Corrosion Control in Pipelines: Techniques and Best Practices for Longevity
When transporting natural gas from one place to another, pipelines are the primary route. These can easily carry gas over several miles, no matter the distance, making sure that every house, business, and industry receives the energy to function. Because of this, pipeline maintenance is of prime importance.
Understanding Corrosion and its Types
The natural process that deteriorates any type of metal due to a chemical reaction is called corrosion. Primarily, the reaction involves exposure of metal to oxygen and moisture. There are several types of corrosion that a pipeline can go through. These types include;
Uniform Corrosion
This type of corrosion occurs along the surface of the pipeline and causes thinning of the metal surface gradually.
Localized Corrosion
Whenever metal wear and tear occurs in certain areas of the pipeline, it is referred to as localized corrosion. It includes pitting and crevice corrosion.
Galvanic Corrosion
When two different types of metal come in contact with one another, leading to corrosion, then it is referred to as galvanic corrosion.
Stress Corrosion Cracking (SCC)
A combination of tensile stress and a corrosive environment leads to stress corrosion cracking. The ultimate effect of this type of corrosion is the cracking of the metal. Every type of corrosion requires specific prevention techniques. However, a general and proactive method of corrosion control is essential to increasing the longevity of pipelines.
Importance of Corrosion Control in Natural Gas Pipelines
Corrosion usually refers to the gradual damage of the metal that the pipelines are made of. It is a process that does not suddenly happen and occurs gradually over time. Once the pipelines corrode, it can lead to leakages, breakages, and eventually costly repairs. The company would require that area to be cordoned off to replace the pipeline with a new one. Corrosion is not only responsible for weakening the pipelines, it also damages the surrounding property and puts it at high risk.
For us, corrosion prevention is highly important. They offer services like recompression, evacuation of the pipeline, and cross-compression. Pipeline maintenance ensures that all the surrounding processes operate smoothly. Moreover, it also saves the clients from spending thousands on repairs and replacements.
The Unique Challenges in Corrosion Control for Mobile Natural Gas Compression
Natural gas compressions can be done primarily in two different ways and both follow different processes. Stationary gas compression systems remain in one place and are mostly utilized in consistent environments. Alternatively, mobile gas compression systems can move from one place to another. Such a system allows it to face various conditions, changing weather and soil types.
Mobile compression systems face harsh environments, so they can corrode much quicker than stationary systems. Several factors, such as moisture and air, contribute to rapid corrosion. We specialize in natural gas compression and take extra precautions to prevent corrosion. Whether the compression systems are stationary or mobile, we ensure they remain corrosion-free.
Common Causes of Pipeline Corrosion
The following are the common causes of pipeline corrosion:
Internal Corrosion
Internal corrosion occurs when natural gas carries impurities such as moisture, sulfur, or even carbon dioxide inside the pipelines. The impurities can easily react with the pipeline metals and gradually wear them down.
Companies like Reco Energy Solutions use mobile compression systems and for any such system, corrosion can create serious problems. During any recompression and pipeline evacuation service, the natural gas is moved and compressed. This entire process can increase the impact of the impurities on the metal. If the gas is not properly purified then the process of corrosion can speed up. Therefore, controlling the quality of natural gas that flows through the pipeline is essential to reduce internal corrosion damage.
External Corrosion
As the name states, the external corrosion affects the outer layer of the pipeline. Contrary to internal corrosion, external corrosion can occur due to environmental factors. These include constant exposure to sun, soil, air, and even water. For instance, we know that the pipelines are buried underground. If there is wet soil around these pipelines then the risk of corrosion also increases. Eventually, the pipelines may get rusty and break.
It is important to remember that pipelines are always at risk of external corrosion, no matter what surrounding areas or soil they are placed in. Preventive measures such as coating with a layer of paint or regular maintenance can reduce the risk of wear and tear due to corrosion.
By properly understanding what causes internal and external corrosion, we can ensure that gas pipelines remain safe and maintained for a longer duration.
Key Corrosion Control Techniques for Longevity
The following corrosion control techniques can be used for the longevity of the pipelines:
Coatings and Linings
Coating and lining the pipeline is one of the most common ways to protect metal pipes from corrosion. Special chemicals are applied to the outer surface of the pipes to prevent environmental damage.
Following are the different types of coatings that can be used to prevent corrosion:
- Fusion Bonded Epoxy (FBE): This powder-based coating firmly attaches to the pipeline’s surface, making it resistant to corrosion and external damage.
- Polyethylene and Polypropylene Coatings: This type of coating is most effective when a pipeline is located in an environment surrounded by soil or water.
- Coal Tar Enamel: This is the traditional type of pipeline coating still used for underground pipelines, especially in humid environments.
Only certain types of coating may work for pipelines specifically involved in mobile compression activities. Most experts recommend epoxy coatings because of their durability and strength. In addition, it is essential to examine these coatings on a regular basis. If, by any chance, the coating gets damaged, then you must carry out maintenance activities and apply a fresh coat.
Cathodic Protection
The second method of protecting the pipelines from corrosion involves an electrochemical reaction. The pipelines work as a cathode and prevent any type of metal from rusting and damaging. The reaction utilized embedding tiny particles of metal on the pipelines such as zinc or magnesium. When the corrosion happens, these metals corrode instead of the actual metal pipelines.
Cathodic protection is achieved through two methods:
- Sacrificial Anode Protection: This method utilizes reactive metals such as zinc or magnesium. The metals are placed near the pipeline. Ultimately, the corrosion affects the reactive metal rather than the pipeline.
- Impressed Current Cathodic Protection: This method utilizes a power supply directly applied to the pipeline. The electrical current prevents corrosion and protects the pipeline from wear and tear.
We utilize these electrochemical reactions to extend the lifespan of their gas pipelines. This method is handy in areas where the pipelines are at higher risk of corrosion.
Corrosion Inhibitors
Adding chemicals to the flowing natural gas prevents the pipelines from rusting internally. These corrosion inhibitors work as a thin film protecting the inside of the pipelines from impurities.
They add these agents as a preventive measure whenever we perform recompression or cross-compression. However, it is also important to maintain and service the pipeline regularly according to the set frequency.
Pipeline Material Selection
Selecting the right material for pipelines is important for preventing corrosion. Some materials, such as stainless steel, are more resistant to corrosion’s wear and tear. These materials can withstand the toughest environments.
We usually work with pipelines that suffer the most wear and tear due to mobile compression services. The selection of suitable materials and constant upgrades can help the client prevent future problems with their gas pipelines.
Monitoring and Maintenance for Corrosion Control
There are multiple ways on how you can monitor & maintain corrosion control:
Advanced Corrosion Monitoring Systems
Technological advancements have also helped us solve corrosion problems. They can detect the early signs of wear and tear in gas pipelines. Moreover, advanced monitoring systems send alerts every time there is an alarming change in the pipeline’s condition.
We utilize these systems and integrate them into their mobile compression devices. It helps in the early detection of issues, allowing them to fix any damage before it goes beyond repair quickly.
Inspection Best Practices
It is essential to regularly inspect the condition of the pipelines to ensure they are always in good shape, especially during the mobile compression operation. The inspection steps must involve a thorough checkup of the pipes’ internal and external condition.
Pipe inspection is also important during a pump-down operation. This ensures that there is no hidden corrosion and that the pipeline is safe to use.
Maintenance Strategies for Mobile Compression Units
Maintaining mobile compression units is equally important as monitoring the pipelines. Proper maintenance allows the equipment to work correctly without failures.
Best Practices for Long-Term Pipeline Longevity
Some best practices for long-term pipeline longevity are:
Preventive Maintenance Planning
Preventive maintenance is one of the best ways to ensure the long-term health of pipelines. The process includes planning and regularly checking the condition of the pipelines according to a schedule. This proactive approach is the key to keeping the pipes corrosion-free for a longer period of time, especially those handled by mobile compression devices.
Pipeline service involves setting up a routine inspection schedule. The pipes are inspected for any wear and tear, especially those that work with mobile compression equipment. It allows to catch of any early signs of corrosion and reduces the risk of a significant breakdown in the future.
Integration of Corrosion Control with Mobile Compression Solutions
We work to ensure that the pipelines stay protected through smart corrosion control. Integrating these corrosion prevention methods into mobile recompression and evacuation services offers the client a complete solution. This allows the pipelines to run smoothly and reduces the long-term maintenance cost.
For instance, the effective use of corrosion inhibitors during recompression and regular inspection for coating damage during pipeline evacuation helps prevent corrosion in the long run. We prevent costly repairs by staying ahead of the problem. Not only this, but they also ensure the safety and longevity of the pipelines.
Case Studies and Success Stories
Multiple real-world examples showcase how effective these strategies can be. In certain cases, pipelines that were at high risk of corrosion damage have lasted far longer than estimated. All of this was possible with the help of the right combination of corrosion control techniques and mobile gas compression services.
We help our clients prevent pipeline failure by proactively addressing corrosion. They use best prevention practices, such as coatings, inhibitors, and cathodic protection. The success stories show just how important proper corrosion management is in protecting the natural gas pipeline.
Wrapping it Up
If you wish to ensure the long-term safety and efficacy of natural gas pipelines then you must use the correct and efficient method of corrosion control. Using techniques such as coating, cathodic reaction, and corrosion inhibitors improves the longevity of the pipelines. Moreover, you must use the correct material for the pipe to prevent corrosion. Regularly maintain and inspect the condition of the pipelines from both the interior and exterior surfaces.
Our services—recompression, pipeline evacuation, cross compression, and pump down—are designed to align with these best practices for corrosion prevention. It is through the Integration of these strategies in mobile natural gas compression solutions that we can help our clients achieve longer lifespans and avoid costly repairs of pipelines.
Our Expertise in Corrosion Control and Mobile Compression
If you wish to protect your gas pipelines from corrosion, you can always get help from us. Our team of experts helps combine mobile compression services with effective anti-corrosion strategies, increasing the lifespan of the pipelines. Reach out to us today for a consultation on how we can assist with both mobile compression and corrosion management to support long-term pipeline health.
