Category Archives: Corrosion

April 24 is Corrosion Awareness Day

Did you know that corrosion costs us an astounding 2.5 trillion dollars globally?

Not to mention corrosion can cost lives and jobs…

Today is corrosion awareness day, so we thought it would be a good idea to reiterate the importance of the NACE IMPACT (International Measures of Prevention, Application, and Economics of Corrosion Technologies) study released in 2016.

According to the study, most corrosion failures, and nearly all catastrophic corrosion failures are preventable. And nearly $875 billion can be saved through the right prevention and risk analysis efforts.

Through the IMPACT study, NACE determined that in order to reduce the astronomical cost of corrosion, we would have to change how decisions are made regarding corrosion. We must not only continue to develop corrosion control methods and technology, but we must utilize organizational management systems and risk tools throughout all levels of an organization to achieve the greatest success in saving lives, jobs and money.

You can learn more by visiting impact.nace.org.

MMO Anode Technology: The latest in Cathodic Protection

MMO anode technology has taken over the cathodic protection industry and MATCOR has been on the forefront for the last 20 years. Ted Huck, our VP of International Sales was interviewed at the recent NACE Corrosion Conference. In this video he discusses MMO anode technology for cathodic protection systems and the importance of reliable anode to cable connections.

MMO Anode Technology

MMO anodes, or mixed metal oxide anodes are the latest technology in the corrosion industry. Mixed metal oxide anodes are lightweight and durable with a very low consumption rate. 

MMO anodes are a mix of metal oxide electrocatalysts. In the presence of a DC voltage source they cause an electrical reaction that generates cathodic protection current. Unlike conventional impressed current anodes that physically consume as part of the cathodic protection reaction (at rates measured in kg/amp-year), MMO anodes are dimensionally stable and do not consume. Instead, they have a long and predictable catalytic life. MMO anodes consist of a thin coating of the MMO catalyst over an inert lightweight titanium substrate and are available in a wide range of shapes and configurations.

Why Cathodic Protection Systems Fail

Waterproof Anode to Cable Connection to protects MMO anode cathodic protection systems
Kynex® Patented, Waterproof Anode to Cable Connection

The most critical component to any cathodic protection anode system is the connection of the anode to the cable that runs back to the power supply. Because the cable is part of the anode system, if it has any nicks or defects or is not water tight, that cable can become part of the anode and will very quickly consume. When that happens, the anode fails. So, with cathodic protection systems it is imperative to have the highest quality connections.

Typically, when a cathodic protection anode system fails, it is not the anode that fails, it is the anode connection that fails. MATCOR has developed a proprietary technology for connecting wire anodes to cable, called Kynex®. Wire anodes are the heart of a lot of our products and this proprietary anode technology is a huge leap forward in the reliability of these connections.

Cost-effective, Reliable Cathodic Protection Solutions

At the end of the day, for our clients, it’s all about delivering value. It’s providing a cost effective solution that’s going to serve them for a very long time. As a designer and manufacturer of cathodic protection anode systems, we are able to specifically address client needs with customized corrosion prevention solutions that provide:

  • Long life
  • Great economic value
  • Superior reliability

MATCOR Products and Services

MATCOR is one of the world’s leading cathodic protection companies. We design, manufacture, install and service cathodic protection systems for clients worldwide. MATCOR provides services to the pipeline, midstream and oil & gas industries, protecting assets such as pipelines, storage tanks, and compressor stations. We also do a lot of work in the power industries, petrochemical, and chemical industries. Anywhere where you have buried steel structures, we are there to stop corrosion.
We encourage you to contact MATCOR through our website where our corrosion specialists and engineers can provide a solution tailored to your needs.

MATCOR Profiled in India Corrosion Publication

MATCOR Profile in Coatings and Anti-Corrosion Engineering Review, Apr/May 2015 issueThank you to Abraham Mathai at Coatings and Anti Corrosion Engineering Review for the profile about MATCOR and our 40th anniversary in the April/May 2015 issue!

MATCOR was founded in 1975 by William R. Schutt when he set out to develop a high quality, reliable source for cathodic protection products and equipment. The company designed and provided the first commercial cathodic protection system for reinforced concrete bridge decks that same year. The company has grown to offer a broad portfolio of proprietary cathodic protection and AC mitigation products, in addition to complete corrosion engineering services.

In March of 2015, MATCOR was acquired by Brand Energy & Infrastructure Services (Brand). Brand also owns CP Masters, Inc., a leader in the design and construction of cathodic protection and corrosion control prevention in the North American energy markets.

READ THE COMPLETE PROFILE

New Energy Report Underscores Need for Cathodic Protection Systems to Prevent Corrosion

Energy Report - Gas Regions in US
Source: U.S. Energy Information Administration

In a recent update to its drilling productivity energy report, the Energy Information Agency revealed that there are now three US oil fields that are producing more than one million barrels of oil a day (BPD). In North Dakota, the Bakken Shale has been a major economic boon for the region while in Texas the Permian Basin and Eagle Ford Shale have both exceeded predictions. As oil and natural gas continues to expand in these regions, the need for cathodic protection systems to prevent corrosion grows.

The three fields are so prolific that they now account for at least a third of the total US daily oil production. In fact, Mark Perry of the American Enterprise Institute found that the output of the three combined fields now surpasses 4 million BPD.

Each of these regions has seen rapid growth that is nearly unprecedented in the United States. The Bakken oil production was less than 200,000 barrels per day in 2008 and is now producing around 1,100,000, an increase of 450% in just over five years.

Meanwhile, in Texas, Eagle Ford’s natural gas production has tripled in the last three years and oil production has also flourished in recent years. The region was producing less 100,000 BPD in 2010 to more than 1,400,000 BPD in 2014.

Finally, wells that had been previously drilled in the Permian zones have found new life with the development of horizontal drilling techniques. Historically, wells had a 34 percent recovery rate, but that benchmark is being challenged with new technologies.

“This Energy Information Agency report is yet another reminder that oil and gas production in the United States will continue to flourish in the years to come,” said Chris Sheldon, utilities practice lead at MATCOR. “With such rapid growth, however, it’s vital that infrastructure is built to accommodate the changes. That means building it fast, but also building it right.”

“Cathodic protection systems, like those produced by MATCOR, ensure the safety of oil and natural gas production and delivery assets.”

Learn More About Cathodic Protection Systems

MATCOR is a corrosion prevention firm that engineers, manufactures, installs, commissions and maintains a proven range of turnkey proprietary cathodic protection and AC mitigation systems worldwide for the oil & gas, power, water/wastewater and other infrastructures industries.

Contact a MATCOR corrosion expert by completing our contact form or calling +1-215-348-2974.

Elite oil fields redefine meaning of crude’s ‘Big Three’,” CNBC, July 27, 2014.

Bakken Oil Production Boom Could Result in Greater Cathodic Protection Needs

Bakken Oil ProductionAfter eight years of extensive oil exploration to define the Bakken formation boundaries, oil production companies are ramping up drilling operations to “harvest” the Bakken oil formation.

There are currently more than 10,000 producing wells in North Dakota, with the majority in the Bakken region. The expansion of oil production has grown at an exponential rate and the area will soon be producing 1 million barrels a day.

While there’s currently a well located on nearly all of 8,000 spacing units, there remains plenty of opportunity to increase well density in the region. In 2013, the permit applications were limited to four wells on a single 1,280 acre unit, but the maximum is expected to increase from eight to 20 wells per unit, depending on the local geology.

As oil companies drilling in the Bakken formation continue to increase well density, the region could see another phase of this oil boom.

“The Bakken area has enjoyed great success over the last decade, and with more opportunities for companies drilling in the Bakken oil field, it’s vital that they protect their assets,” said Glenn Shreffler, executive vice president, engineering at MATCOR.

“Protecting future investments from the devastation caused by the corrosion of pipelines and storage tanks is paramount as the Bakken region continues to see expansion of oil production,” said Shreffler. “Cathodic protection is among the most cost effective means and efficient ways to halt corrosion activity.”

In business for almost 40 years, MATCOR specializes in providing customized corrosion engineering and cathodic protection systems to oil and gas industries nationwide.

Oil lands claimed, the focus shifts now to ‘harvesting it,” The Bismarck Tribune, February 25, 2014.

Pipeline Petroleum Transport Investment May Predict Growing Cathodic Protection Needs

If Warren Buffet’s investment strategy is any indication, pipeline efficiency is going to start playing a bigger role in moving crude oil and natural gas in the United States.

The Berkshire Hathaway luminary is pipeline-efficiency-cathodic-protectionspearheading a swap of about $1.4 billion in shares of Phillips 66 for full ownership of the energy company’s pipeline petroleum transport services business. The business unit’s focus is polymer-based additives that are used to move crude oil and natural gas through pipelines more efficiently by reducing drag.

The shift in Berkshire’s investment strategy comes amid a boom in U.S. crude oil and natural gas production. Since many liquids pipelines in the United States are operating at capacity, producers can use the pipeline petroleum transport additive to quickly increase capacity without immediately growing pipeline infrastructure.

Although future pipeline projects may be in the works to meet the sharp increase in demand, the process of gaining approval for new pipeline projects can be slowed by permitting.

A greater reliance on existing pipelines for transporting liquids means that producers and pipeline owners need to pay even more attention to cathodic protection management, according to Kevin Groll, project management director for MATCOR, a Pennsylvania-based company that specializes in cathodic protection products and services.

“Any time you have pipeline you have to protect it from corrosion,” Groll said. “And that’s especially true when you increase the value of a pipeline by increasing its capacity. If that pipeline were to develop a corrosion problem you’d be facing a situation where your profitability could suffer significantly.”

“With pipeline owners using additives to push greater volumes of liquids it becomes imperative to use cathodic protection products such as impressed current anodes and cathodic protection rectifiers to protect the increased capacity and profitability of the pipeline infrastructure.”

Further Reading

Berkshire Swaps $1.4 Billion in Phillips 66 Stock in Deal,” Bloomberg, December 31, 2013.

Following our success in 2013, MATCOR is expanding by hiring new talent for cathodic protection, corrosion engineering jobs.

MATCOR is a full service provider of customized cathodic protection systems to the oil & MATCOR_Vertical_webgas, power, water/wastewater and other infrastructures industries.  Cathodic Protection is a technique used to control the corrosion of a metal surface by making it the cathode of an electrochemical cell.  MATCOR has an array of proprietary cathodic protection products and systems combined with high-quality corrosion engineering services, and installation and maintenance services.

In business for over 40 years, MATCOR is considered the technology leader in cathodic protection and corrosion engineering.  MATCOR is headquartered in Chalfont, PA, has a major service operation in Houston, TX, provides turnkey services throughout the United States, and has a growing list of international distributors.  MATCOR has been named to the Inc. 5,000 list of fastest growing companies in 2011, 2012 and 2013. Because of strong continued growth, MATCOR is seeking talented new team members to fill cathodic protection and corrosion engineering jobs.

MATCOR employees and culture are driven by three core principles. Whether a technician, engineer or manager, these principles guide us toward positive relationships with our clients and positive outcomes to every project we undertake.  These core values are:  We Respect Others, We Honor our Commitments and We Act in a Safe and Responsible Way.

“Our cathodic protection and corrosion engineering job openings, from technician to management positions, offer you the opportunity to grow with our team of seasoned cathodic protection experts and become part of a unique culture,” said Doug Fastuca, president of MATCOR, “As we are experiencing tremendous growth and request for our products and service offerings, this is an excellent time to join MATCOR.  In addition to competitive benefits, you can become NACE certified and enjoy other advanced educational opportunities.”

Our ideal job candidates will possess these values and hold a positive attitude.  This is a rapidly growing company with many new career opportunities.  Your cathodic protection, corrosion engineering and management job opportunity is here, today!

View the open position here: http://matcor.applicantpro.com/jobs/

Marcellus Shale Production Data Hints at Growing Cathodic Protection Needs

Production from the Marcellus Shale natural gas reserves is expected to exceed 13 billion cubic feet per day this December, nearly seven times the 2 billion cubic feet per day it produced during the same period in 2010, according to a recent report.

The report on Marcellus Shale production data, by the U.S. Energy Information Administration, said the figure would equal about 18 percent of total U.S. natural gas production during the month.

One of the Marcellus Shale companies that’s taking advantage of the natural gas boom is Cabot Oil & Gas Co., based in Houston, which claimed 15 of the 20 highest-producing natural-gas wells in the area during the first half of the year.

According to Dan O. Dinges, Cabot’s chief executive officer, 10 wells from a single well pad in Auburn Township produced enough natural gas in 30 days to meet the average monthly demand of the entire city of Philadelphia.

Cabot plans to increase its Marcellus Shale drill rigs from six to seven in 2013, with each rig capable of drilling 20 wells during the course of the year.

The sharp rise in natural gas reserves production hints at the growing need for Marcellus Shale companies to incorporate pipeline corrosion control equipment like cathodic protection rectifiers into their gas delivery infrastructure, according to Chris Sheldon, who works as utilities practice lead for MATCOR, a Pennsylvania-based cathodic protection company.

“Marcellus Shale companies are experiencing a tremendous upswing in natural gas production and are building new drill rigs and digging new wells to take advantage of the vast natural resource at their feet,” Sheldon said. “That means a lot of new pipes are going to be laid. And more pipes means more opportunities for corrosion.”

“At MATCOR, we’re here to help Marcellus Shale companies, as well as other pipeline companies and natural gas producers, with a full line of advanced cathodic protection equipment, systems and services designed to help them meet their corrosion control needs.”

Further Reading

A Marcellus Natural-Gas Bonanza,” The Philadelphia Inquirer, December 10, 2013.

MATCOR Offers Take on Natural Gas Liquids Production and NGL Transportation

“There is much discussion about the abundance of natural gas deposits in Marcellus Shale, and there is tremendous focus in extracting this precious resource. However, the industry’s ability to get this product to the end user is impacted by the infrastructure that currently exists.

“While rail is a means to transport natural gas, MATCOR is working with a growing number of midstream companies in expanding transmission and distribution piping networks. The key is to get product to market in a cost-effective and safe manor, and MATCOR’s cathodic protection products and services help ensure any new pipeline, regardless of the product it delivers, is in compliance and protected from corrosion.”

John Rothermel, PE

Vice President of Sales, MATCOR

Pipelines Planned for NGL Transportation Through Central Pennsylvania

At least one company is looking to take advantage of the rapid growth of natural gas liquids production from two of the largest shale regions in the nation.

Sunoco Logistics, a Philadelphia-based company that transports, terminals, and stores crude oil and refined petroleum products, recently announced that it was surveying land for a new pipeline, dubbed Mariner II East, that would connect production of natural gas liquids (NGL) from the Marcellus and Utica  shale regions of Pennsylvania, Ohio, and West Virginia to one of the company’s oil and diesel tank farms outside of Mechanicsburg.

The company also has plans to convert its existing Mariner East I pipeline, which used to carry oil and diesel fuel west, so that it carries propane and ethane east to its facility in Marcus Hook, which had also been idled.

The company bought the refinery from the former Sunoco Co. earlier this year for $60 million and is spending an unspecified amount of money to upgrade it and bring it back online as a natural gas liquids production refinery.

Sunoco Logistics is betting on the continued growth of natural gas production, of which NGLs like propane and ethane are byproducts. Natural gas production has increased in recent years thanks to hydraulic fracking, which has resulted in a larger supply that has driven prices down and has therefore, like a circle, created bigger demand for natural gas.

As a result of this process, NGL production has climbed during the last four years from 50 million to 70 million barrels per month. But, without greater avenues for NGL transportation, the increased production is moot.

Sunoco Logistics says that its plan to build a new NGL transportation pipeline, and convert an old pipeline for NGL transportation, will help create a northeast NGL hub in Marcus Hook that will help meet the demands of NGL producers and local and overseas consumers.

The Mariner East projects are only a few of the pipelines being planned by Sunoco Logistics. The company has roughly a dozen oil and gas projects on the books over the next 12 months at a cost of $1.3 billion, four times what it spent on capital expenditures each of the last four years.

MATCOR offers cathodic protection safety products and services to companies like Sunoco Logistics, which require cathodic protection equipment to maximize safety, efficiency, and capital investment in their pipeline projects.

Further Reading

Sunoco Logistics Plans Marcellus, Utica Pipeline Through Susquehanna Valley,” The Patriot News, Nov. 21, 2013.

New Global Cathodic Protection & Corrosion Costs Study Announced By Corrosion Society

NACE International has begun an expansive global study that will examine the cathodic protection and corrosion costs across a variety of industries. The effort will provide research on controlling corrosion-related costs, which will help improve corrosion and cathodic protection strategies. 

NACE International, an international corrosion and corrosion engineering society based in Houston, Texas, has announced the launch of a two-year global cathodic protection and corrosion costs study that will examine the financial and societal effects of corrosion on a variety of industries and provide data about methods for controlling costs related to corrosion.

Industries covered by the corrosion costs study include manufacturing, infrastructure, transportation, utilities and government. The study will integrate research from partners in international and regional industry and academia and will be managed by Elaine Bowman, a longtime corrosion industry advocate and former president of NACE International.

“Corrosion is an inevitable, but controllable process which can result in destructive, even catastrophic incidents when not properly prevented and managed,” Bowman said in a press release. “Costs associated with corrosion control include direct expenses like repair and replacement of assets. But there are additional indirect costs like production lost due to closure for repairs or the environmental and physical impact of corrosion-related failures.”

The cathodic protection and corrosion costs study will help asset owners identity ways to save up to 30 percent on costs related to controlling corrosion, Bowman said.

“The NACE corrosion costs study will likely provide invaluable data for us and our customers going forward,” said Ted Huck, who works as the practice lead for plants and facilities with MATCOR, a cathodic protection company that specializes in providing customized corrosion engineering and cathodic protection systems.

“Essential information and comprehensive scientific modeling about corrosion will only improve our understanding of the impact of corrosion on the oil and gas and other industries we serve,” Huck said. “And that means even better corrosion and cathodic protection strategies and tactics for our customers.”

An earlier corrosion costs study in 2001 estimated that the annual direct costs of corrosion in the U.S. was $276 billion. The study, funded by the U.S. Congress with Federal Highway Administration oversight and NACE International support, resulted in the development of a Corrosion Policy and Oversight (CPO) office within the Department of Defense.

“Quantifying the costs of corrosion is an important effort in educating asset owners to the value of investing in asset life extension technologies such as cathodic protection to provide the lowest total cost of ownership,” said Huck. “Corrosion is a hidden, and often avoidable, cost to asset owners and something that can be mitigated with the appropriate use of current, available technologies.”

The CPO demonstrated a return as high as 40-to-1 on investments for corrosion control programs implemented by the Department of Defense. The 2001 study also resulted in congressional support for the world’s first undergraduate degree in corrosion engineering.

Further Reading

NACE International Commences Global Study on Corrosion Costs and Preventative Strategies,” Press Release, Nov. 14, 2013.