Multiple Causes - This 11 year old sample of 2-1/2 in.
condenser water pipe failed at the threads due to a
combination of galvanic activity at the steel to brass
valve connection and a basic design flaw.
The use of threaded schedule 40 steel pipe for condenser
water use was an even greater factor - with over 50% of
wall lost due to threading, and only 35 mils or 0.035 in.
remaining in that area.
Dry Sprinkler - Top and bottom view of dry
fire sprinkler pipe showing virtually new
pipe on the top at left, and severely
corroded bottom pipe on the right.
Water remaining at the bottom after
pressure testing typically creates
accelerated wall loss along the bottom area
and lower sides. Pinholes are typically the
first indication of a problem, followed by a
general and complete failure of the entire
system.
Total Failure - This extraordinary photo shows a
completely failed threaded nipple at a 24 in. main
condenser water return riser.
Accumulation of interior deposits at the valve first
clogged the 1 in. nipple completely. Then, a
combination of general and galvanic corrosion caused
its failure and total separation - leaving those rust
deposits to alone hold back 15 upper floors of water.
Amazing that it held!
Thread Failure - This is an extremely
common problem due to the use of thin wall
schedule 40 pipe in open water condenser or
process cooling piping applications.
While larger diameter main riser and
distribution lines can be constructed of
schedule 40 pipe in most applications,
schedule 40 for small diameter run-out lines
will not provide sufficient remaining wall
thickness and acceptable service life.

Mold - A combination of poorly insulated chill
water pipe and an excessive humidity condition
combined to create a serious mold problem
throughout this entire area.
While UT testing showed the corrosive
moisture effect against the steel pipe as
surprisingly minimal, mold had thoroughly
contaminated the entire area, creating a health
threat. All ceilings had to be opened, the
insulation removed, the pipe scraped and
coated to prevent further rusting, and heavier
insulation properly applied.
Extremely High Corrosion - A high corrosion
rate of near 15 MPY destroyed this new
piping installation in under 2 years. This
client was in the process of replacing 15 floors
of threaded 2 in. distribution piping
beginning at the bottom floors and working
upward.
Performed halfway through the project,
ultrasonic testing showed that the new pipe
would fail before pipe replacement would be
completed.
Pinhole Leak - This 4 in. schedule 40 condenser
water system produced fine pinhole leaks after
less than 4 years of service.
Ultrasonic testing showed a generally high
corrosion rate of over 15 MPY, with random and
isolated areas showing excessive corrosion rates
exceeding 50 MPY. Areas of pipe showed 0.075 in.
remaining, and further pinholes imminent. The
loss of 0.237 in. of pipe wall for this size pipe itself
defines a corrosion rate exceeding 60 MPY - for
which no piping system can survive.
Internal Deposits - Corrosion of steel pipe
results in iron oxide deposits of
approximately 19 times the volume of the
steel lost. The presence of internal deposits
therefore defines a corrosion problem, and
vice versa.
For the above domestic cold water pipe, loss
of water flow due to internal constriction was
actually the lesser threat. Wall loss at the
threads had reached the point of failure.
   
Cut Grooving - Thread Failure -
Victaulic and Six years of service
other brand under a 6 MPY
groove clamped corrosion rate left
piping systems this schedule 40
offer substantial condenser water
advantages in piping system with
piping only 33 mils or
construction. 0.033 in. of pipe
Rolling or wall remaining at
swagging the the threads -
groove into the therefore the leaks
pipe simply seen.
displaces the
metal inside, and Under normal
therefore no wall corrosion
loss results. conditions of 1-2
MPY, and using
Cutting the heavier schedule
groove, however, 80 pipe, this pipe
a sometimes would last for
used option, decades. However,
significantly its failure, prior to
lessens available any shut off valve,
wall thickness, required draining
and if combined of the entire
with a higher system for
corrosion rate - replacement.
will lead to
advanced joint
failure.

Maintenance Neglect - This roof level pipe
near the cooling tower suffered both from the
outdoor elements and a constant over spray
from the cooling tower itself.
The pipe showed sufficient exterior pitting to
reduce its remaining overall wall thickness to
approximately 0.130 in., requiring placement.
Weld Failure - Generally, a single leak of
failure problem may be attributed to a
random and isolated event. Further examples
usually suggest a more system wide defect
with much greater threat potential.
For welding failures such as above, and other
mechanical questions, metallurgical testing
and ultrasonic flaw detection are the two
main diagnostic tools available.
Weld Failure - A relatively uncommon
problem due to either inappropriate welding
rod use or poor workmanship.
This mechanical defect is often made worse
by a high corrosion rate and can only be
repaired by grinding away the weld and
rewelding it properly, or by total
replacement.
Pipe Repair? - Most often, pipe problems
remain hidden until the first leak brings it to
attention and further diagnosis and repairs
are quickly made.
Then again, some repairs are postponed, and
postponed until no alternative remains -
actions which always increase the potential
for significant damage, the need for
shutdown, and usually overall cost
Line Failure - This is a fairly typical form of
e at cast iron waste lines. Cast iron lines corrode at
varying rates at top and bottom of the pipe, and at
ntal vs. vertical lines. Moisture alone is especially
ctive to cast iron.
sting at cast pipe is difficult due to the inherent
ty of the material, and due to its varying corrosion
cteristics.
Cast Pipe - Another example showing the typical
corrosion characteristics of cast iron pipe.
This 75 year old cast iron pipe had multiple leak clamps
applied to its top surface but showed acceptable wall
thickness elsewhere. Wall thickness at the bottom was not
far below specification - yet the top was obviously beyond
service

 
Tank Corrosion - Steel domestic Hidden Corrosion -
water tanks often suffer from a Discoloration of piping
combination of internal and insulation is always a stro
external corrosion, as shown sign that a leak is underw
here. Interior protective coatings In many cases, this may b
can fail in areas, which allows attributed to condensatio
deep pitting activity. though unlikely.

In addition, the cold inlet water Fiberglass insulation can

often produces condensation at absorb a substantial amo
the tank exterior, and corrosion water, more if jacketed a
where the coating has weakened. painted, and can allow a
A lack of maintenance is the pinhole problem the time
obvious cause, more so than a necessary to develop into
corrosion problem. more serious threat.

Under Deposit Corrosion - This extreme case
of under deposit corrosion resulted in the total
penetration of some areas of 12 in. schedule 40
pipe in under 10 years. Shown here is the very
beginning of a pipe failure.
Ultrasonic testing showed thickness values of
under 0.100 in. in some areas, with other areas
at near factory new thickness specification of
0.406 in. The removal of the pipe showed that
high volumes of iron oxide deposits along the
bottom of the pipe were the cause.
Replacement Due - Secondary equipment can
often show corrosion problems far sooner
than the actual piping itself. This centrifugal
separator had three leaks beginning, while
none were found at the main piping.
With an original wall thickness of only 0.100
in. the pitting in this system reached through
this metal wall sooner than the 0.280 in. of the
6 in. condenser water pipe.
Contractor Error? - These two adjacent
samples of 12 in. pipe were taken from the
same condenser water system. Comparison of
wall thickness in areas of little deposit and
corrosion showed it as schedule 40 on the left,
and schedule 20 on the right.
Examples of schedule 20 substitution were
found throughout. Compounding the problem
is the under deposit corrosion present - which
is more threatening to the schedule 20 pipe.
Weld Failure - Multiple causes always exist
for explaining problems at a pipe weld, and
usually require a close metallurgical
examination to provide a reliable answer.
Improper cleaning or joint preparation, lack
of weld penetration, incorrect rod selection,
or just poor workmanship can all produce the
same result. Multiple examples of the same
deposits are sure sign that faulty welds exist.

Pinhole Leaks - An aggressive pitting condition usually
spells disaster for any piping system. Here, a reliance on
temporary pipe clamps produced a virtual lawn
sprinkler system at this section of condenser water
piping.
Where one pinhole leak might be assumed to be an
isolated case possibly related to a material defect or very
localized condition, multiple leaks demand prompt
attention and usually replacement.
Insulation Failure - Here, breaks in the
hard outer insulation covering allowed
water and moisture to enter. Saturating the
insulation with water substantially
deteriorated the pipe's outer surface.
Ultrasonic testing showed that the pipe wall
had been reduced to below acceptable
minimum levels and that replacement of
those exterior pitted sections of pipe was
required. The degree of exterior corrosion
and hidden water damage also destroyed
the electrical heat tracing cable - a fact
previously unknown.
Missing Insulation - A lack of insulation can often produce
even worse piping damage at cold water piping than an
excessive internal corrosion condition.
Such corrosion activity is often random and very difficult
to predict. It is largely dependent upon area humidity,
surface temperature, as well as the natural corrosion
susceptibility of the pipe itself. Exterior corrosion is often
too severe to permit any nondestructive testing.
Pinhole Leaks - This relatively new piping
system showed multiple pinhole leaks due to
a severe pitting condition at its interior. In
many cases, a growth or encrustation of
rust deposits will seem to appear to grow at
the pipe's outer surface. This is actually due
to a microfine pinhole leak.
In such examples, the rate of evaporation
exceeds the rate of the leak - which them
produces the deposit made up of formerly
dissolved iron and minerals which have
precipitated out at the pipe's outer surface.

Galvanizing Failure - A severe internal
pitting condition at this domestic water line
produce near total failure after
approximately 12 years of service.
Wet insulation suggested a corrosion under
insulation condition, but the pipe had become
nearly porous in some areas due to severe
pitting.
Deep Pitting - Various examples of exterior
rust product at this fire sprinkler line
suggested a failure at the threads. However,
testing showed a system wide deep pitting
condition primarily at the bottom of the pipe
to be the cause of the leaks.
Leaks at the threads had not occurred first
simply due to the randomness of the pitting
condition not existing in that area.
Localized Pitting - Deep internal pitting
exposed at galvanized domestic water pipe.
Cross section of soon to fail area revealed by
ultrasonic testing illustrates the depth of wall
loss at this 6 in. pipe.
Less the thread cut, failure was certain
Insulation Failure - Failure of pipe insulation,
especially at underground installations such
as here, can easily produce dramatic
corrosion rates of 50 MPY or more.
Testing of pipe where the insulation held
showed wall thickness readings at
specification for this hot water piping after 25
years of service. In this example, outer
corrosion penetrated 0.375 in. of thickness in
the same time