Julie Holmquist, Cortec® Corporation, USA, considers corrosion
control during pipeline construction and delays.
P
ipeline construction can take several years or more,
especially if the project is delayed by problems with
permitting, accidents, or environmental issues, to name a
few. One NGL pipeline that was recently completed took
five instead of three years to finish due to complications from a
drilling mud fluid spill.1 The cost of any such delay is massive. For
example, one pipeline development company claimed to have
lost US$583 million in project value simply due to legal delays,
with ROW maintenance costing close to US$20 or US$25 million
per month.2 Yet another pipeline faced an increased price tag
of US$1.1 billion at one point after regulatory delays and winter,
environmental, and COVID-19 issues affected construction costs.3
In short, delays are both common and expensive.
One side effect of delays that can be avoided is the loss
of asset value due to corrosion. Delays mean that assets sit
outside for extended periods, often unprotected and exposed
to the elements, at high risk of corrosion. Considering that
capital costs of crude oil pipeline construction can be between
US$500 000 and US$800 000 per mile, the stakes of losing assets
to corrosion are high.4 However, delays or no delays, corrosion
is always a threat to asset integrity and value during the pipeline
construction period and thereafter. Fortunately, protection
does not have to be complicated, as Cortec® demonstrates by
its vapour phase corrosion inhibitor technology and related
strategies that offer corrosion inhibition through multiple stages
of pipeline construction and unwelcome delays.
Pipeline segment protection
The most obvious place where corrosion protection is needed
is inside pipeline segments. Although typically protected with a
special coating on the outside, pipeline internals are often left
bare and open to the environment (Figure 3). On the outside, weld
ends are left uncoated and more susceptible to corrosion. Pipe
segments sit outside in staging yards by the hundreds until they
can be installed. Depending on how quickly the project is moving,
this could mean weeks to years for thousands of pipe segments
to be left exposed to the elements. Considering that line pipe and
equipment could make up 23.8 - 27.2% of crude oil pipeline capital
costs, the loss of these assets to corrosion could be a significant
financial impairment.5
In contrast, protection is relatively simple and cost-effective
with vapour phase corrosion inhibitors that can be used to protect
pipe segment internals during shipping, transit, and outdoor
Figure 1. Heavy equipment is critical for many
aspects of pipeline construction, not least of
which is digging a trench for pipeline placement.
15
 storage. Typically based on salts of amine carboxylates, vapour
phase corrosion inhibitors come in many forms but work in the
same basic way. These inhibitors vaporise and diffuse throughout
an enclosed space until they have achieved equilibrium. When
there is no more room in which to disperse, the vapour phase
corrosion inhibitors give into their metal attraction and begin to
adsorb onto the metal surfaces in a molecular protective layer
(Figure 2). As long as the void remains closed – or even if it is
briefly opened – the ambient vapour phase corrosion inhibitors
continue to replenish the protective molecular layer. Removal
and cleaning of the layer is typically not needed before asset
commissioning, although compatibility should be verified with
each specific product.
One of the newest forms of vapour phase corrosion inhibitor
technology is CorroLogic® Fogging Fluid VpCI®-339. This 100%
vapour-phase inhibitor product can be fogged into pipe segments
and trapped inside by capping the ends for one to two years
of protection. Once the caps are opened, the vapour phase
Figure 2. How vapour phase corrosion inhibitors (VpCI) protect
metals in an enclosed space (image courtesy of Cortec).
Figure 3. Pipeline segments stored outdoors are vulnerable to
rust on unprotected internals and weld ends.
16 World Pipelines / FEBRUARY 2023
corrosion inhibitors begin to dissipate and there is typically no
need for manual corrosion inhibitor removal before pipeline
installation.
EcoPouch® is another form of vapour phase corrosion
inhibitor application that can be added before transit or storage.
This was used in Malaysia for an oil and gas project that needed
24 months of corrosion protection inside pipe spools that would
be stored in a harsh environment. EcoPouch contains VpCI-609
powder in a breathable pouch that allows the vapour phase
corrosion inhibitors to escape (Figure 4). Two EcoPouches were
inserted into each pipe spool before the ends were capped,
trapping the vapour phase corrosion inhibitors inside. This offered
an easy and clean method of protection as the pouches could be
taken out whenever necessary.6
In another case, a subsea LNG pipeline project needed internal
protection of 1300 pipeline segments that would be stored
outside for 12 - 18 months. The pipeline segments were externally
covered in cement for sea floor ballasting, but pipe internals and
cutbacks were exposed, and light rust had already started to form
in some segments. A vapour phase corrosion inhibitor fogging
fluid was applied inside the pipes. External ends were coated with
VpCI-389 water-based corrosion inhibitor coating. VpCI-126 Film
was then tightly secured on the ends. Upon early inspection it was
found that existing corrosion had been arrested and pipes that
were initially corrosion free remained so.7
The previous example brings up the important point of
coating pipeline weld ends. While ends are often left uncoated
to make welding easier, they are also more likely to develop
corrosion that must be ground off to provide a clean weld surface
when welding does take place. This extra hassle can be avoided by
protecting ends with an inobtrusive Cortec VpCI coating. VpCI-391
is a clear water-based temporary coating that dries to a non-
tacky film. If desired, it can be cleaned off with an alkaline cleaner
prior to welding. This eliminates some of the extra steps, such as
grinding, that are often necessary to remove rust and ensure a
clean weld surface.
Preservation of valves and other critical assets
Valves are another example of pipeline components that can
be expensive and may sit outside while awaiting installation.
Preservation of these critical assets can be done even before
they arrive at the construction site, as seen by one pipeline valve
and fitting surplus company that inventories new components
acquired from oil and gas companies. Standard procedure for
protecting this inventory, which sometimes includes assemblies
of more than 40 000 lb (18 144 kg), is to place a source of
vapour phase corrosion inhibitors inside (e.g. VpCI-111 Emitters or
EcoAir® 337 fogging fluid) and cover openings with VpCI-126 bags
or film. Those stored outside use custom VpCI-126 HP UV bags.8
Depending on how long the equipment has already been outside
at the supplier or is expected to sit outside at the staging site,
pipeline components preserved in this way may not even need
reapplication of preservation materials for one to two years after
they have been transported to the field.
Heavy equipment protection
Pipe segments are not the only metals in need of corrosion
protection at a pipeline jobsite. The quantity of heavy equipment
 needed for pipeline construction is massive. Bulldozers and
stump grinders may be needed to clear ROWs; excavators and
jack hammers are needed to perform a variety of earth-moving
jobs (Figure 1).9 While this equipment is made for rough outdoor
work, it can still face deterioration if left out in the open for
extended periods of time, particularly in harsher environments
such as coastal areas or the Middle East. As heavy equipment sits
out in the rain, snow, sun, or sea spray, rust develops over time
and the expected lifespan of the equipment drops, causing an
accelerated loss of value. Some heavy equipment owners in other
industries have had good results from applying EcoShield VpCI-386
Figure 4. EcoPouch is easy to place inside new pipe spools for
protection. They can be removed at any time, leaving the pipeline
segment clean and protected (image courtesy of Cortec).
Figure 5. Fogging pipe internal with VpCI in powder form (image
courtesy of Cortec).
18 World Pipelines / FEBRUARY 2023
or VpCI-391 right over existing coatings. These provide an extra
layer of corrosion protection for the equipment bodies without
affecting their appearance or usability. In the case of VpCI-391, if
the temporary coating begins to wear off through normal use, it
can be reapplied as part of an annual maintenance routine.
Corrosion protection during and after
hydrotesting
One of the last steps of pipeline construction is hydrostatic
testing to ensure pipeline integrity. Large amounts of water
are flushed through the completed pipeline at high pressure.
While this is critical to verifying pipeline safety, it also introduces
corrosives to the internal environment. To protect against flash
rusting during hydrotesting and corrosion caused by residual
water thereafter, VpCI-649 can be added to the hydrotest water.
VpCI-649 is a film forming corrosion inhibitor that leaves behind a
protective layer inside the pipeline, with vapour phase protection
for hard-to-reach areas like the very top of the pipe. It is widely
used in a variety of industries and is an excellent addition to
almost any hydrotesting application.
Conclusion
Pipeline construction delays are a fact of life, leaving equipment
and construction materials exposed to the risk of corrosion for
long periods of time. Even without delays, equipment and pipe
segments are necessarily exposed to corrosive elements, often
for extended timeframes while construction work is completed.
Corrosion protection is an important step to counter the potential
asset value loss from environmentally-induced metal deterioration.
It also keeps equipment and components in ready-to-use, ready-
to-install condition and minimises concerns about future failures
stemming from corrosion that happened before the pipeline was
ever commissioned. By strategically using vapour phase corrosion
inhibitor technology and VpCI coatings, pipeline developers
can discover an excellent solution to minimise corrosion during
pipeline construction and delays.
References
1. PHILLIPS, S. “Mariner East pipeline project is finished, after years of environmental
damage, construction delays.” WHYY.org. 17 Feb 2022 <whyy.org/articles/mariner-east-
pipeline-project-is-finished-after-years-of-environmental-damage-construction-delays>.
Accessed 7 Nov 2022.
2. TONY, M. “MVP developer calls for Congress to force project completion amid
$583M project impairment.” WV Gazette Mail. 1 Nov 2022 <www.wvgazettemail.
com/news/energy_and_environment/mvp-developer-calls-for-congress-to-force-
project-completion-amid-583m-project-impairment/article_9899b10d-b9d9-5182-9120-
b16354a59ff7.html>. Accessed 9 Nov 2022.
3. LOVRIEN, J. “Line 3 pipeline costs increase another $1.1B.” Pioneer Press. TwinCities.com.
16 Feb 2021 <www.twincities.com/2021/02/16/enbridge-line-3-pipeline-costs-mn-nd-wi>.
Accessed 8 Nov 2022.
4. O’NEIL, B., et al. “The Economic Impact of Crude Oil Pipeline Construction and
Operation.” Consulting Report. IHS Economics. February 2016 <documents.nam.
org/Nam.org_Web_Archive/www.nam.org/Issues/Energy-and-Environment/
CrudeOilImpact_March2016.pdf> p. 5. Accessed 7 Nov 2022.
5. Ibid.
6. Cortec Corporation. “Pipe Spool Preservation.” Case History #714. Apr 2021 <www.
corteccasehistories.com/?s2member_file_download=access-s2member-level1/ch714.
pdf>. Accessed 8 November 2022.
7. Cortec Corporation. “VpCI-126 Film, VpCI-389 Coating, & VpCI 609 Powder.”
Case History #311. April 2007 <www.corteccasehistories.com/?s2member_file_
download=access-s2member-level1/ch311.pdf>. Accessed 8 Nov 2022.
8. Cortec Corporation. “Preservation of Pipeline Valve Inventory.” Case History #762. Mar
2022 <www.corteccasehistories.com/?s2member_file_download=access-s2member-
level1/ch762.pdf>. Accessed 8 Nov 2022.
9. Fractracker Alliance. “Pipeline Construction: Step by Step Guide.” Copyright 2022
<www.fractracker.org/resources/oil-and-gas-101/pipeline-construction>. Accessed 9
Nov 2022.