar metals are in contact within a corrosive environment.

Main Causes of Corrosion in Underground Structures

• Moisture and Water Table Fluctuation: Persistent moisture around pipelines facilitates electrochemical reactions.
• Soil Composition: Soils rich in salts and organic matter can accelerate corrosion.
• Stray Currents and Electrical Interference: Electric currents from nearby power lines or other pipelines contribute to corrosion.​
• Microbial Action: Certain bacteria create acidic byproducts that attack metal surfaces.

Consequences of Corrosion

• Leakage and product loss
• Environmental contamination
• Safety hazards, including explosions and fires
• High maintenance and repair costs

Prevention Techniques for Corrosion

1. Protective Coatings and Linings

Applying epoxy, polyurethane, or fusion-bonded epoxy (FBE) coatings forms a physical barrier between the pipeline and corrosive agents. Coatings are essential for both above-ground and underground pipelines, significantly extending their lifespan.

Key Benefits

• Shields from moisture, salts, and chemicals
• Reduces frequency of repairs and maintenance

2. Cathodic Protection Systems

Cathodic protection uses either sacrificial anodes (zinc, magnesium) or impressed current systems to turn the entire pipeline into a cathode, thereby preventing oxidation of the metal. This method is especially effective for buried pipelines and is often used alongside protective coatings.​

Types

• Sacrificial Anode Systems
• Impressed Current Systems

3. Corrosion-Resistant Materials

Using materials less susceptible to corrosion, such as stainless steel, polyethylene, or composite materials, can prevent corrosion at the source. Smart material selection is a cost-effective, long-term solution.​

Examples

• High-density polyethylene (HDPE) pipes
• Composite and fiberglass reinforcement

4. Regular Monitoring and Inspection

Consistent inspections using methods like smart pigging, ultrasonic testing, and video surveillance help detect early signs of corrosion and other issues. Early detection allows for timely intervention and reduces pipeline failures.​

5. Corrosion Inhibitors

These are chemicals introduced inside pipelines to form thin protective films on interior surfaces or to neutralize corrosive substances. Inhibitors are particularly effective in combating internal corrosion.​

6. Environmental Control Measures

Managing soil properties and moisture content around underground pipelines, such as backfilling with non-corrosive materials, reduces the risk of corrosion.​

7. Optimized Design Practices

Designing pipelines with minimal sharp bends, good drainage, and isolation of dissimilar metals can reduce mechanical and electrochemical stress points.​

Frequently Asked Questions

What Is Microbiologically Influenced Corrosion (MIC)?

MIC is caused by bacteria, such as sulfate-reducing bacteria, that produce chemicals (e.g., hydrogen sulfide) leading to rapid pipeline degradation, especially in moist conditions.​

Why Is Cathodic Protection Important?

Cathodic protection is a proven electrochemical method that shields pipelines from corrosion by altering the electrical charge of the metal, thus preventing the oxidation reaction responsible for rusting.​

Conclusion

Pipeline and underground structure corrosion is a critical concern that requires a multifaceted prevention strategy. Utilizing protective coatings, cathodic protection, proper material selection, regular monitoring, and environmental management ensures longer service life, safety, and cost efficiency. Staying proactive in corrosion prevention not only secures infrastructure but also protects the environment and public health.​

References

• 7 Proven Methods for Preventing Pipeline Corrosion (Petersen Products)
• Pipeline Corrosion Prevention Methods for Oil & Natural Gas Lines (Linc Energy Systems)
• Pipe Corrosion: Causes, Prevention, and Remediation Techniques (Aqua Group)

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