In fact, most major corrosion disasters we document are due to years of operation where favorable coupon results contradicted even the most obvious evidence of a corrosion problem.
The CorrView® corrosion monitor measures true wall loss inside the pipe itself, not in an isolated loop absent of most environmental factors. CorrView is installed directly into the piping system to provide a brilliant color change and warning after its predetermined metal surface corrodes away. Simple, low cost, and easy to install, CorrView's maintenance free design extends corrosion monitoring coverage. Ideal for HVAC and fire protection systems
CorrView is affected by all corrosion related forces such as particulate and abrasive content, flow rate, galvanic activity, electrical currents, under deposit pitting, and micro biological growths, etc. In effect, CorrView remains in place to act as a virtual "Pipe Fuse" - providing a bright visual warning indication after a preset amount of wall loss has been exceeded.
In addition to CorrView, this site provides 30+ years of large volume of useful information relating to common corrosion problems. We offer a large Technical Bulletins section as well as a Corrosion Photo Library useful in identifying most common corrosion problems.
American Welding Society - Understanding Pipe Corrosion Problems
A piping system that satisfies service life demands, requires the recognition of piping design vulnerabilities, effective corrosion monitoring, and the adoption of corrective measurements. With corrosion related failures on the rise, advanced planning and an awareness of potential threats becomes more important.
World Pipelines - Investigation vs. Procedure
Substantially different findings are likely where ultrasonic pipe testing is approached as a forensic investigation based upon known system problems and vulnerabilities, rather than simply a linear based measurement procedure. A critical importance is understanding the inherent corrosion related problems to various piping systems.
Fire Protection Contractor - When Pipe Corrosion In a Fire Protection System Can Cost Lives
The time to learn of a pipe corrosion problem is not during a true fire emergency when lives are in jeopardy. Thinner pipe, more corrosive steel, lower quality galvanizing, foreign pipe, dry systems, MIC - all are pushing toward higher internal corrosion deposits to render your fire protection system worthless.
Fluid Handling Systems - Finding The Remaining Service Life
Ultrasonic testing is, by far, the most informative diagnostic method available for determining pipe status. An effective piping analysis is much more than a spreadsheet of a few wall thickness measurements - requiring careful statistical analysis and practical interpretation.
World Pipelines - Multiple Metering And Monitoring Needs
With no single form of corrosion monitoring capable of proving full coverage to the many different forms of pipe corrosion possible, multiple testing methods are always advised. These should include ultrasonic testing, spool pieces, LPR, regular internal inspection, and a close observance to the often obvious signs of a problem.
A Simple Dial Caliper Measurement Of New Steel Pipe May Reveal Surprising Results
In addition to the many corrosion influences negatively impacting piping systems, many new building properties are constructed using carbon steel pipe which is below factory specification. To the surprise of many, an FM or UL approval, like its ASTM stamp, does not define that the pipe actually meets ASTM thickness standards.
The Decline In The Quality Of Today's Piping Products Means Greater Corrosion Problems
A large number of negative influences have comined to produce a higher frequency of corrosion problems - often in spite of all precautionary measures taken. Of those, lower quality pipe, undersized pipe, more complex piping layouts, and generally less effective chemical treatment options have produced a "Perfect Storm" contributing to more piping failures.
If Corrosion Activity Is Only 0.4 MPY, What Is Wrong With The Above Picture?
Corrosion coupons reported a 0.4 MPY corrosion rate for 6 years where the actual rate exceeded 25 MPY. Believed implicitly in contrast to multiple leaks and failures, the slow but total destruction of the entire condenser water piping system was the net result. A case history illustrating the threat from relying exclusively upon this highly flawed testing method.
When Pipe Corrosion At A Fire Protection System Can Cost Lives
The time to learn of a fire pipe corrosion problem is not during an actual fire emergency. Internal rust deposits can, and have, totally blocked water flow through the sprinkler heads - resulting in the loss of human life. More common at dry systems, internal deposits are a serious threat to all fire protection systems.
Major Misconceptions Within The Fire Protection Industry
Ignoring the obvious does have serious consequences when it comes to fire protection systems. From the use of thin wall schedule 10 & 7 pipe, to lower quality pipe products, to frequent flow testing which brings in new fresh water, clear and well documented reasons exist to explain the higher corrosion activity found at today's fire protection systems.
The Threat Of A High Corrosion Condition To A Fire Sprinkler Line
Often viewed only in terms of water damage in the case of a corrosion induced pipe failure, far more serious concerns exist, although rarely considered. Unlike HVAC piping systems, corrosion activity at fire related piping can impede and in some cases totally block water flow - a potentially life threatening condition during any fire emergency.
The Benefits of Ultrasonic Testing in Determining Corrosion Rate and Service Life
Ultrasonic testing provides the most comprehensive, accurate, and cost-effective tool to assess the condition and remaining service life of any piping system. Planned and performed properly, ultrasound offers the first step toward identifying a potential corrosion problem, or for certifying a piping system as fit for service.
Why Not All Pipe Failures Are The Fault Of Your Chemical Water Treatment Provider
Various design elements to any piping system can have dramatic impact upon its corrosion activity. Pipe origin, schedule used, physical layout, and many other unknown factors can produce a pipe failure. And yet they are completely beyond the realm of protection offered by chemical water treatment.
Pipe Corrosion Problems No Water Treatment Program Can Protect Against
Various changes have occurred to mechanical piping designs over the past few decades, with virtually all HVAC, plumbing, and fire protection systems having been affected in some way. Many changes relate to the materials themselves. Major changes in piping design, however, have introduced new corrosion problems no chemical treatment program can stop.
The Benefits and Limitations of Corrosion Coupons
Relied upon for decades as an indicator of corrosion activity within piping systems, corrosion coupons are highly unreliable in most examples, and totally worthless in others. Many of the most damaging corrosion failures have occurred while at the same time corrosion coupons produced excellent results. Here is why.
Unfortunately, the above is a very common progression of events for many of our clients. Often, greater attention to chemical corrosion control and corrosion monitoring could have saved the system and avoided the problem. In others, a decades prior design flaw or poor choice of pipe supplier may be traced back as the primary fault.
During the 20 years that we have been involved in the field of ultrasonic pipe testing / corrosion monitoring, we have authored various Technical Bulletins for the benefit of our clients. These Technical Bulletins address frequent problem issues to any building owner or operator, and offer both insight as well as reasonable and proven solutions.
We offer below the various categories available, and continue to add new bulletins as time permits.
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