Failure and Degradation Mechanisms of Steel Pipelines: Analysis and Development of Effective Preventive Strategies

The increasing challenges related to the reliability and durability of steel pipeline infrastructure necessitate a detailed understanding of degradation and failure mechanisms. This study focuses on selective corrosion and erosion as critical factors, analyzing their impact on pipeline integrity using advanced methods, including macroscopic analysis, corrosion testing, microscopic examination, tensile strength testing, and finite element method (FEM) modeling. Selective corrosion in the heat-affected zones (HAZs) of longitudinal welds was identified as the dominant degradation mechanism, with pit depths reaching up to 6 mm, leading to tensile strength reductions of 30%. FEM analysis showed that material loss exceeding 8 mm in weld areas under standard operating pressure (16 bar) induces critical stress levels, risking pipeline failure. Erosion was found to exacerbate selective corrosion, accelerating degradation in high-stress zones. Practical recommendations include the use of corrosion-resistant materials, such as duplex steels, and implementing integrated monitoring strategies combining non-destructive testing with FEM-based predictive modeling. These insights contribute to developing robust preventive measures to ensure the safety and longevity of pipeline infrastructure.