Vol. 11, No. 1 (jul. 2026), eblg004
- Blog Prof. Ricardo Luiz Perez Teixeira, Itabira
- Jul 6
- 6 min read
Updated: 15 hours ago
FAILURE ASSESSMENT OF CORROSION IN INDUSTRIAL PIPING SYSTEMS: A COMPARATIVE ANALYSIS OF GALVANIZED STEEL AND CARBON STEEL APPLICATIONS
Blog Prof. Ricardo Luiz Perez Teixeira, Itabira, Version 1.0, v. 11, n. 1, eblg004, 2026.
ISSN: 3086-5557
06/07/2026
Amanda Vieira Souza¹, Luiza Vitória Araújo Pereira², Wendy Anara Cristina Souza Gonçalves³, Ricardo Luiz Perez Teixeira⁴
¹ Undergraduate Student, Materials Engineering Program, Institute of Integrated Engineering (IEI), Federal University of Itajubá (UNIFEI), Itabira Campus, Minas Gerais, Brazil.
E-mail: amandavieira@unifei.edu.br
² Undergraduate Student, Materials Engineering Program, Institute of Integrated Engineering (IEI), Federal University of Itajubá (UNIFEI), Itabira Campus, Minas Gerais, Brazil.
E-mail: luizavitoria96@gmail.com
³ Undergraduate Student, Materials Engineering Program, Institute of Integrated Engineering (IEI), Federal University of Itajubá (UNIFEI), Itabira Campus, Minas Gerais, Brazil.
E-mail: wendyanara@unifei.edu.br
⁴ Professor, Institute of Integrated Engineering (IEI), Federal University of Itajubá (UNIFEI), Itabira Campus, Minas Gerais, Brazil.
Ph.D. in Engineering.
E-mail: ricardo.luiz@unifei.edu.br
Corresponding Author: Amanda Vieira Souza
E-mail: amandavieira@unifei.edu.br
Abstract
Corrosion is one of the main causes of degradation in metallic piping systems and represents a significant challenge for the reliability and durability of engineering assets. This study presents a technical assessment of corrosion failures affecting galvanized steel piping used in building hydraulic systems and carbon steel pipelines employed in petroleum production facilities. The objective was to investigate the causes, manifestations, and operational consequences of corrosion under different service conditions.
The methodology was based on the analysis of two documented case studies, supported by field inspections, laboratory investigations, non-destructive testing techniques, and operational records. One study evaluated galvanized steel piping installed in a residential building in Goiânia, Brazil. At the same time, the second investigated API 5L Grade B carbon steel pipelines employed in produced-water transportation at the Geólogo Pedro de Moura Operational Base in the Amazon region.
The results demonstrated that corrosion behavior is strongly influenced by the chemical composition of the transported fluid and by operational conditions. In galvanized steel systems, tuberculation was identified as the predominant degradation mechanism, resulting in internal deposits, flow restriction, pressure losses, and reduced hydraulic performance. In carbon steel pipelines, elevated concentrations of chlorides, dissolved carbon dioxide (CO₂), hydrogen sulfide (H₂S), and suspended solids intensified localized corrosion and erosion-corrosion mechanisms, particularly in welded regions and heat-affected zones.
The findings indicate that corrosion management strategies must be adapted to the specific operating environment. For building systems, replacement of aged galvanized steel components with corrosion-resistant alternatives can significantly improve service life. For industrial systems, continuous monitoring, preventive maintenance, and structural integrity assessment are essential to ensure operational reliability and minimize failure risks.
Keywords: corrosion; galvanized steel; carbon steel; industrial piping; localized corrosion; structural integrity.
Introduction
Corrosion affects a wide range of metallic systems and is responsible for substantial economic losses and operational risks. In industrial applications, metallic pipelines are continuously exposed to aggressive environments, pressure variations, temperature fluctuations, and chemically active substances that can accelerate degradation. According to Abreu et al. (2019), corrosion results from interactions between materials and their surrounding environment, causing physical, chemical, and electrochemical deterioration.
In building hydraulic systems, galvanized steel piping was historically employed because of its mechanical strength and zinc protective coating. However, prolonged exposure to water can progressively degrade the protective layer, promoting the formation of corrosion products that reduce the pipe's internal diameter and compromise hydraulic performance (Souza et al., 2018).
In petroleum production systems, corrosion becomes even more complex because of the presence of aggressive species such as chlorides, carbon dioxide, and hydrogen sulfide. These compounds promote localized attack and significantly increase degradation rates. The internal morphology associated with corrosion-product accumulation is illustrated in Figure 1.
Materials and Methodology
The study was developed through an analysis of scientific publications retrieved from the CAPES Journal Portal. Two case studies involving galvanized-steel and carbon-steel piping systems were selected.
For the building application, the investigation focused on galvanized steel piping and malleable cast iron fittings installed in a residential building constructed in 1976. Technical documentation, hydraulic plans, field inspections, photographic surveys, and macroscopic analyses of removed components were examined.
For the industrial application, the investigated material consisted of API 5L Grade B carbon steel pipelines employed in produced-water transportation. Water samples were chemically characterized, and non-destructive liquid penetrant testing was performed in accordance with applicable standards. Maintenance records and operational data were analyzed to correlate corrosion morphology with flow and pressure conditions.
Results and Discussion
The comparative assessment revealed distinct corrosion mechanisms associated with each application.
In galvanized steel piping systems, tuberculation was identified as the dominant degradation mechanism. The accumulation of corrosion products reduced the effective flow area, resulting in reduced flow capacity, pressure losses, and increased maintenance requirements. These observations are consistent with the internal corrosion morphology shown in Figure 1.
In carbon steel pipelines, corrosion was significantly more severe. Localized attack was observed near welded joints, bends, and heat-affected zones, where flow turbulence and metallurgical heterogeneity favored degradation. Additionally, dissolved chlorides, CO₂, and H₂S accelerated wall-thickness reduction and increased susceptibility to structural failure.
The principal corrosion mechanisms identified, along with their operational consequences, are summarized in Table 1. Tuberculation was predominantly associated with galvanized-steel systems, whereas localized corrosion and weld-related degradation were characteristic of industrial carbon-steel pipelines operating under aggressive service conditions.
The results reinforce the importance of inspection programs, corrosion monitoring systems, and preventive maintenance strategies to ensure long-term operational reliability and to minimize degradation-related failures.
Acknowledgments
This work was developed within the extension project Seminar on Corrosion and Materials Degradation – EMTi21 (PJ167-2026) at the Federal University of Itajubá (UNIFEI), Itabira Campus, coordinated by Ricardo Luiz Perez Teixeira. The project integrates teaching, research, and extension activities in Materials Engineering and promotes scientific communication related to corrosion, materials degradation, sustainability, and engineering education.
Conclusions
The analyzed case studies demonstrate that corrosion remains a major challenge for the integrity of metallic piping systems. Although different degradation mechanisms were observed in galvanized and carbon steel applications, both systems exhibited performance reductions attributable to corrosion.
The results emphasize the importance of periodic inspections, integrity monitoring, and preventive maintenance practices. Material selection and operational control play fundamental roles in mitigating degradation and extending service life.
From a materials engineering perspective, implementing corrosion-management strategies tailored to specific service conditions is essential to ensuring structural reliability, minimizing maintenance costs, and improving operational safety.
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References
Abreu, R. S. A., Oliveira, R. T., Guimarães, R. F., Parente, M. M. V., & Freitas, F. N. C. (2019). Corrosão em tubulações de aço carbono pertencentes ao sistema STU-85 da Base Operacional Geólogo Pedro de Moura (BOGPM) – PETROBRAS/Urucu-AM: Estudo de caso. Revista Matéria, 24(1), e-12292.
Gentil, V. (2018). Corrosão (7th ed.). LTC.
Jones, D. A. (1996). Principles and Prevention of Corrosion (2nd ed.). Prentice Hall.
Souza, S. B. S., Cruvinel, K. A. S., Reis, R. P. A., Fleury, G. C. E., & Silva, B. A. (2018). Effects of corrosion on the performance of galvanized steel piping systems. In Proceedings of the 48th National Congress of Sanitation of ASSEMAE. ASSEMAE.
Teixeira, R. L. P. (2016). Educação em práticas de corrosão e química (Version 02, Vol. 1, No. 1, p. eblg001). Blog Prof. Ricardo Luiz Perez Teixeira, Itabira. https://doi.org/10.5281/zenodo.20290724
Teixeira, R. L. P. (2019a). Oficina de siderurgia e oficina de corrosão (Version 02, Vol. 4, No. 1, p. eblg001). Blog Prof. Ricardo Luiz Perez Teixeira, Itabira. https://doi.org/10.5281/zenodo.20291858
Teixeira, R. L. P. (2019b). Dissemination of the Processing and Materials Workshop for Engineering. Blog Prof. Ricardo Luiz Perez Teixeira, Itabira. https://doi.org/10.5281/zenodo.20291985
Wolynec, S. (2003). Electrochemical Techniques in Corrosion Engineering. EDUSP.
Figures & Tables
Figure 1
Internal surface of a metallic pipe affected by corrosion processes.
Note. The figure illustrates the accumulation of corrosion products on the internal surface of a metallic pipeline. Such deposits contribute to flow restriction, pressure losses, and progressive deterioration of hydraulic performance. Adapted from Abreu et al. (2019).
Table 1
Principal Corrosion Mechanisms Identified in Metallic Piping Systems and Their Operational Impacts
Corrosion Mechanism | Main Characteristics | Potential Consequences |
Tuberculation | Formation of corrosion-product deposits on the internal pipe surface. | Reduced flow capacity, increased pressure losses, and deterioration of hydraulic performance. |
Localized Corrosion | Concentrated attack occurring at specific areas of the metallic surface. | Wall penetration, leakage, and premature pipe failure. |
Weld Corrosion | Preferential degradation in welded joints and heat-affected zones (HAZ). | Loss of structural integrity and increased susceptibility to cracking and failure. |
Note. The table summarizes the principal corrosion mechanisms identified in galvanized- and carbon-steel piping systems analyzed in the selected case studies. Tuberculation was predominantly observed in galvanized steel piping, whereas localized corrosion and weld-related degradation were more frequently associated with carbon steel pipelines operating under aggressive industrial service conditions. Adapted from Souza et al. (2018) and Abreu et al. (2019).
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