5 Early Warning Signs of Pipe Corrosion
Did you know that replacing damaged and corroded piping in the United States could cost over $75 billion? Shocking, isn’t it? Up to 18 percent of pipeline failures are attributed to pipe corrosion. This makes corrosion one of the most potentially damaging issues to both commercial and industrial properties, causing everything from minor inconveniences to major operational disruptions and costly repairs.
In any system that relies on pipes — whether it’s for water, gas, or chemical transport — pipe corrosion is an ever-present threat. If left unchecked, corrosion can lead to failures, leaks, and structural damage. So how do you know if pipe corrosion is becoming a problem at your facility? Let’s look at some early warning signs of corrosion to watch for and act on before the damage becomes irreparable.
1. Pipe Corrosion: Pipe Thread Leaks
One of the most common early indicators of pipe corrosion is the appearance of leaks at the pipe threads. Threads are a weak point in any piping system, and corrosion accelerates the wear and tear on these connections. You might notice a small leak initially, but over time, this can escalate. As pressure builds on the corroded threads, the situation could progress to a full pipe rupture.
Many plant managers and facility operators focus on larger piping systems, but threaded pipes are often overlooked and can be the source of some of the most significant damage. Pipe thread leaks caused by corrosion can disrupt operations and lead to costly repairs if not addressed promptly. If you’re noticing recurring leaks or moisture around pipe threads, it’s time to inspect for corrosion before it becomes a more severe issue.
2. Multiple Pipe Repairs: A Hidden Sign of Corrosion
If you find yourself repairing the same pipe repeatedly, it’s a clear red flag that pipe corrosion could be the underlying cause. Often, multiple repairs are made without investigating the root cause, which only results in temporary fixes. Ignoring corrosion as a potential culprit can lead to escalating costs and more frequent pipe failures.
The problem with not addressing the corrosion at its source is that you might only be treating the symptoms, not the cause. Each repair you make might be masking deeper, more widespread corrosion that will continue to worsen. Identifying and addressing pipe corrosion early is crucial for maintaining the long-term integrity of your piping system.
3. Visible Damage: Rust, Galvanic Corrosion, and More
Rust is one of the easiest signs of pipe corrosion to spot. It typically forms on steel or iron pipes, indicating that moisture has compromised the protective coating or metal surface. However, galvanic corrosion can also cause significant damage. This type of corrosion occurs when two different metals are in contact with each other, and an acidic solution is introduced.
In systems with open condenser water or process water, galvanic corrosion is common, especially between galvanized steel and brass connections. If you notice a bluish-green deposit around a valve or pipe, this is a clear sign of galvanic corrosion at work. Additionally, discoloration or crystallization on the pipe’s outer insulation is another visual cue that corrosion has taken hold. Wet insulation can be a serious concern and should be investigated immediately to prevent further damage.
4. Pitting Corrosion: Small Holes, Big Problems
Pitting corrosion occurs when small holes or pits form along the surface of the pipe. Although these holes may seem minor at first, they can be much larger beneath the surface. Stainless steel, nickel alloys, and aluminum alloys are particularly susceptible to pitting corrosion, which can be exacerbated by environmental factors like the presence of chloride, hypochlorite, bromide, or fluoride.
In facilities with high humidity, exposure to corrosive chemicals, or areas prone to moisture accumulation, pitting corrosion can quickly become a serious issue. Over time, these pits can expand, compromising the pipe’s integrity and leading to leaks, bursts, or catastrophic failures.
5. Mold or Algae Growth: An Indirect Sign of Leaks and Corrosion
While mold and algae growth may not directly cause pipe corrosion, they often indicate that a leak has occurred. Leaks are typically a result of corrosion that weakens the pipe, causing it to crack or develop pinholes. While mold itself doesn’t contribute to the deterioration of the pipe, it’s an obvious sign that something is wrong.
If you spot mold or algae growth around your piping system, especially in damp or humid areas, it could be a sign of a leak that may be the result of underlying pipe corrosion. Addressing the leak and checking for corrosion should be a priority to prevent further issues down the line.
Preventing Pipe Corrosion Damage: How to Protect Your Facility
Pipe corrosion doesn’t have to lead to catastrophic failure if caught early. By staying vigilant and watching out for the warning signs listed above, you can take proactive steps to prevent the most costly and damaging repairs. Regular maintenance, inspections, and the use of corrosion-resistant materials can significantly extend the life of your piping systems and reduce the risk of costly disruptions.
At RAK Industrial Services, Inc., we specialize in identifying and addressing deterioration issues before they become major problems. Whether you need expert corrosion inspections or recommendations for corrosion-resistant materials, our team has the experience and expertise to keep your pipes in optimal condition.
Contact us today to learn more about how we can help you avoid the high costs of pipe corrosion and keep your operations running smoothly.
