All posts by MATCOR

MATCOR Featured in Tanks and Terminals

In the June 2021 issue of Tanks and Terminals, a quarterly supplement to Hydrocarbon Engineering, MATCOR’s Ted Huck discusses cathodic protection of terminal marine structures including docks, jetties, piers, seawalls and sheet pilings.

Protecting Marine Structures From Corrosion

The article includes a case story discussion from a Texas gulf coast facility using impressed current cathodic protection for a combi-wall structure (consisting of pipe piles and sheet walls.).

MATCOR provides industry leading cathodic protection and AC mitigation solutions to tank and terminal operators around the globe.

MATCOR’s New Offices Rock Customer Satisfaction

In 2019, MATCOR opened new offices in Casper WY, and Midland, TX to better support those regions.

Two years and one pandemic later, we have seen great success from both regions as we’ve increased our service capacity, deployed construction crews and technicians and staffed each office with experienced cathodic protection professionals.

We recently highlighted a success story from our Casper Wyoming office detailing a successful AC Mitigation installation project.

This month we wanted to highlight a similar customer success story from our Horizontal Directional Drilling crew for two recent tank anode systems installed for a Texas based Midstream company with operations in the Permian.

Upon completion of the project, we received a compliment from the client’s Corrosion Supervisor, who reached out to MATCOR’s Permian based project manager, Mario Mahabir saying:

“Gentlemen, just wanted to extend our gratitude for the performance and professionalism we experienced from your team on the recent project at our facility.”

Well MATCOR appreciates the opportunity to work on this project!

For the this project, MATCOR designed, installed and commissioned dedicated under tank cathodic protection systems on two above ground storage tanks.

Installation was performed using our horizontal directional drilling rig and MATCOR’s proprietary mixed metal oxide anodes to install anodes and reference electrode pull tubes under two existing tanks.

Give the MATCOR Permian and Rockies teams a look—we think you will like what you see.

Have questions or need a quote for AC interference mitigation materials or services? Contact us at the link below. For immediate assistance, please call +1-215-348-2974.

Contact a Corrosion Expert

Preventing Corrosion of Near Shore Structures

Rusty Talks about the MATCOR PW® anode, which protects near shore structures in water from the effects of corrosion…

“It’s summertime and our thoughts go to water—backyard swimming pools, kayaking along rivers, boating on lakes, and lounging around the ocean.

Well, here at MATCOR, when we think water, we think about the very versatile MATCOR PW® ANODE system.

Check out some details below and contact our team for assistance.” — RUSTY

Corrosion Prevention of Structures in Water

The MATCOR PW Anode is ideal for corrosion protection of docks, piers, pilings and more.

The PW anode is a lightweight, long life anode system that can be installed to protect a wide range of near shore marine structures from corrosion, including:

  • Docks
  • Piers
  • Jetties
  • Sheet pile walls
  • Wind turbine jackets and monopiles
  • Stationary floating vessels such as riverboat casinos and historic naval vessels

The PW anode system consists of a custom fabricated PVC anode housing and a MATCOR Mixed Metal Oxide anode assembly.

The PW Anode can be supplied with a lowering rope, eye bolt assembly, and optional weight assembly for hanging.

This versatile anode is available in a wide range of sizes and current outputs or can be custom designed for a specific application’s requirements.

To get in touch with our team of corrosion 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.

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MATCOR’s innovative engineered grounding system, the MITIGATOR®, was honored as a winner of the Open Innovation Factory 2021 Awards on June 22nd in Lyon, France.

Over 65 different innovations were nominated, and the MITIGATOR was one of seven trophy winners.

MATCOR MITIGATOR® is an Engineered AC Mitigation System

MATCOR’s innovation was nominated by GRT GAZ France, a European leader in natural gas transportation operating over 32,000 km of buried pipelines to transport natural gas from suppliers to consumers connected to its networks.

The MATCOR MITIGATOR is an engineered linear grounding system. It consists of a central copper conductor packaged inside a fabric housing with an enhanced grounding backfill that incorporates a copper corrosion inhibitor to protect the central copper conductor.

This product is ideal for AC mitigation using a parallel gradient control wire grounding configuration.

To get in touch with our team of 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.

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6 Things to Look for in a CP Rectifier

The AC/DC transformer cathodic protection rectifier is a relatively simple and highly reliable piece of equipment that is a proven workhorse in the cathodic protection industry.

In the short time since our parent company BrandSafway acquired JA Electronics, we’ve learned a lot from them about how they build the best CP rectifier in the corrosion industry.

Best CP Rectifier

A lot of little things add up to a big difference between a merely good CP rectifier or a best in class rectifier.

And these little things don’t really add to the unit’s cost. In some cases, they are both best in class and lower cost.

JA Electronics recently published an article entitled Building the Best Cathodic Protection Rectifier. Here are the top 6 things they recommend if you want the best cathodic protection rectifier at the best price:

  1. A marine grade aluminum case
  2. Color coded engraving and wiring
  3. Thoughtful layout for ease of use and long life
  4. Left side maintenance door for simplified access
  5. A modular bridge diode assembly for easy troubleshooting
  6. Brass solder lugs for reliability

To get in touch with our team of cathodic protection 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.

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VCI for Tank Bottom Protection

The American Petroleum Institute (API) recently issued a landmark technical report regarding vapor corrosion inhibitor (VCI) use for storage tank bottom corrosion protection (API TR 655).

VCI has been promoted as a technology for use under above-ground storage tanks for the past decade. This effort recently received a big boost with the American Petroleum Institute’s publication of its long-awaited technical report on VCI.

Vapor corrosion inhibitor technology for tank bottom corrosion protection gets boost from API technical report.

API TR 655 Vapor Corrosion Inhibitors for Storage Tanks; First Edition; April 2021 provides the first set of guidelines for VCI issued by an internationally recognized non-governmental technical standards organization.

MATCOR has been an early adopter of VCI technology as we believe that it can be an important and effective component in a corrosion prevention program for tank bottoms. We have partnered with Zerust to be an authorized distributor and installer of VCI products for tank and other applications.

We are excited that API has led the way on recognizing VCI technology, and we would expect that other organizations–AMPP for one–will adopt similar guidelines and recommendations.

For a more detailed review of the technical report, visit our VCI partner company Zerust’s summary at the link below:

Summary of API’s Vapor Corrosion Inhibitor Use for Storage Tank Bottom Protection API TR-655

To get in touch with our team of cathodic protection 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.

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Safety Programs for the Cathodic Protection Industry

June is National Safety Month, established in 1996 by the National Safety Council.

To honor this critical program, Rusty reached out to Zachary Seese, MATCOR’s Safety Manager, to talk about the safety programs in place at MATCOR.

Zac, thanks for joining us for this safety Q&A. Let’s start by asking the big question, what are MATCOR’s Safety Goals?

At MATCOR, our employees are the most important aspect of our business. Therefore, we are dedicated to providing a work experience that is always free from exposed hazards.

“Goal Zero” is the milestone we wish to achieve at all MATCOR work sites. In order to achieve zero injuries, we must identify remove hazards. To accomplish this, we utilize multiple safety methodologies.

How do you go about identifying and removing hazards in the work environment?

Behavior Based Safety (BBS) is one of the primary programs MATCOR employees and management participate in to communicate jobsite hazards and to audit jobsite conditions.

BBS involves active participation in three programs:

1) BrandSafway’s Employee Intervention System (EIS)
All MATCOR employees are encouraged to use the EIS program to document hazards experienced in the workplace and to share how they were mitigated. MATCOR employees also utilize the EIS program to document Good Catches and to make recommendations on how to improve processes.

2) Supervisor Observation System (SOS)
All field level supervisors complete SOS’s when they visit jobsites. Supervisor Observations is an audit tool which engages supervisors with our employees to assure that they are complying with MATCOR/BrandSafway EHS expectations.

3) Management Safety Review (MSR)
Top level supervisors including EHS Managers, Project Managers, Regional and Area Managers and above complete MSR’s as an upper level audit tool to ensure that all field employees and field supervisors are complying with MATCOR/BrandSafway EHS expectations.

These three programs are the cornerstone of our safety program, and everyone is responsible for identifying and removing hazards in the workplace.

What if an employee sees a hazardous situation?

Stop Work is the most important tool an employee at MATCOR possesses.

Any employee can stop any job at any time when they recognize a hazard. It is that simple – if something appears wrong our employees are required to Stop Work. In addition, all MATCOR employees and supervisors are trained to support stop work and to not retaliate against any employee who does so.

We recently received recognition from one of our customers for our proactive use of stop work. While completing close interval survey work, an employee began to show possible signs of heat exhaustion and their supervisor observed the symptoms. The supervisor immediately made the decision to stop the job for the day and give the employee an opportunity to recover. The near hit/stop work was reported and documented. The following week, one of the customer’s corporate officers commended the MATCOR supervisor’s use of stop work and described how those actions align with their safety expectations as well.

How important is training to maintaining a workplace environment free of all hazards?

Training is critical to our safety programs. And since our Behavioral Based Safety involves all levels of the organization, we have developed extensive safety training programs to engage our entire organization.

MATCOR training provides our employees with the knowledge they require to perform their tasks in a safe manner. In addition, it provides them with the ability to recognize hazards and the knowledge about how to react and report them.

We provide instructor- and computer-based training, competency training and hands-on assessments.

What are some examples of the safety training MATCOR provides to its employees?

The following list contains some examples (not all) of the trainings MATCOR provides its employees:

Computer-Based Training
New employee orientation (including our Life Saving Rules)
Code of Conduct
Stop Work Obligation
Distracted Driver
Defensive Driving
Confined Space

Instructor-Led Training
Fall Protection
NSC Basic Orientation Plus
PEC Basic Orientation
PEC H2S Clear
Incident Reporting

Competency/Hands-on Assessments
Task-Specific Operator Qualifications (in house and third party)
Aerial lift

Our supervisors receive higher-level training to ensure they are able to teach and ensure compliance with EHS standards at all jobsites. These supervisor-specific trainings include but are not limited to:
EIS/SOS Program
Job Safety Planning
Fall Protection
Personal Risk Tolerance
Drug and Alcohol Awareness
Stop Work Obligation
Material Handling

Where does technology fit in to MATCOR Safety Programs?

One key technology component in our arsenal is the use of tracking equipment on our extensive fleet of construction equipment.

This equipment travels from jobsite to jobsite, and while being transported, they are subject to DOT regulations. We utilize Geotab Electronic Log Devices with GPS tracking on all company DOT regulated vehicles. GPS tracking enables us to comply with DOT regulations, monitor for and correct adverse driving habits. It even allows us to locate and recover missing equipment, or to locate an employee who might be in danger with no communication.

Another key technology that is integral to our Behavior Based Safety system is our in-house Integrated Management System (IMS). The IMS allows us to track, collect, compile and perform data analytics on all of the collective reporting from our field personnel while performing observations. This data can be used to identify and focus on critical issues.

Thanks Zac, any last words on Safety?

One final comment – communication and continued improvement are necessary to ensure that our EHS program is successful. Our EHS department is engaged daily with all levels of our Operations to encourage active participation, and we know that it works. We can create a work environment that is free of hazards.

To get in touch with our team of cathodic protection experts for more information, to ask a question or get a quote for safe, industry leading products and service, please click below. We will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.

Contact a Corrosion Expert

Pipeline Internal Corrosion Prevention with VCI

MATCOR recently completed a significant pipeline preservation project at a newly constructed pipeline station in West Texas. The project involved injecting Zerust Vapor Corrosion Inhibitor into multiple above ground pipeline manifolds to prevent internal corrosion. The rest of the pipeline remains under construction.

Using vapor corrosion inhibitors (VCI) to protect internal pipeline surfaces is an established technology proven very effective for pipelines post hydrotest.

Preparing for VCI Installation for pipeline internal corrosion prevention

Typically, all pressure-containing piping requires hydrotesting once the piping fabrication is complete. This ensures that there are no faulty welds and that the piping system can handle the design pressure without any leakages.

This fitness for service testing, unfortunately, introduces water and possibly bacteria into the piping. After the hydrotest is completed, and the water is drained, there remains residual moisture (and potentially bacteria) that can prove very corrosive even with efforts to dry the internal surfaces.

For pipeline preservation applications, the VCI chemical is typically mixed with water into a slurry. Then, it is pumped into the piping manifolds using a series of injection pumps and injection ports through hoses from multiple mixing tanks.

How Does VCI Prevent Pipeline Internal Corrosion?

The VCI molecules diffuse and adsorb to the surface, forming a very thin (molecular level thin) protective layer that blocks water and oxygen from reacting with the internal metallic surface of the piping. The molecular level VCI barrier, when properly applied, can last for months and even years as the balance of the pipeline construction is completed.

For this project in West Texas, MATCOR prepared and installed over 24,000 gallons of VCI Solution inside the piping manifolds after their fabrication and testing. Because of the above ground nature of the project, we added methanol (anti-freeze) to the VCI slurry mixture to provide freeze protection for the winter months.

In addition to pipeline preservation projects, VCI is a great product for tanks and pipeline casings.

To get in touch with our team of cathodic protection 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.

Contact a Corrosion Expert

Navigating Cathodic Protection Supply Chain Issues

Historically, MATCOR has enjoyed an exceptional on-time delivery record, and over the past decade our lead times for anodes have gone down to the point that 1-2 weeks for rush orders is quite achievable, and 3-4 week deliveries are the norm for MATCOR manufactured cathodic protection products. Even through the pandemic challenged year of 2020, we were generally able to navigate the cathodic protection supply chain and avoid delays resulting from material availability.

However, if you are reading the news, you cannot help but see stories such as a Bloomberg’s recent article “Supply Lines: Shipping Delays and Supply Shortages to Constrain Firms all Year” and CNN’s “Supply chain interrupted: Here’s everything you can’t get now”, it seems as if the general state of the global economy is one of delay and disruption accompanied by price increases and surcharges.

In our cathodic protection manufacturing business, we have not been immune to these pressures. We have seen tightening supplies and order delays for key items that we use on a regular basis—from lumber for anode reels to Iridium for the coatings used in our mixed metal oxide anodes. Cathodic protection cable availability, especially for Kynar dual insulated cable, has gone from 4-6 weeks to 15+ weeks.

Another challenge facing manufacturers, in addition to the availability and pricing for materials, is the cost and reliability of shipping channels. Both ocean freight and motor freight are struggling with shortages of containers, truck drivers, port congestion and rising fuel costs. Getting materials to our manufacturing facility and shipping them out is more difficult and less reliable than ever before.

At MATCOR, we have a great logistics team and a very flexible manufacturing team. While our on-time delivery record has taken a step backward, we are doing everything we can to minimize the impact on our customers, and where required, we are communicating early and often with those affected to let them know of any supply delays that we may be facing.

We encourage our customers to give themselves additional lead time by purchasing materials a little earlier than normal to assure that they have them on site well in advance of their planned installation. Engage early with MATCOR and your other suppliers to coordinate delivery timeframes for both planned projects and for critical timeline projects as we navigate these challenging times.

Don’t allow cathodic protection supply chain issues to affect your project. Plan ahead by contacting us at the link below. For immediate assistance, please call +1-215-348-2974.

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Cathodic Protection Systems | Cathodic Protection Design | alternatives to sacrificial anodes and galvanic anodes