Corrosion is a natural, electrochemical process that deteriorates metallic materials through interaction with their environment. This process affects a variety of industrial assets and infrastructure, from pipelines and above ground installations to structural steel in commercial buildings. Several mechanisms contribute to corrosion, including oxidation, reduction, galvanic interactions, and microbial activity. In specific environments—such as oil and gas facilities, chemical plants, and refineries—factors like humidity, salinity, temperature extremes, and exposure to aggressive chemicals can accelerate corrosion rates.
When steel comes into contact with moisture and oxygen, it forms iron oxide, better known as rust. However, corrosion is not limited to rusting alone. Industrial assets may experience pitting on tank linings, crevice corrosion beneath coatings, or even stress-corrosion cracking under load.
Soil resistivity surveys and potential surveys often inform the design studies and conceptual design phases of corrosion prevention. Technologies such as cathodic protection and anodic protection are crucial for managing electrochemical corrosion, particularly for buried tanks and pipeline protection.
The Economic Impact of Corrosion on Industries
The financial consequences of unmanaged corrosion are profound. Globally, the direct and indirect costs associated with corrosion run into trillions of dollars each year, according to industry reports following API guidelines and NACE International standards. Major industries like oil and gas, petrochemical, and commercial buildings face frequent repair costs, production downtime, and even catastrophic failures if corrosion isn’t properly controlled. Companies such as Marathon, Valero, Phillips 66, and HollyFrontier regularly invest in comprehensive corrosion protection services to safeguard operational continuity and meet rigorous quality management objectives.
Effective project management relies on robust inspection and audit processes—from supply units and material supply to coating system recommendations and project specifications. Losses aren’t just related to replacement parts or asset degradation. They also encompass environmental liabilities, regulatory fines for API guideline violations, and lost revenue from restricted operations.
Types of Industrial Assets Vulnerable to Corrosion
A variety of critical industrial assets demand specialized corrosion protection:
- Pipelines and Buried Tanks: Typically used for transporting and storing oil, gas, and chemicals, these systems face continuous exposure to soil, moisture, and fluctuating chemical environments. Corrosion Protection Services (CPS) and Corrosion Service recommend comprehensive cathodic protection, ac mitigation, and dc interference mitigation alongside regular field surveys to evaluate health and integrity.
- Above Ground Installations: Refineries, chemical plants, and terminals use large above ground storage tanks and extensive piping networks that are susceptible to atmospheric corrosion. Industrial coatings, such as those supplied by Tnemec, Carboline, Jotun, and US Coatings Highland, are essential for atmospheric and chemical resistance.
- Structural Steel: Structural assets in commercial buildings and process infrastructure experience corrosion due to moisture ingress, condensation cycles, and pollutants. Protective coatings—including intumescent coatings and cementitious coatings—help ensure fireproofing and structural integrity.
- Specialized Equipment: Valves, pumps, reaction vessels, and heat exchangers often require tailored solutions, system recommendations, and field inspections to mitigate internal and external corrosion threats. Valve customers in energy and utility sectors, such as Spire Energy and MLGW, benefit from these advanced protection strategies.
- Tank Linings and Facility Components: Internal corrosion in tanks containing aggressive chemicals or high-conductivity water underscores the need for specific epoxy coatings, urethane coatings, and water-based coatings, furnished by global partners like Mascoat, Sauereisen, and Denso.
Regular maintenance, routine site surveys, and detailed design reviews during the asset life cycle ensure ongoing protection and compliance with industry standards.
Common Corrosion Protection Techniques
Implementing corrosion protection for industrial assets requires a multi-pronged, evidence-based approach:
Cathodic and Anodic Protection
Cathodic protection remains one of the primary electrochemical engineering solutions against corrosion for buried pipelines, storage tanks, and marine structures. By making the protected asset the cathode of an electrochemical cell using a direct current source (such as a switch mode power supply), the natural corrosion reaction is suppressed. Anodic protection, conversely, is used where passivation can be induced on metals in aggressive environments, often in chemical plants and refineries. Both methods are complemented by regular system recommendations, current mapping, and isolation joint testing as part of ongoing field services.
Protective Coatings and Industrial Coatings
Selecting the appropriate protective coating system ensures effective corrosion prevention across diverse environments and substrates. Protective coatings such as epoxy coatings, urethane coatings, and water-based coatings provide chemical resistance and physical durability. Spray-applied fire-resistive material, intumescent coatings, and cementitious coatings impart vital fireproofing qualities for structural steel and above ground installations. For specialized products and treatments in Australian infrastructure maintenance, consulting with experts like Australian Inhibitor provides access to region-specific corrosion protection solutions backed by rigorous testing and compliance standards.
