Advanced corrosion of steel piping systems has become a serious and expensive problem to many facility managers and plant engineers. At a growing number of commercial properties and process plants, high corrosion rates have forced the replacement of critical piping systems - some within as short a period of time as three or four years. At others, it has created loss of service, equipment damage, excessive maintenance demands, high energy costs, major repairs, and overall unnecessary expense.

     While lower quality pipe and restrictions on the use of specific corrosion inhibitors and biocides have clearly contributed to the problem, it remains a fact that many building properties and plant facilities regularly maintain open system corrosion levels in the 1 mil per year (MPY) range. Excellent corrosion control and high operating efficiencies can, in fact, be achieved by carefully evaluating current operating conditions and implementing certain precautionary, and often necessary, changes.

     In order to prevent the damaging effects of uncontrolled corrosion, CVI strongly advises incorporating as many of the following general recommendations as feasible into any building operation and maintenance program. While the benefits may not be immediately apparent, such steps will better ensure reliable and trouble free system operation.

     In almost every investigation CVI has been involved, a major corrosion problem can be traced back to a failure to administer many of the above recommendations. And the larger, more serious, and more expensive the corrosion problem - the more likely responsibility and blame is sought.

     While in rare instances excellent corrosion control can be produced by purchasing a standard water treatment program and little else, such results are becoming far more rare due to the much greater negative influences on pipe which exist today. Some of the best efforts toward producing an effective corrosion mitigation program have been met with failure due to special circumstances beyond an owner's or operator's control. Review a summary of piping quality, operating, and design changes which have occurred.

     It is our strong opinion that additional steps toward corrosion control are absolutely necessary today, rather than an option. The benefits far outweigh the annual costs involved, and where the replacement of an entire piping system is the unfortunate end result, such preventative measures become invaluable in terms of money and careers saved.

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