Corrosion Galleries

Corrosion Galleries

A result of our 30+ years of involvement in the field of corrosion control, corrosion monitoring, and ultrasonic testing has been a very large archive of corrosion related photographs taken from actual case histories.  

These photos have been broken down into three general galleries related to common corrosion problems, piping system specific corrosion issues, and those associated with water storage tanks and vessels.  Within each category are further divisions based upon specific problem examples, such as galvanic corrosion, dry fire piping, or domestic cold water tanks.

We offer these galleries for the two-fold purpose of providing a comparison upon which to categorize and assess a potential corrosion problem, as well as to illustrate the all to frequent end result of a corrosion problem hidden from view or left unaddressed. 


Corrosion Gallery Categories


Forms Of Corrosion


corrosiongalleryProvided are 25 individual photo galleries related to specific forms of corrosion or their related end result.

Common problems such as galvanic corrosion, under deposit corrosion, MIC, corrosion under insulation, weathering,  and dezincification are detailed.

Also detailed are the end result of different corrosion conditions resulting in interior rust deposits, thread failures, wet insulation, and separated cut grooved pipe.




Fire Pipe Corrosion


firegallerythumbVarious examples of corrosion at wet and dry fire piping systems are provided to illustrate the wide difference in corrosion events which exist. 

Variables in pipe schedule, materials, design, operation, and testing dramatically vary the level of corrosion occurring.

Dry and preaction systems typically show the greatest deterioration, while presenting the highest potential for system failure due to the volume of iron oxide rust products which can be generated. 

Examples of internal corrosion products significantly constricting the pipe are shown for both wet and dry fire systems.





Tanks And Vessels


tankgallerythumbTanks and pressure vessels are often overlooked as a source of a corrosion problem.   For some serving domestic cold water service, required annual inspections will often reveal a problem in time to address it, although our gallery is proof that such is not always the case.

Stand alone fire protection water storage tanks are significantly different, and generally do not receive regular maintenance.  Corrosion activity is typically slower, but can produce failures after a few decades. 


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  Installed in an isolated loop,
                                             corrosion coupons never suffer the same environmental effects as the pipe
                                             itself, and rarely provide accurate test results. Hardened deposits, electrical
                                             activity, under deposit corrosion, micro biological buildup, flow effects, and
                                             other common environmental factors typically do not exist for corrosion

A flow requirement, by definition, prevents their installation
                                             in precisely those locations traditionally showing the highest corrosion

In addition, installing corrosion coupon racks at multiple
                                             points throughout a circulating system is not practical and is almost never
                                             performed - thereby forcing the unlikely assumption that the test results shown
                                             for one specific location are representative over the entire piping







  Periodically cutting out samples of
                                             pipe for metallurgical analysis is extremely expensive, usually requires a
                                             system shutdown, is rarely carried out for large diameter piping, and for any
                                             critical or 24/7 operation - is virtually impossible to perform. Combined
                                             maintenance and metallurgical costs can easily exceed $4,000 per

Metallurgical analysis does offer valuable information
                                             unavailable through any other means, and is especially useful in order to
                                             identify the cause of a corrosion condition, but is generally limited in use
                                             due to its cost and inconvenience.

Metallurgical analysis usually plays
                                             an inportant role in defining a corrosion problem, rather than discovering







  Spool pieces, which are nothing more
                                             than removable sections of actual pipe within the system, provide valuable
                                             information regarding the actual net effect of corrosion activity against the
                                             pipe surface. Unfortunately they are only applicable for smaller diameter
                                             piping separate from the main lines.

Properly installed, spool pieces
                                             offer a true inside look at deposits, surface pitting, inhibitor and cleanout
                                             effectiveness, as well as provide samples for micro biological cultures. Like
                                             corrosion coupon racks, however, they are rarely installed throughout a piping
                                             system and enjoy limited use.







  Ultrasonic wall thickness testing
                                             provides the greatest volume of reliable data, and will typically produce a
                                             thorough corrosion evaluation as long as a sufficient number of test points are

Ultrasound is often used as a prerequisite to other testing
                                             methods due to its low cost and wide coverage, or as a confirmation that wall
                                             thickness conditions known to exist in one area do or do not exist elsewhere
                                             within the piping system.

It is most often used as a tool to identify
                                             the extent of an already recognized leak or rusting problem, and long term
                                             corrosion monitoring using ultrasound requires establishing specialized testing
                                             procedures. Read more about
                                             ultrasonic pipe testing.







  A wide variety of electronic
                                             techniques eixst to produce an estimate of corrosion rate generally based upon
                                             the principal of Linear Polarization Resistance, or LPR.

LPR provides
                                             the benefit of an immediate corrosion measurement that can be routed to
                                             monitoring electronices, or data logged for download, and offers an extremely
                                             useful corrosion measurement tool.

LPR is generally expensive to install
                                             and maintain. Regular celaning and calibration is often required, and even
                                             then, results may not approximate true corrosion activity - expecially if
                                             underdeposit corrosion or MIC is active.







  The insertion of a remotely
                                             controlled camera into the pipe offers a valuable thought very limited
                                             inspection option. Its use requires the system to be out of service and
                                             drained, and is greatly limited by access into the piping system. Pipe size,
                                             physical configuration, internal conditions, and length of travel offer further
                                             restrictions in its use.

Remote Video Inspection (RVI) cannot provide
                                             any wall thickness data, but can quickly locate those internal indications that
                                             wall loss has occurred - such as tubercular deposits, deep pitting, or
                                             suspected MIC growths.

Combined with ultrasound or metallurgical
                                             testing, RVI can quickly and cost effectively document whether similar problem
                                             conditions exist in other areas of a piping system.







  X-ray offers limited application for a
                                             piping evaluation primarily due to its high cost and safety concerns. While
                                             x-ray can provide the wall thickness values necessary for a true pipe condition
                                             analysis, it is most often used for the inspection of weld integrity or for
                                             identifying cracks, voids, or a major localized deterioration in a pipe

Cost, health, and environmental issues severely restrict its
                                             use in all but the most critical of applications.







  Similar technology also exists for an
                                             excellent but rarely used tool in measuring a wide variety of piping related
                                             problems. Its use of safe, low powered gamma radiation rapidly identifies areas
                                             of higher wall loss - quickly locating those areas in need of further

By detecting variations in metal density, this hand held
                                             device can also detect pipe blockages, identify wet insulation, show liquid
                                             level, or confirm pipe schedules, etc.

Company Info


CorrView International, LLC

P.O. Box 8513
Landing, NJ  07850
Ph:    973-770-7764
Fax:  973-770-6576

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