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Large AC Interference Mitigation Project in Southern Wyoming

MATCOR expedited manufacture and installation for this “late start” AC interference mitigation project requiring over 73,000 feet of gradient control wire.

MATCOR Crew Installs Substantial AC Interference Mitigation System in Southern Wyoming
MATCOR Crew Installs Substantial AC Interference Mitigation System in Southern Wyoming

Installation Challenges

The construction window in the High Plains Region encompassing southeastern Wyoming is a relatively short one as the winter months can be quite inhospitable to construction activities.

As such, the disruption caused this year by COVID-19 resulted in numerous projects’ starts being delayed as companies dealt with the pandemic, leaving installation contractors with less time to complete critical installations.

MATCOR was recently involved in one of these late start projects. A new construction AC transmission line was built, encroaching on the right of way of an existing pipeline in Southern Wyoming. AC transmission was scheduled to begin in early November of 2020.

AC Modeling & Mitigation Design

The pipeline operators had commissioned an AC modeling study and mitigation design which was not finalized until early August.

MATCOR was hired on August 5th, by the pipeline owner, to supply and install the mitigation design with a completion date of October 1st.

The mitigation design called for the installation of:

  • Approximately 73,500 linear feet of MATCOR’s Mitigator® Engineered AC Mitigation System gradient control wire
  • Three deep well grounding systems
  • AC coupon test stations
  • Satellite RMUs (remote monitoring units)
  • Solid state decouplers

MATCOR did not hesitate to commit to this aggressive installation schedule that required materials to be manufactured and procured on an expedited basis.

MATCOR is the OEM for the AC Interference Mitigation System

As the original manufacturer of the Mitigator, MATCOR was able to immediately ship 10,000 feet from stock inventory. The balance of the material was immediately moved to the front of our production schedule. Within a few days of receiving the order, MATCOR had mobilized to the site and was making preparations to kick off the installation.

MATCOR performed the Mitigator installation using a cable plow with a dozer providing a pre-rip. MATCOR also deployed a new hydro-vac truck to perform pot holing for line locating and test station installations.

A MATCOR drilling rig and crew performed the deep grounding drilling.

Completed Ahead of Schedule

The entire AC installation was completed and commissioned one day ahead of the scheduled completion date without incident and to the pipeline owner’s satisfaction.

This project highlighted all of MATCOR’s core competencies:

  • Manufacturing of materials
  • Broad construction capabilities
  • Professional project management
  • Field technical expertise

When you need to get it done and the clock is ticking – MATCOR performs.


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.
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MATCOR MMO ANODE SURCHARGE

In response to the surging hyperinflation of global iridium prices, MATCOR is instituting, effective February 1st, a temporary surcharge on the price of all our MMO anode products.

The surcharge is necessary to offset the significant increases in MMO coated materials, specifically iridium.

The surcharge varies depending on the product and its MMO cost component and will be shown as a separate line item in our material proposals.

Learn more about the iridium pricing surge at the link below.

Global Iridium Pricing Crisis »

Price Quotes for MMO Anodes

Additionally, MATCOR is reducing our quote validity dates to two weeks and stipulating that the price validity is based on the price of Iridium remaining below 4500/oz. Should the price of Iridium exceed 4500/oz, MATCOR will review and confirm validity of the pricing at time of order placement.

We regret that these measures must be taken, but these are extraordinary times. MATCOR is committed to working with you to minimize the cost impact of the global iridium price surge.

This includes reviewing your project needs and evaluating alternate anode solutions.

Please contact us with any questions or to review existing quotes or alternatives for your upcoming cathodic protection projects.

Contact a Corrosion Expert

Global Iridium Pricing Crisis – FAQ

Iridium Price Increase cathodic protection

Surging Iridium prices have shocked the cathodic protection industry. We have put together the following FAQs to explain what iridium is and how it is used in cathodic protection materials.

What is Iridium?

Iridium is a rare earth metal that is, as the name implies, quite rare. It is considered part of the Platinum Group of metals as it is found as a trace element in the extraction of platinum. It is the second densest, and the most highly corrosion-resistant of all metals.

How is iridium used in cathodic protection?

It is the primary active element for all Mixed Metal Oxide (MMO) anode coatings used in oxygenated environments which include coke, soil, mud, fresh water – basically anything but seawater which is a chlorinated environment.

How expensive is iridium?

Up until a few weeks ago, Iridium prices were generally stable throughout 2020 in the range of $1500 to $1700 per ounce. In mid-December the price of Iridium skyrocketed over 200% in the space of a few short weeks. This hyperinflation in the cost of Iridium has caught the CP industry by surprise, and MMO anode suppliers are being forced to dramatically raise prices because of the significant additional costs of Iridium Oxide used as the active catalytic element.iridium price increase january 2021
SOURCE: dailymetalprice.com

Why is the price of iridium skyrocketing?

There are a couple of factors that have created this pricing crisis. First, most of the world’s Iridium comes from a few Platinum mines in South Africa, and with the global pandemic having recently hit South Africa very hard with a new and more virulent strain of Covid-19, the mining output has diminished significantly. We hope this is a short-term supply issue. The second factor has to do with the European Union announcing a major investment in Hydrogen as a green fuel for electrical generation. A new membrane technology (PEM) uses iridium as a catalyst to generate hydrogen. The announcement led to several speculators buying up Iridium supplies and driving the price up.

What happens next and how long will this last?

It is impossible to predict how high the price of Iridium will rise before reaching a peak, how long the pricing remains at these elevated levels, and what the stable price in the future might be for Iridium. What is certain is that the supply of Iridium will adjust as the mines in South Africa go back to production and as the elevated price leads to more supply being developed to meet the demand. Historically the supply of Iridium has always been available to meet the demand and when that equilibrium is restored, we can expect the price to drop and stabilize.

What is MATCOR doing to address this issue?

MATCOR is applying a surcharge on all MMO Anode products effective February 1st. We will continue to monitor the MMO situation and work with our suppliers to maintain our supplies and contain our costs as best we can. We hope that this is a temporary situation that will resolve itself in the next several months.

Are there alternatives for cathodic protection that do not utilize iridium?

We still believe that MMO anodes remain the best anode material when considering the outstanding track record of this anode, its dimensionally stable properties, and its long service life. However, MATCOR can also supply conventional anodes including high silicon cast iron and graphite anodes. We are also evaluating Platinum anodes which were the original dimensionally stable catalytic anode before the advent of MMO, although platinum has its limitations and is simply not as robust an anode material.
If you have further questions please feel free to contact your local MATCOR sales representative or visit our website and submit your question there

Effect on MATCOR MMO Anode Pricing »

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Natural Gas Fueling US Steel Competitiveness

Cheap and abundant Marcellus Shale gas derived from US fracking technology helps to drive competitiveness for a wide range of industries in the United States. This is especially true for the US Steel industry, and MATCOR’s recent project in Western Pennsylvania in the rolling hills of the Monongahela Valley is a great example of this.

US Steel Irvin Plant

Nestled on a hilltop 250 feet above the valley is US Steel’s Mon Valley Works–Irvin Plant. This hot strip mill in the Pittsburgh West Mifflin suburbs first opened in 1938. The hilltop site required more than 4.4 million cubic yards of earth to be moved, more than any other project other than the Panama Canal. In May of 2019, US Steel announced plans to invest $1 billion dollars at the site to expand it and to build a cogeneration power facility expected to be operational by 2022.

MATCOR was selected by US Steel to install, commission and test an impressed current cathodic protection system to protect the critical coke oven gas (COG) product pipelines mixed at the West Mifflin COG facility. The coke oven gas is a mixture of commercial natural gas and recovered waste coke gas. This blending of natural gas with recovered gas reduces costs and improves US Steel’s energy efficiency. The pipeline, affectionately called the Green Monster, traverses the valley feeding various facilities. Mostly above grade, the pipeline goes below grade in numerous locations.

US Steel Cathodic Protection System Installation

MATCOR’s MMP 3605 mixed metal oxide based canister anodes were selected as the new cathodic protection system anodes to protect the buried piping. Fifteen anodes were installed in individual 20-foot depth augered holes and connected to a #2 HMWPE buried header cable requiring approximately 1500 linear feet of trenching. The project included site specific safety training, regular coordination with site personnel and site restoration (seed, straw and fertilizer) after completion of the installation.

The project was a tremendous success and MATCOR is proud to have been able to partner with US Steel for their buried pipe corrosion protection.


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

Transmission Line Monitoring Through Partnership with LineVision

MATCOR is pleased to announce that we have partnered with LineVision, a Massachusetts based technology company, to provide their innovative overhead transmission line monitoring technology to the pipeline industry as part of MATCOR’s comprehensive suite of AC Interference and Monitoring services.

Solar-powered remote transmission line monitoring solution from LineVision.

LineVision’s PACT® (Pipeline AC Threats) system is a patented, self-contained, solar powered utility power line remote monitoring solution that provides pipeline operators with critical information regarding the operation of high voltage transmission lines owned by the power utility company. These innovative power line sensors provide critical data to operators without relying on the power company to provide it.

The ability to independently monitor critical transmission line information can greatly reduce the time required for modeling and eliminate any need for guesswork or assumptions when utility data is not readily available from the power company. Information obtained from the power line sensor includes:
• HVAC current being transmitted
• Phase order information

For AC Interference Modeling efforts, we can temporarily install this overhead line monitoring solution along the right-of-way (ROW) in strategic locations. This allows us to collect representative data over a period of time to provide the necessary inputs for the AC modeling software.

The LineVision PACT transmission line monitoring equipment can also be incorporated into your AC mitigation system monitoring program to provide information on the actual HVAC line usage. This is especially helpful when understanding how the line’s power flow usage level varies—the PACT system provides alerts if the usage increases over time.

This information, combined with your AC Test station AC and DC current density data trends can help to provide a more accurate picture of your mitigation system’s compliance with the AC mitigation criteria as detailed in NACE SP 21424-2018. This standard requires demonstrating that your system is mitigating to the required criteria level on a time averaged basis, and that it accounts for variations that could impact mitigation. Monitoring the AC transmission power flow is one of those variables.


Have questions about the LineVision PACT technology, or need a quote for AC mitigation services? Contact us at the link below. For immediate assistance, please call +1-215-348-2974.
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And the winner is – RUSTY!

The Jolly Green Giant, the Pillsbury Doughboy, the Geico Gecko, Ronald McDonald, the Energizer Bunny… please all step aside and make room for the world’s newest, and soon to be famous, icon, RUSTY the MATCOR Chili Pepper spokesperson.

“My mission is to protect the world’s infrastructure from the evil scourge of corrosion.”

—RUSTY

RUSTY is not trying to sell vegetables, biscuits in a can, hamburgers or batteries. No, RUSTY’s mission is to protect the world’s infrastructure from the evil scourge of corrosion. We look forward to RUSTY’s corrosion adventures.

A big shout out to Ted Morris of Nustar Energy, a 38-year veteran of the pipeline industry who has spent the last 29 years in Corrosion Control. Ted Morris was the grand prize winner of our “Name MATCOR’s Icon Contest”. The contest garnered a tremendous number of very thoughtful entries, but RUSTY was an immediate favorite of the selection committee. Ted will be retiring in the near future, having served the industry well, and we at MATCOR dare say that RUSTY may prove to be one of his great legacies. Thanks Ted!

A very close second place in the naming contest goes to Fernando Villamizar Ariza of Ingacor Colombia, with his name entry of “Cowboy Rust”. Thank you Fernando!

There were many honorable mentions and we thank everyone for the effort and creativity.

Name the MATCOR Hot Sauce Character!

For the past several NACE Conferences, MATCOR has spiced up the lives of NACE Conference attendees by handing out our highly coveted Hot Sauce with a cheerful Chili Pepper character on the bottle.

So Much Hot Sauce!

This year’s cancelled NACE Conference has left us with a large inventory of Hot Sauce that we intended to hand out in Houston. On the bottle this year our Chili Pepper character dons a Texas sized cowboy hat and boot for the occasion.

This character has also been included in several recent NACE eNews ads and our marketing team feels that he/she needs a name!

So, we thought we would ask our newsletter recipients for suggestions. 

Send us a name suggestion and we’ll mail you a bottle of MATCOR Hot Sauce!

The first 50 people to respond with a name will be sent a free bottle of Hot Sauce. 

Plus a T-shirt for finalists!

The top 5 suggestions, as determined by our Marketing team, will also receive a “MATCOR Factory Safe” long sleeved T-shirt for their participation.

Please help us give our Chili Pepper character a fitting name!

Complete the form below to submit your idea!


Turnkey Project Includes Pipeline Recoating & CP Upgrade

Working with fellow BrandSafway company Industrial Specialists LLC, MATCOR successfully completed a turnkey pipeline recoating and cathodic protection upgrade project ahead of schedule and to the operator’s complete satisfaction.

pipeline recoating project
MATCOR & Industrial Specialists team up on a complex pipeline recoating project.

Earlier this year, MATCOR purchased two state of the art dual air/hydro vacuum excavators. We have put these units to work as we expand our capabilities to include pipeline recoating services.

“We recently completed a major project in Oklahoma for a midstream client that leveraged our ‘Big Air’ vacuum excavators. This complex project challenged our existing capabilities and allowed us to draw on the resources and capabilities of our parent company, BrandSafway, to provide a full service cathodic protection upgrade and pipeline recoating in multiple locations.”—Josh Johnston, MATCOR Director of Sales

Pipeline Recoating Added to Anode Bed and Test Station Installation

The project consisted of six (6) anode bed installations and seven (7) test station installations – standard CP work for MATCOR; however, at each of the test station locations, we were also tasked with coating removal and recoating of the approximately 20 ft of pipeline exposed at each location.

The coating removal was complicated by the presence of asbestos. Prior to 1980, asbestos was typically used in a felt wrapping around the pipe along with an asphaltic (tar) outer wrap.

Asbestos can still be found in the coating of hundreds of thousands of feet of buried pipeline installed prior to 1980. MATCOR’s crew received one week of asbestos removal training to be properly qualified to identify, remove and dispose of the coating containing asbestos.

MATCOR’s parent company, BrandSafway, has in its portfolio of businesses Industrial Specialists, LLC (IS), which is an extremely well-qualified industrial coatings services team with over 35 NACE trained and certified inspectors and over 1,700 painters and supervisors.

MATCOR was able to partner with the IS Tulsa, OK office to deliver the entire project using in-house BrandSafway resources, making us a one stop shop for this level of work. MATCOR’s CP construction crews performed the vacuum excavation and asbestos coating removal, and then the BrandSafway industrial services crew performed the blasting, inspection and recoating work. One big company with a wide range of industrial capabilities.

Project Completed Ahead of Schedule

The project was executed successfully, completed two weeks ahead of schedule and to the pipeline operator’s complete satisfaction. We even identified two areas where the pipeline was directly on top of rock and the owner asked that MATCOR install a layer of rock shield over the completed recoat areas. At the end of the project, the pipeline operator affirmed that they would be using MATCOR again for similar project work.


Have questions or need a quote for cathodic protection or pipeline recoating services? Contact us at the link below.

CONTACT A CORROSION EXPERT

Durammo Helps You Do More With Your Money.

MATCOR’s proprietary deep anode system is a cost-effective approach to installing deep anodes.

Recently a customer asked MATCOR to bid the installation of multiple deep anode systems, each consisting of 15 high silicon cast iron anodes to be installed in 350-ft. deep holes. MATCOR provided an alternate proposal based on our proprietary Durammo® system.

Durammo® Deep Anode System

2 Major Benefits of Durammo 

  1. It eliminates the need for a junction box
  2. It requires a lot less cable due to its being a continuous anode system with only two primary cables

Meaningful Cost Savings

When you are looking at 15 individual anodes with hundreds of feet of dual insulated HMWPE/Kynar® or Halar®  (pick your preferred fluorinated polymer – they are very similar in their chemical resistance and are both suitable for deep anode installations), the cabling costs are significant as is the cost of a suitably sized junction box. Multiply these savings over several sites and it can lead to a meaningful costs savings over the typical conventional anode installation.

9 Reasons DURAMMO® Beats Conventional Anode Systems »

Expand Your Scope of Work!

Our client took advantage of the cost savings for the Durammo and awarded MATCOR the installation work and used the cost savings to have MATCOR repair, replace and add additional test stations instead of paying for a lot of additional cable and junction boxes. The Durammo cost savings allowed the operator to expand the scope of work doing more with the monies budgeted on the project.

Talk to your MATCOR representative to see how the Durammo can allow you to get more done with your limited CP budget monies.


To get in touch with our team of 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

Trying to Complete 2020 CP Projects?

Can this year end any sooner?

Wait, I still have stuff that needs to be completed this year!

This is a sentiment that many of us feel. It’s been a crazy year the likes of which we have never seen before and hopefully we will not see again.

But before we turn the page on 2020, many of our clients have expressed to MATCOR that they still have projects that were supposed to be completed in 2020—budgeted projects that still need to be completed this year. Between the lockdowns and the uncertainty over oil prices, too many projects were delayed or slow to get started. Now that we are several weeks into the fourth quarter and the weather is starting to turn, the working daylight hours are winnowing, the holidays are approaching, and the demand for cathodic protection installations is quickly filling up the available capacity in the market place.  There are only so many hours left in this year.

MATCOR is here to help.

We are working as hard as we can to satisfy as many customers as possible with our remaining capacity, and we are also encouraging customers to consider getting an early start to their 2021 construction project schedule.

Typically, January and February are slow construction months. In part this is because of weather issues, but often it is a budget cycle issue – clients are still finalizing their budgets, project teams are just getting back from the holiday season, and bid packages are being developed to be issued in February or March for a lot of CP construction work.  We expect 2021 will be a very busy year as owners and operators catch up on work that was pushed out, could not be completed in 2020, and begin to comply with new PHMSA Mega Rule requirements.

Purchase Cathodic Protection Materials Now with Your 2020 Budget for Installation in 2021.

We encourage all customers to consider getting started early – MATCOR is available to work with you.  If you have 2020 budget money but are not able to get the work completed in 2020, consider purchasing the materials with your 2020 monies and completing the installations in early 2021.  MATCOR can work with you to procure and store the materials and to plan an early first quarter installation.

Contact your MATCOR representative at the link below to discuss options for work that has been delayed or that needs to be done quickly.  We will do our best to support you.


Contact a Corrosion Expert

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