Carbon steel pipes are widely used in industrial pipeline systems, and they used to be popular in household pipeline networks as well before they were largely replaced by plastic pipes. Steel pipes are preferred for fluid transportation because they are really durable and impact-resistant, which makes them perfect for handling high-pressure and moving fluids over long distances. Steel pipes are utilized in many commercial industries and are made in all types, dimensions, and sizes.
Steel pipes are mainly composed of iron, and 2% of carbon is added to make iron tougher and harder. Carbon steel is available in multiple grades, with each grade having a different percentage level of carbon. The greater the carbon percentage, the greater the hardness of the steel pipe. On the downside, the addition of carbon makes the steel more brittle and less ductile. Apart from carbon, trace amounts of other elements are also added, like
The amounts of elements added to iron and carbon steel pipes play a vital role in giving steel its hardness, weldability, and corrosion resistance.
Carbon steel pipes have a range of characteristics that make them particularly effective for a range of applications. This includes use in wholesale stamping bends and seamless bend manufacturers. These characteristics are
· Strength and Durability: Carbon steel has superb strength and does not get damaged easily, which allows the steel pipes to handle high pressure on a continuous basis. Carbon steel is also wear-resistant.
· Temperature resistance: carbon steel handles temperature fluctuations pretty well and does not lose its integrity with frequent temperature changes.
· Easily moldable: carbon steel can be shaped in a lot of ways, so it is very adaptable to fit in a lot of applications that require custom dimensions.
· Inexpensive: Steel pipes are cheap to manufacture and easy to mass manufacture.
Carbon steel pipes corrode over long-term use. Let us see what are the main causes behind these.
Rust forms when iron in carbon steel forms an oxide layer. Moisture is the main cause of rust, and rust forms throughout the pipe surface.
A carbon steel pipe that is in a high moisture environment, like a coastal area, is the most vulnerable to rust corrosion. The atmosphere contains water droplets and salt particles, which are the perfect conditions for rust formation. Gradually, the rust affects the pipe by forming a familiar red-brown coating that weakens its structural integrity. This causes leaks to occur, and the pipe can break when it loses its strength.
This is another type of steel pipe corrosion that has a negative impact on usage life and causes damage to the steel pipe. Galvanic corrosion takes place when carbon steel is in contact with another metal, and both metals are in contact with water. These conditions favor the corrosion of the less noble metal, which is carbon steel.
This type of corrosion takes place in pipe systems that have copper pipes connected to carbon steel pipes. In such scenarios, the copper becomes a cathode, steel becomes an anode, and the electrolyte, which is water, allows electrons to flow between the two metals, which corrodes the steel pipe. This weakens the steel pipe and causes it to rust away, resulting in leaks.
This kind of corrosion occurs in steel pipes that are placed underground and are in constant contact with soil that has a high chloride content. The chloride ions are potent enough to react with the protective oxide layer, which results in rust spots on the pipe’s surface. These spots deepen and become pits and holes which cause leakage and also weaken the pipe.
Such rusting happens between the gaps of the pipes and is particularly difficult to detect. The main areas are bolted joints of a pipe section. The rainwater or moisture that leaks into the gap or crevice within a joint becomes stagnant and creates an environment where oxygen levels are low. This causes the metal to become anodic while the external surface of the pipe becomes the cathode as it is exposed to a higher oxygen level. Hence, the corrosion grows within the joint and weakens it.
The common problem of rusting can be avoided by taking the following preventive measures.
Apply Protective Coatings: Covering the pipe surface with paint, epoxy resin, or zinc layer adds a protective barrier between the steel and the corrosive chemicals, and this slows down the rusting process significantly. This is one of the most effective steel pipe corrosion protection methods to extend the life of your pipes.
Cathodic protection: it involves the electrochemical deposition of iron with a more corrosion-prone metal layer, such as zinc or magnesium, which will protect the steel pipe by arresting the rusting process. This method is widely used as corrosion prevention for steel pipelines, ensuring long-lasting durability.
Corrosion inhibitors: These are chemicals added to fluid flowing through a pipe to reduce the process of corrosion. Incorporating these inhibitors into the pipeline system can significantly reduce the likelihood of carbon steel pipe corrosion, ensuring better performance over time.
Rust-resistant materials should be chosen. For high moisture environments, corrosion-resistant alloys may prevent the rusting process. Selecting steel pipe protection materials specifically designed to handle harsh conditions will reduce the chances of corrosion-related damage.
Regular Maintenance: Like any other pipeline system. Steel pipeline systems require regular inspection so that the problem of rust can be diagnosed at an early stage. With scheduled maintenance, the buildup of corrosive substances can be prevented. Early detection of issues can help avoid the risk of corroded steel pipes, ensuring the system remains functional and durable.
If the corrosion has started and has reached a dangerous level, then the need is for more intensive strategies like
Cleaning and preparation of surface: In this method, which targets surface-level corrosion, all kinds of dust, old paint, and rust are removed from the surface using sandblasting. In sandblasting, high-pressure water or air is used to blow away the grime. There are other ways to prevent surface-level corrosion, like wire brushing or washing surfaces with cleaning chemicals.
Parching and Repairing: In cases where the rust has not affected a large area, it can be remedied quickly by patching the surface. This is effective when the rust has pockmarked the surface and created pits and holes. Patching up can be done by filling these holes with a filler like epoxy resin, Such fillers create a barrier which stops corrosion.
Pipe replacement: In situations where the level of rust has reached a more serious level, rendering the pipe useless, it is best to replace the rusted section and weld a new piece.
Add Lining and Coatings: This is a foolproof way of stopping rust. The lining is done on the internal surface of the pipe, while the coating is done on the outer surface. The linings are a protective barrier against corrosive chemicals.
Rust is considered one of the biggest problems a carbon steel piping system faces on the face of this earth, as it causes quite a pretty penny to have fixed. We can prevent rust and manage it.
The thing is, rust is the result of certain factors, including the environment (rain, salty air), the composition of the metal the pipe is made of, and how the pipe is used. Therefore, if we understand these things, then we can take measures to stop rust before it starts.
We can coat the pipes with special coatings, such as putting on a raincoat. We can also use a trick called "cathodic protection," where we use a different metal to attract the rust instead of the pipe. And we can even put special chemicals in the pipes to slow down rusting. By taking the following measures, we can keep our pipes working well for a long time and avoid costly repairs and frequent replacement.
The most essential processes of metal shaping are welding and bending, and the processes normally
READ FULLHow to Choose Between Weld and Threaded Flanges
READ FULLCarbon steel pipes are widely used in industrial pipeline systems, and they used to be popular in
READ FULL
