Cast Iron Pipe Research Articles

Improving experimental methods for hygienic assessment of the use of metallic materials and their alloys in drinking water supply systems

Introduction. For many years, steel and cast iron pipes have been used in the practice of domestic drinking water supply. However, they can be a source of pollutants entering drinking water. During the hygienic assessment, special attention is paid to metal impurities in corrosion products, which under certain conditions can enter drinking water distribution systems, thereby polluting drinking water and creating a health risk. Materials and methods. The material was scientific reports and laboratory studies on the problem of the use of metal materials and their alloys in drinking water supply systems, with special attention to the specific properties of the analyzed materials. Results. The objective of our research is an attempt to standardize hygienic studies of metal materials (alloys) used in drinking water supply. The object developed was a research laboratory stand that recreates the conditions of a real water supply system, which makes it possible to simulate operating conditions for sanitary and chemical testing of metals and alloys intended for use in contact with drinking water. The stand guarantees a continuous flow of water through the tested material, simultaneous testing of the required number of samples, including control ones, as well as connection to cold and hot water supply systems (with test temperatures from 60 °C to 85 °C). It also allows temporarily stopping the flow of water to simulate standing water (test lines are closed for four hours before sampling), collect at least 3 liters of contact water for further testing, and also makes it easy to install the system and replace test samples. Limitations. Modelling of operating conditions for sanitary and chemical testing was carried out on metal materials (alloys), which are one of the possible options for using materials in drinking water supply. It is necessary to conduct similar studies on other groups of materials used. Conclusion. This stand can be used by laboratories to carry out sanitary-chemical analysis of alloys that are used in drinking water supply systems. The developed methodology makes it possible to improve the quality and accuracy of the analysis of metallic materials and alloys through the use of a unified research system.

Effect of Pipe Materials and Interspecific Interactions on Biofilm Formation and Chlorine Resistance: Turn Enemies into Friends

Drinking water distribution systems (DWDSs) may be contaminated to various degrees when different microorganisms attach to the pipe walls. Understanding the characteristics of biofilms on pipe walls can help prevent and control microbial contamination in DWDSs. The biofilm formation, interspecific interactions, and chlorine resistance of 10 dual-species biofilms in polyethylene (PE) and cast iron (CI) pipes were investigated in this paper. The biofilm biomass (heterotrophic bacterial plate count and crystal violet) of dual species in CI pipes is significantly higher than that in PE pipes, but the biofilm activity in CI pipes is significantly lower than that in PE pipes. The interspecific interaction of Sphingomonas-containing group presented synergistic or neutral relationship in PE pipes, whereas the interspecific interaction of the Acidovorax-containing group showed a competitive relationship in CI pipes. Although interspecific relationships may help bacteria resist chlorine, the chlorine resistance was more reliant on dual-species groups and pipe materials. In CI pipes, the Microbacterium containing biofilm groups showed better chlorine resistance, whereas in PE pipes, most biofilm groups with Bacillus exhibited better chlorine resistance. The biofilm groups with more extracellular polymeric substance (EPS) secretion showed stronger chlorine resistance. The biofilm in the PE pipe is mainly protected by EPS, while both EPS and corrosion products shield the biofilms within CI pipe. These results supported that dual-species biofilms are affected by pipe materials and interspecific interactions and provided some ideas for microbial control in two typical pipe materials.

Prototyping of vibration-sensing-actuation device which is contained high-power electrodynamic speaker for diagnosis of actual water main network

Water leakage and bursting due to deterioration of water distribution mains lead to water outages and economic losses. To prevent the accidents, we are conducting research to develop measurements and diagnostic methods for buried water mains. In this study, we focused on the shift in eigenfrequencies of in-plane bending vibration of rings because of deterioration. Therefore, we are developing the vibration-sensing-actuation device which detects the frequency changes of in-plane bending mode. The water distribution network is mainly composed from cast iron pipe. Moreover, the attached facilities for example fire hydrant and water valve are contained. Since attached facilities are fabricated from cast iron component, actual water main network is heavy facilities which have high rigidity. In order to excite the desired in-plane bending mode in heavy components, the proposed sensing-actuation device requires the high-power actuator. In this study, we introduce the high-power electromagnetic actuator more than 100W output into the proposed device. Furthermore, the fundamental operational tests were conducted under the various input signals in the laboratory situations. In addition, the field operation confirmation was performed in an actual water main network.

Pipe material and natural organic matter impact drinking water biofilm microbial community, pathogen profiles and antibiotic resistome deciphered by metagenomics assembly

Biofilms in drinking water distribution systems (DWDSs) are a determinant to drinking water biosafety. Yet, how and why pipe material and natural organic matter (NOM) affect biofilm microbial community, pathogen composition and antibiotic resistome remain unclear. We characterized the biofilms’ activity, microbial community, antibiotic resistance genes (ARGs), mobile genetic elements (MGEs) and pathogenic ARG hosts in Centers for Disease Control and Prevention (CDC) reactors with different NOM dosages and pipe materials based on metagenomics assembly. Biofilms in cast iron (CI) pipes exhibited higher activity than those in polyethylene (PE) pipes. NOM addition significantly decreased biofilm activity in CI pipes but increased it in PE pipes. Pipe material exerted more profound effects on microbial community structure than NOM. Azospira was significantly enriched in CI pipes and Sphingopyxis was selected in PE pipes, while pathogen (Ralstonia pickettii) increased considerably in NOM-added reactors. Microbial community network in CI pipes showed more edges (CI 13520, PE 7841) and positive correlation proportions (CI 72.35%, PE 61.69%) than those in PE pipes. Stochastic processes drove assembly of both microbial community and antibiotic resistome in DWDS biofilms based on neutral community model. Bacitracin, fosmidomycin and multidrug ARGs were predominant in both PE and CI pipes. Both pipe materials and NOM regulated the biofilm antibiotic resistome. Plasmid was the major MGE co-existing with ARGs, facilitating ARG horizontal transfer. Pathogens (Achromobacter xylosoxidans and Ralstonia pickettii) carried multiple ARGs (qacEdelta1, OXA-22 and aadA) and MGEs (integrase, plasmid and transposase), which deserved more attention. Microbial community contributed more to ARG change than MGEs. Structure equation model (SEM) demonstrated that turbidity and ammonia affected ARGs by directly mediating Shannon diversity and MGEs. These findings might provide a technical guidance for controlling pathogens and ARGs from the point of pipe material and NOM in drinking water.

Leakage Quantification in Metallic Pipes under Different Corrosion Exposure Times

The combined effects of aqueous corrosion, stress factors, and seeded cracks on leakage in cast iron pipes have not been thoroughly examined due to the complexity and difficulty in predicting their interactions. This study seeks to address this gap by investigating the interdependencies between corrosion, stress, and cracks in cast iron pipes to optimise the material selection and design in corrosive environments. Leakage experiments were conducted under simulated localised corrosive conditions and internal pressure, revealing that leakage increased from 0 to 25 mL with crack sizes of 0.5 mm, 0.8 mm, 1 mm, and 1.2 mm, along with corrosion times of 0, 120, 160, and 200 h, and varying stress levels. An empirical model was developed using a curve-fitting approach to map the relationships among corrosion time, crack propagation, and leakage amount. The results demonstrate that the interaction between corrosion, stress, and crack propagation was complex and nonlinear, and the leakage amount increased from 0.7 to 0.10 mm every 15 min, as evidenced by SEM microstructure images and empirical data.

Reproduction of fissure corrosion and mechanism for fissure formation on ductile cast iron

On some cast iron pipes corroded under tensile stress, corrosion with a characteristic surface appearance, known as “fissure corrosion,” was occasionally observed. Because fissure corrosion on ductile cast iron pipes has been rarely studied, the detailed conditions and mechanism for fissure formation are still elusive. In this study, the levels of tensile stress and anodic current density causing fissure corrosion on ductile cast iron were investigated through laboratory experiments to reproduce fissure corrosion and elucidate its mechanism. Fissure corrosion was reproduced at bending tensile stresses ≥200 MPa. The depth difference between the peak and valley of fissures increased with increasing anodic current density, and the fissure corrosion was attributed to the difference between the anodic current densities of the peak and valley due to plastic deformation by stress concentration. Fissure corrosion was likely to be suppressed by reducing the anodic current flowing out of ductile cast iron surface.

A mechanistic deterioration point assignment model for water pipe condition assessment

ABSTRACT A pipe condition assessment model is required to implement effective and economical planned maintenance of the water distribution system. The application of such a model requires sufficient accuracy, which, however, is limited by the complexity of the pipe deterioration process and data storage capacity of the water utility. The majority of previous studies have focused on the improvement of assessment algorithms for data mining. In this study, a mechanistic deterioration point assignment (MDPA) model is developed to make advancements in the modes of data input and result output to enhance the model's accuracy and application scope for cast iron and steel pipes. In this MDPA model, (1) indicators/sub-indicators on external corrosion, external load, internal corrosion, and internal load are constructed and can be obtained by data estimation or techniques and (2) assessment results include both pipe overall condition and detailed conditions on corrosion and load, offering evidence for primary maintenance measures. The weights of the indicators/sub-indicators are estimated using the Bayesian statistics theory. The modelling results of pipe samples demonstrate that this MDPA model is an effective tool for pipe condition assessment.

Behavior Assessment of Exhumed Cast Iron Pipes Using Distributed Strain Sensing

Behavior Assessment of Exhumed Cast Iron Pipes Using Distributed Strain Sensing

Corrosion at the Steel–Medium Interface

Corrosion on the interface between a metal alloy, such as steel, and a wet, permeable non-metallic medium is of considerable practical interest. Examples include the interface between steel and water, the atmosphere or concrete, as for steel reinforcement bars; between metal and soil, as for buried cast iron or steel pipes; deposits of some type, as in under-deposit corrosion; and the interface with insulation, protective coatings, or macro- or micro-biological agents. In all cases, corrosion initiation depends on the characteristics of the interfacial zone, both of the metal and the medium, and the spatial variability. For (near-)homogeneous semi-infinite media with good interfacial contact, the pitting, crevices and general corrosion of the metal will be largely controlled by the metal (micro-)characteristics, including its inclusions, imperfections and surface roughness. In other cases, these may be overshadowed by the macro-characteristics of the medium and the degree of interfacial contact, possibly with severe resulting corrosion. Where the build-up of corrosion products can occur at the interface, they will dominate longer-term corrosion and govern the long-term corrosion rate. For media of finite thickness, diffusion issues and material deterioration may also be involved. The practical implications are outlined. It is argued that with the presence of a suitable medium, it is possible to achieve negligible long-term corrosion but only if certain practical actions are taken.

A Safe Frost Growth Screening Method to Accurately Predict Ice Plug Formation Completion during Waterpipe Freezing Repairs

Fixing waterpipes using cryogenic technology is a complicated activity because it is difficult to see the transformation of water into ice inside a pipe. To solve this problem, a series of experiments and testing was carried out on three types of waterpipes—75, 100, and 150 mm cast-iron pipes (CIP), respectively—to monitor the external characteristics and the frost growth to accurately predict the completion of ice plug formation inside the pipe before applying the freeze-fixing method. A CCD camera was set up to capture four frosting images per minute and to send one image every 15 s to the computer for processing and for identifying the interface between frost and no frost. The results showed that when the brightness distribution along the pipe axis goes down from the 100% brightest and coldest region near the freezing jacket to 90% and hits the 1/10th mark away from the brightest area, which is the interface, the freezing process is finished, and the ice plug has completely formed and can effectively block water flow to allow safe repairs. In other words, the findings determined that the frost length was more or less equal to the ice plug length. Additional testing was done to increase water pressure up to 35 kg/cm2 for about 10 min on one end of the freezing jacket, which is higher than the regular pressure testing of 10 kg/cm2. When 0 kg/cm2 was recorded on the other end of the freezing jacket, it was concluded that the ice plug was strong enough to resist high pressure. The success of these experiments and testing confirmed that this innovative freezing method was safe, cost-effective, and suitable to be used efficiently in semiconductor factories and modern buildings.

Effects of chloride on corrosion scale compositions and heavy metal release in drinking water distribution systems

Variations in water chemistry may lead to the release of harmful heavy metals in drinking water distribution systems (DWDSs). In this study, the effects of chloride on the release of heavy metals such as Fe, Mn, As, Cr, Mo, V, Sr, and Co were examined using steel and cast iron pipe loops. After chloride was added, the relative contents of goethite (α-FeOOH), lepidocrocite (γ-FeOOH), and siderite (FeCO3) in pipe scales increased, but the contents of magnetite (Fe3O4) decreased. The most prevalent compounds were α-FeOOH and γ-FeOOH. When the chloride levels were increased, the effluent concentrations of Fe, Mn, As, Cr, Mo, V, Sr, and Co significantly increased. These heavy metals were released presumably because of the destabilization and dissolution of corrosion scales induced by chloride and adsorption site competition. Strong positive correlations were also observed between Fe&Mn, Fe/Mn&As, Fe/Mn&Cr, Fe/Mn&Mo, Fe/Mn&V, Fe/Mn&Sr, and Fe/Mn&Co, indicating the co-release of Fe, Mn, and other metals. This study may be helpful for the potential strategies on avoidance of heavy metal release and improvement of water supply security.

Heat transfer characteristics and thermal insulation optimization of buried ductile iron heat-supply pipeline

ABSTRACT This study investigates heat transfer in a ductile iron heat-supply pipeline and develops a mathematical model through a comparative assessment of different techniques. The goal is to accurately describe non-steady state heat transfer in buried pipelines. A high-precision model is established by considering assumptions, equations, boundary conditions, calculation domain, geometry, and grid number. Calculation time is reduced, and accuracy is improved, providing a foundation for optimizing the thermal insulation layer. ANSYS software is used to simulate and optimize the thermal insulation of the pipeline. Results show a maximum error range of 1.20% to 10.20% with consistent temperature trends, verifying the model’s accuracy. The heat-affected zone of the thermal bridge is evaluated and optimized, and preventive measures are proposed to reduce the impact of heat bridges in joint areas. The study also compares nodular cast iron pipes with conventional steel thermal pipes under the same conditions. It reveals that the economic thickness of the thermal insulation layer for nodular cast iron pipes increases from 31 mm to 39 mm due to the thermal bridge effect, which is significant.

Synergistic effects of trace sulfadiazine and corrosion scales on disinfection by-product formation in bulk water of cast iron pipe

The effects of trace sulfadiazine (SDZ) and cast-iron corrosion scales on the disinfection by-product (DBP) formation in drinking water distribution systems (DWDSs) were investigated. The results show that under the synergistic effect of trace SDZ (10 μg/L) and magnetite (Fe3O4), higher DBP concentration occurred in the bulk water with the transmission and distribution of the drinking water. Microbial metabolism-related substances, one of the important DBP precursors, increased under the SDZ/Fe3O4 condition. It was found that Fe3O4 induced a faster microbial extracellular electron transport (EET) pathway, resulting in a higher microbial regrowth activity. On the other hand, the rate of chlorine consumption was quite high, and the enhanced microbial EET based on Fe3O4 eliminated the need for microorganisms to secrete excessive extracellular polymeric substances (EPS). More importantly, EPS could be continuously secreted due to the higher microbial activity. Finally, high reactivity between EPS and chlorine disinfectant resulted in the continuous formation of DBPs, higher chlorine consumption, and lower EPS content. Therefore, more attention should be paid to the trace antibiotics polluted water sources and cast-iron corrosion scale composition in the future. This study reveals the synergistic effects of trace antibiotics and corrosion scales on the DBP formation in DWDSs, which has important theoretical significance for the DBP control of tap water.

The interaction between extracellular polymeric substances and corrosion products in pipes shaped different bacterial communities and the effects of micropollutants

There are growing concerns over the effects of micropollutants on biofilms formation and antibiotic resistance gene (ARGs) transmission in drinking water distribution pipes. However, there was no reports about the influence of the interaction between extracellular polymeric substances (EPS) and corrosion products on biofilms formation. Our results indicated that the abundance of quorum sensing (QS)-related genes, polysaccharide and amino acids biosynthesis genes of EPS was 6747–8055 TPM, 2221–2619 TPM, and 1461–1535 TPM in biofilms of cast iron pipes, respectively, which were higher than that of stainless steel pipes. The two-dimensional correlation spectroscopy (2D-COS) analysis of attenuated total reflectance–Fourier transform infrared spectrometry (ATR–FTIR) results indicated that polysaccharide of EPS was more easily adsorbed onto the corrosion products of cast iron pipes. Therefore, more human pathogenic bacteria (HPB) carrying ARGs were formed in biofilms of cast iron pipes. The amide I and amide II components and phosphate moieties of EPS were more susceptible to the corrosion products of stainless steel pipes. Thus, more bacteria genera carrying mobile genetic elements (MGE)-ARG were formed in biofilms of stainless steel pipes due to more abundance of QS-related genes, amino acids biosynthesis genes of EPS and the functional genes related to lipid metabolism. The enrichment of dimethyl phthalate (DMP), perfluorooctanoic acid (PFOA) and sulfadiazine (SUL) in corrosion products induced upregulation of QS and EPS-related genes, which promoted bacteria carrying different ARGs growth in biofilms, inducing more microbial risks.

Causes and consequences of changes in the values of hydraulic characteristics of metal water supply and sanitation networks during their operation

Purpose: It consists in carrying out a comparative analysis of the values of the characteristics of the hydraulic potential of metal pipelines used in assessing the energy consumption of pumping units installed on pipelines with different thickness of the layer of internal deposits.
 Methods: The reasons for changing the values of hydraulic characteristics of metal pipelines during their operation are developed in tabular form. A concrete example shows the change in the values of the characteristics of the hydraulic potential of pipes with different thickness of the layer of internal deposits included in the calculated dependence for determining the actual energy consumption of pumping units.
 Results: It is proposed to develop for the entire range of manufactured steel pipes and pipes made of gray cast iron, a scale of maximum permissible values of the thickness of the layer of internal deposits, according to which a decision should be made to continue or stop the operation of pipe wires.Conclusion: To recommend, based on the hydraulic calculation of the characteristics of the hydraulic potential of pipes for the given example, minimizing the use of steel and cast iron pipes made of gray cast iron in projects of water supply and drainage networks. When operating metal pipelines, take into account the dynamics of changes in the energy consumption of pumping units with different thickness of the layer of internal deposits.

Pressure-induced fatigue failures in cast iron water supply pipes

Cast iron pipes have been extensively utilised in water supply networks worldwide. Many of these pipes are either at the onset or within their wear-out phase, during which failure rates rapidly increase, and the pipes should be repaired or replaced. However, the replacement and rehabilitation of these pipes might require extensive resources and time. Therefore, it is essential to investigate the effects of operational practices that might reduce failure rates for ageing cast iron pipes. In this paper, we investigate the conditions under which water pressure fluctuations may impact and accelerate fatigue failures in cast iron pipes. We carried out a systematic review of the mechanical properties of cast iron pipes and conducted sensitivity analyses to estimate fatigue crack propagation using fracture mechanics. Our investigation suggests that cast iron pipes which are affected by reduced wall thickness due to corrosion may experience a significant decrease in their operational life when subjected to water pressure fluctuations. Moreover, this negative influence of pressure fluctuations is exacerbated with an increase in the mean operating pressure. As an example, a 150 mm pipe featuring a corrosion patch of about 7 mm depth could extend its remaining fatigue life by over fourfold through a minor reduction of both mean pressure and pressure fluctuations of approximately 10 mH2O each. The manuscript further explores various pressure reduction combinations and trends, demonstrating the beneficial effects of reducing both mean pressure and pressure fluctuations. Consequently, the presented analysis suggests that water operators should proactively manage (reduce) the magnitude of both pressure components to extend the operating life of ageing cast iron pipes.

Online micro defects detection for ductile cast iron pipes based on twin light photometric stereo

Ductile cast iron pipes (DCIPs) are widely utilized in water and gas supply due to their exceptional mechanical and material properties. Quality control during production is paramount for optimal performance, with surface defect detection being of utmost importance. Currently, production sites primarily rely on manual visual inspection, which presents several challenges, including high labor intensity, low efficiency, and subjectivity in defect judgment. 2D detection algorithms based on single images struggle to effectively detect small defects such as pores, pinholes, and scratches, resulting in high missed detection rates and vulnerability to interference from oil and water stains. To address these issues, this paper proposes a symmetrical twin-light photometric stereo (TLPS) detection algorithm based on photometric stereo theory, and image correction algorithm for mitigating the effects of ambient light. A visual inspection prototype system was designed and successfully implemented at a production site. The system comprises eight visual inspection units, each equipped with a high-speed line scan camera and two bar light sources for image acquisition of moving DCIP. Under the Lambertian model and parallel light source assumption, the gradient expression in the texture direction of the DCIP surface is derived based on light source symmetry. Production experiment results demonstrate that the gradient map obtained through the proposed TLPS effectively enhances defect contrast and accurately detects and locates micro defects such as pores, pinholes, and scratches on cast pipe surfaces. This verifies the effectiveness of the TLPS algorithm, addresses the shortcomings of traditional 2D detection algorithms, and lays the foundation for subsequent online detection of DCIP surface defects.

A Self-Supervised Model Based on CutPaste-Mix for Ductile Cast Iron Pipe Surface Defect Classification.

Online surface inspection systems have gradually found applications in industrial settings. However, the manual effort required to sift through a vast amount of data to identify defect images remains costly. This study delves into a self-supervised binary classification algorithm for addressing the task of defect image classification within ductile cast iron pipe (DCIP) images. Leveraging the CutPaste-Mix data augmentation strategy, we combine defect-free data with enhanced data to input into a deep convolutional neural network. Through Gaussian Density Estimation, we compute anomaly scores to achieve the classification of abnormal regions. Our approach has been implemented in real-world scenarios, involving equipment installation, data collection, and experimentation. The results demonstrate the robust performance of our method, in both the DCIP image dataset and practical field application, achieving an impressive 99.5 AUC (Area Under Curve). This presents a cost-effective means of providing data support for subsequent DCIP surface inspection model training.

Identifying key pipe attributes and locations to best determine chlorine decay coefficients within a water distribution system

Abstract Water distribution system (WDS) characteristics can impact drinking water quality. Kinetic reaction coefficients of residual disinfectant associated with bulk water (kb) and pipe wall (kw) during water distribution can lead to water quality degradation. Determining these coefficients can be expensive and time-consuming. The main objective of this study is to determine the most relevant pipe characteristics and locations to best determine chlorine decay coefficients in a WDS. This article aims to evaluate various scenarios of kb and kw values and compare them to measured data in a full-scale WDS. The most accurate scenario is also compared with the lowest-cost scenario to identify the most effective information needed to determine these coefficients, in terms of location within the WDS and pipe characteristics (age, diameter, and material). Results showed that the scenario with the highest kw and kb values corresponds best to the field-measured data. Moreover, determining specific kinetic coefficients was shown to be more accurate for gray cast iron pipes, pipes installed in a period before 1960, and vulnerable zones for residual chlorine decay.

Repair Welding of Broken Gray Cast Iron Pipes Instead of Applying Lock-Stitching Method

Repair Welding of Broken Gray Cast Iron Pipes Instead of Applying Lock-Stitching Method