Chalfont, PA – MATCOR, Inc., a BrandSafway company and a leader in cathodic protection and AC mitigation solutions, proudly announces that its PF™ Anode is now officially NSF/ANSI 61 certified, ensuring its compliance for potable water applications. This certification validates the PF Anode’s safety for drinking water systems and underscores MATCOR’s commitment to delivering corrosion prevention solutions that meet the industry’s highest standards.
The PF™ Anode is designed to prevent corrosion in water tanks, wells, and storage facilities. Featuring mixed metal oxide (MMO) technology, chlorine-resistant Kynar® braiding, and versatile installation options, it provides long-lasting and reliable protection for drinking water infrastructure.
“NSF-61 certification is a significant milestone,” said Ted Huck, Director of Sales at MATCOR. “Customers can trust the PF Anode as a safe, effective, and fully compliant solution for protecting water systems.”
For more information about the PF Anode or MATCOR’s cathodic protection and AC mitigation solutions, visit matcor.com.
To get in touch with our team of cathodic protection and AC mitigation experts for more information, to ask a question or get a quote, please click below. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.
Cathodic protection, when applied properly, is an effective means to prevent corrosion of underground plant piping. For many underground applications, such as pipelines, cathodic protection system design is relatively straightforward. Plant and facility environments, however, are not simple applications. Plants have congested underground piping systems in a tightly spaced footprint. The presence of copper grounding systems, foundations with reinforcing steel embedded in concrete, conduit, utility piping and structural pilings (either bare or concrete with reinforcing steel) can greatly complicate the task of designing a pipe cathodic protection system.
For simple plant facilities, it is possible to isolate the piping and utilize a conventional galvanic corrosion prevention system. This works only if the plant piping is electrically isolated from other underground structures for the life of the facility. For most plant and facility applications, it is not practical to isolate the piping from the grounding system for the life of the facility. In these cases an impressed current anode system is the only alternative.
3 Methods of Cathodic Protection for Underground Piping and Structures
There are three basic approaches to cathodically protect underground piping and structures using impressed current anodes.
Deep Anode
One method is the deep anode in which high current capacity anodes are installed from the structure in a deep hole drilled vertically 150+ feet deep. This is analogous to lighting a football field with floodlights.
Shallow Anode or Distributed Anode Bed
Another method is to use a shallow ground bed anode design where many smaller capacity ground bed anodes are spaced near the intended structures – analogous to street lamps lighting a street.
Linear Anode
The third method is to place a linear anode parallel to and in close proximity to the piping to be protected discharging current continuously along its length – similar to fiber optic lighting.
This technical bulletin details the advantages of using the linear anode approach for new plant construction projects to protect buried piping in a congested environment. This approach provides the most effective solution both technically and commercially.
Pipe Cathodic Protection Design Issues for Plants & Facilities
Electrical Isolation in a Congested Plant Environment
Electrical isolation is a major concern when designing a CP system for any plant or facility application. Isolating a single cross country pipeline segment from point A to point B is achieved rather simply through the use of electrical isolation flanges/isolation joints that the pipeline operator maintains and tests regularly. The realities of power plant piping networks, on the other hand, significantly complicate electrical isolation. By code, everything above grade in a plant must be grounded, yet it is common to see pipe cathodic protection systems designed based on isolation of the buried piping. Even if electrical isolation is achieved during the plant construction, maintaining electrical isolation over the life of the facility may not be realistic. Given the speed and complexity with which new plants are erected, achieving electrical isolation during construction is no simple task. Once installed, electrical isolation flange kits require regular monitoring and periodic replacement that often does not occur. Piping modifications and other plant maintenance activities can also result in an inadvertent loss of electrical isolation. Cathodic protection for underground piping that relies on electrical isolation should be avoided for plant applications.
Current Distribution – a Critical Issue in Pipe Cathodic Protection Design
Another critical issue that must be properly considered during the design of a CP system for plant applications is the highly congested underground environment and the challenges of achieving thorough current distribution. Buried piping is often located in congested underground areas in close proximity to grounding systems, foundations with reinforcing steel, pilings systems, metallic duct banks and other structures that can shield current from the piping systems that are the intended target of plant cathodic protection systems. It is virtually impossible to assess where current will go in a plant environment – the more remote the anode source, the more difficult it is to assure appropriate current distribution.
Stray Current
When discussing current distribution, it is also important to discuss the potential for stray current. For grounded systems, current that is picked up by other buried metallic structures is merely current that is wasted and not available to protect the intended buried piping structures. For isolated metallic structures, such as foreign pipelines, ductile iron piping systems, and nearby facilities or structures, stray current may be a significant concern. Stray current problems occur when current is picked up on an isolated structure and later discharges off that structure and back to a grounded structure. At the location where stray currents discharge, rapid corrosion may be inadvertently induced on the isolated structure.
The Case for Linear Anode Cathodic Protection System Design
The linear anode solution consists of long runs of linear anode installed parallel and in very close proximity to the piping being protected. The current output is kept very low and is generally consistent across the entire system. A linear anode is in effect a distributed system with an infinite number of anodes spaced continually. This system provides the best technical cathodic protection solution and minimizes the current output required as follows:
Does not require electrical isolation. Because the linear anode is closely located next to the piping being protected, electrical isolation is not a significant concern. The anode is “closely coupled” to the piping and operates with a very low anode gradient that minimizes any losses to nearby structures including grounding.
Assures good current distribution as the anode runs parallel to the piping being protected. The linear anode cathodic protection system design eliminates any requirement for supplemental anodes to address areas where remote anodes may be shielded after the CP system is commissioned. Wherever the piping goes, the linear anode follows in the same trench. This also makes it very easy to adapt the design during piping revisions that may change the piping system routing as the plant construction proceeds.
Eliminates risks of stray current. Close proximity to the piping being protected significantly limits current losses to other structures and virtually eliminates shielding and stray current concerns. This also significantly reduces the total current requirements for the system, reducing the rectifier requirements.
Access issues – the linear anode is installed in very close proximity to the piping that is to be protected. This minimizes the risk of third party damage and reduces trenching required for buried cable. If installed in conjunction with the piping, the anode can be placed in the same trench as the piping affording the anode protection by the piping itself from external damage. This is a very cost effective cathodic protection installation when installed concurrently with the piping.
Ease of installation – when installed alongside the piping as the piping is being installed, the installation is simply a matter of laying the anode cable in the trench.
Our experts are happy to answer your questions about cathodic protection for underground piping.
Chalfont, PA – MATCOR, Inc., a BrandSafway company and a leader in cathodic protection and AC mitigation solutions, announces the relaunch of its patented Iron Gopher® Linear Anode, now available at a significantly reduced price, providing cost-effective insurance to users for challenging horizontal directional drilling (HDD) projects, minimizing risks and reducing costs during installation.
This price reduction is the result of MATCOR’s move to in-house production, reducing reliance on third-party suppliers and shipping delays while ensuring superior quality control. The result is a stronger, more reliable linear anode that minimizes the risk of breakage during installation, helping you avoid idle crews and project delays.
“When we introduced the Iron Gopher, its cost limited adoption despite its superior performance,” said Ted Huck, Director of Sales at MATCOR. “By bringing production in-house, we’ve cut costs dramatically, allowing us to offer this premium solution at just a small premium over standard linear anode products.”
The Iron Gopher has already proven its value in major pipeline projects. A recent customer shared: “The Iron Gopher’s design and strength are unmatched for HDD applications. Installation was seamless, and the product is performing exactly as expected. We look forward to using it on future projects.”
For more information about the Iron Gopher or MATCOR’s cathodic protection and AC mitigation solutions, visit matcor.com.
To get in touch with our team of cathodic protection and AC mitigation experts for more information, to ask a question or get a quote, please click below. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.
In his article for World Pipelines, Ted Huck of MATCOR tackled a pressing issue for pipeline operators: the challenge of managing aging pipeline coatings and maintaining effective cathodic protection (CP). The solutions outlined in this article—particularly the use of linear anodes—remain as relevant and impactful as ever.
Huck explores cost-effective alternatives to recoating pipelines, focusing on improving CP distribution and reducing costs. These systems, which distribute CP current evenly along the pipeline, address key issues associated with deteriorating coatings, including:
Poor current distribution and high localized potentials.
Increased operating costs and reduced efficiency of traditional CP systems.
The high expense and disruption caused by recoating.
Case Study: Saving $1.5 Million with Linear Anodes
Huck highlights a 5-kilometer pipeline segment where installing linear anodes saved over $1.5 million compared to recoating. The system not only extended the pipeline’s service life but also demonstrated superior performance, making it a valuable tool for operators worldwide.
Huck’s insights continue to guide pipeline operators in rehabilitating aging infrastructure efficiently and economically.
To get in touch with our team of cathodic protection and AC mitigation experts for more information, to ask a question or get a quote, please click below. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.
MATCOR’s Ted Huck presented at the Middle East Corrosion Conference on innovative strategies for pipeline rehabilitation, detailing advancements in cathodic protection technology over the decades.
Innovative cathodic protection systems address challenges like aging coatings and poor current distribution. Huck’s presentation explores:
The history and advancements of linear anode technology.
Installation methodologies, including trenching, cable plowing, and horizontal directional drilling.
Case studies demonstrating successful pipeline rehabilitation.
To discover how linear anodes provide localized cathodic protection, enhance current distribution, and extend the lifespan of pipelines without the need for costly recoating, read the full paper or view the presentation.
To get in touch with our team of cathodic protection and AC mitigation experts for more information, to ask a question or get a quote, please click below. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.
As pipeline coatings age, their ability to prevent external corrosion diminishes. MATCOR highlights cost-effective strategies to rehabilitate pipelines with aging coatings in a Materials Performance article.
From advanced cathodic protection systems (CP) to high-performance recoating solutions, the article explores practical solutions to extend pipeline service life while addressing challenges like soil stress and coating disbondment.
To get in touch with our team of cathodic protection and AC mitigation experts for more information, to ask a question or get a quote, please click below. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.
Pipelines are a crucial part of the US infrastructure, but they face a serious challenge: corrosion. This guide explains pipeline corrosion, the different types, and how to prevent it to avoid costly and dangerous failures.
The Problem of Pipeline Corrosion in the United States
The United States has over 2,225,000 kilometers of pipelines transporting oil and natural gas. No other country comes close—Russia, in second place, has approximately 260,000 km. These pipelines are owned and operated by hundreds of companies and regulated by the US Department of Transportation’s Pipeline and Hazardous Materials Safety Administration (PHMSA).
Experts consider pipelines very safe—roughly 70 times safer than trucks1 and 4.5 times safer than rail2. However, many pipelines are at least 50 years old. This increases the risk of corrosion, which threatens their safety and reliability.
Why Pipeline Corrosion Prevention is Critical
Corrosion is a natural process where metal electrochemically reacts with the environment and deteriorates over time. Without regular maintenance and monitoring, this can lead to leaks or even pipeline ruptures.
The good news? Corrosion is completely manageable. By using the right technologies and maintenance practices, pipeline operators can manage corrosion and prevent failures.
Several strategies exist to prevent corrosion, depending on whether it occurs internally or externally.
Preventing External Corrosion of Pipelines
The two most effective methods to prevent external corrosion are:
Pipeline coatings: These create a protective barrier between the pipeline and its environment. However, installation can damage them, and they can wear out over time.
Cathodic protection systems: This method uses electrical currents to prevent the metal from corroding and requires frequent testing.
These methods work well, but require regular monitoring and maintenance to remain effective.
Preventing Internal Corrosion of Pipelines
Internal corrosion occurs when contaminants in the oil or gas being transported react with the pipeline. Common contaminants include oxygen, hydrogen sulfide, carbon dioxide, chlorides, and water. The severity of this corrosion is influenced by several factors, including:
The concentration of contaminants
The combination of different contaminants within the pipeline
Operating pressure and flow velocity
Pipeline design and holdup points
Operating temperature
To effectively manage internal corrosion, operators must use a combination of assessment and prevention strategies, including:
Reducing contaminants before they enter the pipeline.
Applying internal pipeline coatings to create a protective barrier.
Injecting inhibitors to minimize corrosion reactions.
Frequent internal cleaning to remove residues.
The Role of Internal Corrosion Direct Assessment (ICDA)
Assessment is the foundation of effective corrosion management. Internal Corrosion Direct Assessment (ICDA) identifies high-risk areas and helps operators prioritize maintenance. ICDA is particularly valuable for:
Evaluating risks based on contaminants, flow conditions, and pipeline design
VCIs are an advanced solution for preventing internal corrosion. They diffuse and bond with internal surfaces to create a protective barrier against water and oxygen.
VCIs are especially effective when used alongside other strategies, such as cathodic protection.
To explore the technology and benefits of VCIs across industries, visit our Vapor Corrosion Inhibitors guide.
While pipeline corrosion is a serious issue, it can be effectively managed through proper monitoring and preventative measures. Whether facing internal or external corrosion, a strong integrity management program is essential to lowering the risk of failure.
To get in touch with our team of cathodic protection and AC mitigation experts for more information, to ask a question or get a quote, please click below. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.
Rusty chats with Ted Huck, Director of Manufacturing and Quality Assurance.
Rusty: Ted, thanks for taking a few minutes to discuss the application of VCI for cased pipeline crossings. First, what is a cased crossing?
Ted: Cased pipeline crossings are a common feature in the industry. They are used primarily at road and rail crossings.
The casing (also referred to as the encasement pipe) is a larger diameter pipe that is designed to take the loading from vehicle or train traffic on the road and absorb/deflect that loading from the carrier pipeline inside the casing.
In addition to the encasement pipe and the carrier pipe there are other key elements to a case crossing. Notably, there are non-metallic spacers that position the carrier pipe inside the encasement pipe, and dielectric end seals that prevent the ingress of water and soil. Finally, there are vent pipes on each end of the casing. These provide a warning and route product to a safe location in the event of a pipeline leak inside the sealed casing.
Pipeline Casing Vents on each side of a road crossing in Chalfont, PA
There are tens of thousands of these cased pipeline crossings throughout the United States.
Rusty: So, what are the corrosion challenges with cased crossings? What can go wrong?
Ted: Pipeline operators have found that an inordinate amount of pipeline leaks occur at cased crossings. Therefore, operators are actively looking to eliminate these whenever possible.
It is important to evaluate existing casings periodically. Two mechanisms can adversely affect pipeline integrity at cased crossing locations.
The first is a metallic short. This results from the carrier pipe shifting inside the encasement pipe. It causes a direct metallic contact between the carrier pipe and the encasement pipe.
Shorted casings can significantly impact the cathodic protection system protecting the pipeline. This is due to the encasement pipe drawing CP current away from the carrier pipe. Shorted casings also increase the risk of AC Interference, AC induced corrosion and shock hazards at the above ground vents.
The second casing failure mechanism is related to the integrity of the end seals over time. In many cases, these end seals develop leaks allowing water and soil into the space between the carrier pipe and the encasement pipe. This creates an electrolytic couple. The introduction of these contaminants can lead to accelerated rates of corrosion of the carrier pipe.
Rusty: What are my options if my casing is shorted or the carrier pipe exhibits signs of corrosion?
Ted: You can employ several strategies to address corrosion concerns with cased pipeline crossings:
Excavate ($$$). With this first approach, you dig up the casing and either remove it entirely or repair it. Repairing involves exposing one or both ends to repair the end seals and if necessary, readjust the spacers to clear the shorted condition. This is a construction intensive operation but, in many cases, can restore the cased crossing to an as-new condition.
Fill with Wax ($$). A second approach is to fill the annular space with a high di-electric wax. There are a variety of wax treatment options available. Typically, the wax is introduced through the vents and every effort is made to fill the entire annular space with the wax material.
The wax acts much like a coating covering the carrier pipe and prevents corrosion like a coating system. The industry has found that this is not always a complete solution, since voids in the wax fill can allow pockets of corrosion.
Fill with VCI ($). The third approach is to pump the annular space full of an aqueous gel or powder, or a slurry formulation of corrosion inhibitor material. The corrosion inhibitor is typically a combination of volatile corrosion inhibitor (VCI) and soluble corrosion inhibitor (SCI) that combine to stop corrosion. This method has received industry and regulatory approvals over the past decade and is gaining market share as operators become familiar with the technology and its advantages.
Rusty: How challenging is it to fill a pipeline casing with wax or with VCI?
Ted: Both operations are similar in many respects.
For both wax and VCI filling installations, repairing the existing casing is often the first step. You inspect the end seals and spacers, and where appropriate, remove and replace them.
The interior space between the carrier piping and the casing is flushed clean of dirt and other debris. Once the repairs are complete and the ends are sealed, you calculate the volume of product needed to completely fill the space between the carrier pipe and the casing.
Then the product is prepared according to the manufacturer’s recommendations. Pumping or filling the space is different for each of the type of fill, but both technologies require appropriate equipment and experienced installers.
Wax fills typically use a heated wax product for larger casings. Cold flowing wax can be used on some smaller casings.
For wax fill applications, the space between the carrier pipe and the casings must be completely flushed and cleared out during the repairing of the end seals.
Even with a well-prepared casing, achieving a complete wax fill is very difficult. Voids and gaps are typical.
One published study of 143 wax filled casings found that the average fill was 81%.
For VCI installation plans, the appropriate vapor corrosion inhibitor types and delivery methods are an important considerations. The VCI slurry needs to be mixed properly before being pumped into the casing using the appropriate pumping equipment.
Because VCI applications typically use an aqueous slurry with an experienced installer, VCI is easier to install than a similar wax application. The VCI component is designed to release from the aqueous solution after being pumped into the casing to fill all vapor spaces. Therefore, concerns over gaps and voids are non-existent.
Rusty: What about concerns with bacteria in the space between the carrier pipe and the casing?
Ted: This is an area where the two fill types differ significantly.
For wax filled casings the goal is to completely fill the space with wax displacing or encapsulating any bacteria. However as noted above, areas of incomplete fill or voids in the wax encapsulation can leave space for bacteria to continue to grow.
With VCI, the VCI chemistry increases the pH (9 to 9.5 is typical) inside the casing. This range makes it very difficult for bacteria to grow, while also neutralizing any acid secretions from the bacteria.
Rusty: Can Cathodic Protection help with protecting carrier pipes inside filled casings?
Ted: With wax filled casings, the wax has a high dielectric value and does not allow cathodic protection current to pass.
This prevents the carrier pipe and casing from draining cathodic protection current from the pipeline CP system, but it also provides no protection to the carrier pipe. The VCI gel that sets up is conductive and allows cathodic protection current flow. Some evidence supports the benefit of cathodic protection and VCI working in tandem to prevent corrosion.
Rusty: How can pipeline operators monitor the effectiveness of any cased crossing corrosion solution?
Ted: Most pipelines can be assessed using In Line Inspection (ILI). These pipelines can use smart tools with MFL, and other tools, to assess and monitor corrosion in the carrier pipe with a casing.
For wax filled casings, if ILI is not an option, there are no other good monitoring options. For pipelines that cannot be inspected using smart pig technology, conventional above ground pipeline testing technology is limited.
For VCI filled casings, we employ various technologies in conjunction with VCI including coupons, ER Probes and /or UT probes installed between the carrier pipe and the pipeline casing, to monitor the effectiveness of the VCI in the casing. These are installed and connected to RMUs for remote monitoring, or wired to a local junction box for direct reads during surveys.
Rusty: Any final comments on Cased Pipeline Crossings?
Ted: Cased crossings are a challenge for pipeline owners.
Should you have any additional questions, please reach out to a MATCOR account representative for more information. As a full-service corrosion company, we have extensive experience and a wide range of capabilities including both wax and VCI installations for casings.
Have questions or need a quote for corrosion prevention materials or services? Contact us at the link below. For immediate assistance, please call +1-215-348-2974.
In the Autumn 2024 edition of Tanks & Terminals magazine, MATCOR’s Ted Huck highlights an alternative to traditional corrosion prevention methods for aboveground storage tanks (ASTs): Vapour Corrosion Inhibitors (VCIs).
ASTs, especially those storing hazardous materials like hydrocarbons, are highly susceptible to corrosion on their steel tank bottoms. Typically built on sand or soil foundations with a concrete ring wall, these tanks are vulnerable to soil-side corrosion over time.
While cathodic protection (CP), often combined with a secondary containment liner, has been a standard solution to prevent leaks and environmental damage, it has limitations. VCIs are a newer technology that offers an additional layer of protection for external tank bottoms, addressing some of the challenges CP alone cannot solve.
To get in touch with our team of experts for more information, to ask a question, or to get a quote, please click below. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.
BrandSafway seminars provide you with in-depth knowledge and practical skills across a wide range of topics. Each seminar includes a 1-hour educational session, a tour, and lunch. MATCOR-specific seminars offer specialized training in cathodic protection and rectifier management:
Cathodic Protection 101: An introduction to cathodic protection, its principles, techniques, and its application in preventing corrosion. This seminar is perfect for those new to the field or looking to refresh their knowledge on preventing corrosion in various structures.
Rectifier School: Comprehensive training on rectifier operation, maintenance, and troubleshooting for effective cathodic protection systems. This seminar is ideal for corrosion technicians responsible for impressed current rectifiers.
AC Interference and Mitigation: A detailed introduction to AC interference and mitigation for engineers and corrosion professionals, focused on practical theory and solutions.
For a full list of BrandSafway’s technical seminars, click here.
To request a lunch and learn seminar, please email matcorsales@matcor.comor call Lisa Porter at 215-327-3002.
BrandSafway’s Specialty Services
At BrandSafway, we pride ourselves on being the leader in industrial specialty services, offering unparalleled expertise and the largest fleet of scaffolding and access equipment in North America. In addition, MATCOR maintains the largest fleet of construction equipment for cathodic protection projects. Whether your project is large or small, our innovative solutions and dedicated team are here to ensure you meet any challenge safely and efficiently.
As part of BrandSafway, MATCOR specializes in providing advanced corrosion protection, including cathodic protection and AC mitigation solutions. Explore our brochure to learn about how BrandSafway and MATCOR can support your unique needs with industry-leading services and equipment.
For more information, to ask a question, or schedule a seminar, please contact our team of corrosion experts. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.
Cathodic Protection Systems | Cathodic Protection Design | alternatives to sacrificial anodes and galvanic anodes
