Introduction
Subsea pipelines operate in one of the harshest environments imaginable. Constant exposure to saltwater, pressure, and shifting seabeds can deteriorate pipeline coatings—the first line of defense against corrosion and structural damage. Ignoring early warning signs of coating failure can lead to costly repairs, operational downtime, and environmental hazards.
This case study highlights five warning signs that pipeline coatings are deteriorating and explains how addressing these issues early can save infrastructure from catastrophic failure.
Key Warning Signs of Pipeline Coating Failure
1. Cracking or Blistering
Cracking and blistering are some of the earliest signs of coating failure. These small imperfections might seem minor, but they expose the underlying pipeline to corrosive elements, allowing moisture to seep in and initiate corrosion.
- Cracking: Often caused by environmental stress or aging, cracks allow saltwater and other corrosive substances to penetrate the coating.
- Blistering: Results from trapped moisture or gases beneath the coating, weakening the bond and creating pathways for corrosion.
Addressing cracking and blistering early prevents structural instability and reduces the risk of costly repairs.
2. Discoloration or Fading
Changes in the coating’s color may seem cosmetic, but they are often the first indication of chemical or UV degradation. Discoloration signals that the material’s protective properties are weakening.
- UV Degradation: Prolonged sun exposure breaks down coating pigments and reduces elasticity.
- Chemical Reactions: Exposure to seawater and industrial chemicals accelerates coating breakdown.
Regular visual inspections can catch these early signs, ensuring timely reapplication and extending the coating’s lifespan.
3. Peeling or Flaking
Peeling and flaking coatings expose bare metal to corrosive elements, leading to rapid deterioration. These failures often result from poor surface preparation, environmental stress, or the natural aging of the material.
- Improper Adhesion: Weak surface bonds cause coatings to detach under pressure or temperature fluctuations.
- Environmental Stress: High-pressure subsea environments exacerbate peeling and flaking.
Immediate action, such as spot repairs or recoating, is critical to prevent further corrosion and structural damage.
4. Visible Rust or Corrosion
Rust is a clear sign that the protective coating has failed completely. Corrosion spreads quickly in marine environments, weakening pipeline integrity and increasing the risk of leaks or structural failure.
- Advanced Oxidation: Visible rust indicates prolonged exposure to water and air due to coating failure.
- Metal Loss: Corrosion thins the pipeline walls, reducing its ability to withstand pressure.
Regular maintenance and inspections are essential to address rust before it causes irreversible damage.
5. Increased Maintenance and Inspection Failures
Frequent maintenance issues or inspection failures are signs that coatings are no longer effective. As coatings degrade, pipelines become more vulnerable to leaks, abrasions, and chemical damage.
- Inspection Data: Non-destructive testing methods can detect under-film corrosion before it becomes visible.
- Rising Costs: Increased repair frequency signals the need for comprehensive recoating or system upgrades.
Proactive responses to inspection data can save time and costs while preventing operational disruptions.
Mark Tool’s Solutions
Mark Tool offers advanced coating solutions like ThermoTRON® and SplashTRON®, designed to withstand the harsh conditions of subsea environments. These coatings provide superior protection against:
- Saltwater corrosion and UV degradation
- Mechanical stress and pressure changes
- Chemical exposure and abrasions
With a proven track record of durability, these solutions help extend pipeline lifespan, reduce maintenance costs, and minimize environmental risks.
Conclusion
Pipeline coating failure poses significant risks to operations and infrastructure. By recognizing early warning signs like cracking, discoloration, peeling, rust, and increased maintenance needs, operators can prevent costly damage and downtime.
Contact Mark Tool today to request a quote and learn how our high-performance coatings can protect your subsea pipelines.