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Cathodic Protection, Horizontal Directional Drilling, Linear Anodes, Storage Tanks, Tank Bottoms

Replaceable Anode System Success: A First for Critical Middle East Tank Assets

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Last month, MATCOR successfully completed the first ever HDD tank cathodic protection system installation in the Middle East, utilizing a replaceable anode system.

Replaceable Anode System Installation

Background—Initial Recommendation for HDD Cathodic Protection System

Equate Petrochemicals is one of the world’s largest producers of Ethylene Glycol. They initially contacted MATCOR in 2012 to discuss options for cathodic protection on a critical service Ethylene storage tank at their flagship Kuwait petrochemical facility. This tank was originally constructed in 1995, and the initial CP system installed with the tank was no longer providing sufficient current to achieve NACE Criteria. At the time, MATCOR suggested installing anodes directly under the tank using horizontal directional drilling technology. The plant’s engineering and operations team had significant reservations about this approach. The tank was critical to the plant’s operation and could not be taken out of service. Should the HDD operations result in damage to the structural integrity of the tank, the results would be catastrophic.

Perimeter Anodes—An (Unsuccessful) Alternative Approach

As a result of Equate’s concerns in 2012, they attempted an alternate approach, suggested by others, using perimeter anodes. Discreet anodes were installed offset around the perimeter of the tank—thus avoiding any possible risk to the tank during the anode installation. The use of perimeter anodes around larger diameter tanks is generally not a good idea. This is because it is very difficult to drive current to the center area of the tank, often resulting in adequate protection levels only for the outer edges of the tank bottom. For the Ethylene Storage Tank, the presence of heating pipes below the tank bottom only exacerbated the current distribution challenges. Ultimately, the results were not satisfactory.

In 2018, the plant engineering team reached back out to MATCOR to discuss our HDD solutions.

Replaceable Anode System Solution

Replaceable Anode SystemMATCOR provided the plant with a detailed proposal to design and install a complete cathodic protection system using MATCOR’s Replaceable Tank Anode system. The RTA system is based on installing MATCOR SPL linear anode assemblies in a series of parallel slotted PVC pipes that have coke backfill pneumatically blown into the PVC pipe as part of the anode system installation. In addition to the linear anode segments and coke backfill, the slotted PVC pipes have a venting system to allow gases produced during the cathodic protection reaction to vent. This prevents gas buildup and blockage inside the PVC anode pipe.

Replaceable Anode System Installation Drawing

One of the key advantages of the RTA system is that once the PVC tubes are installed, it is possible to flush out the anode assemblies and coke backfill should the anode assemblies fail and/or they are at the end of their design life making this a replaceable anode system that will assure cathodic protection for the entire service life of the tank.

Additionally, a slotted Reference Cell Tube would be installed to allow for two calibrated fixed cathodic protection reference electrodes to be inserted for full polarized and non-polarized potential measurements across the entire tank bottom. This would allow for testing of the CP system with calibrated reference electrodes for the life of the tank.

Experienced HDD Installation—Assuring a Safe Installation

Horizontal Drilling Anode InstallationWhile the plant conceptually agreed with MATCOR’s solution from a technical perspective, there remained a significant concern within the plant’s operation and safety groups about drilling under this critical service tank and the possibility of a catastrophic event should the drill head drift up to the tank bottom. MATCOR put together a thorough installation procedure including detailed information on the sophisticated drill head tracking systems being utilized to assure that the drill head location was being continuously monitored throughout the bore. Utilizing an experienced local HDD drilling sub-contractor, MATCOR deputed its senior HDD installation drilling supervisor to Kuwait for the installation. Our Senior HDD Drilling Supervisor has completed hundreds of tank HDD installations in the United States and his on-site presence, along with the advanced electronic tracking package being used, assured that each bore went as planned.

Replaceable Anode System Installation Complete!

In December of 2019, MATCOR, working with our local Kuwaiti sub-contractor and the client’s engineering, construction and safety teams, successfully completed the installation of the replaceable anode system. The initial commissioning results showed that the anodes were installed properly. Each anode was distributing current as expected, and the polarization levels were meeting appropriate NACE criteria. The system has been left to operate and fully polarize. A subsequent visit by MATCOR’s technical team is scheduled in early 2020 to make final adjustments to the anode system current output and to confirm that the system continues to meet NACE criteria.

Conclusion

MATCOR’s successful installation in Kuwait of a horizontal directional bored CP system under an existing critical service tank is a first for the Middle East Region. The innovative MATCOR design, combined with the technical knowledge and operational expertise, makes this an interesting and viable option for other tank owner/operators worldwide to consider for their existing tanks with CP systems that are not performing properly.

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.

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Cathodic Protection, Corrosion, Storage Tanks, Tank Bottoms

Vapor Corrosion Inhibitors

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This guide explores how Vapor Corrosion Inhibitors (VCIs) work, their diverse applications, and why they’re becoming a cornerstone of modern corrosion prevention strategies. Whether you’re in oil and gas, manufacturing, or aerospace, discover how VCIs can transform your approach to corrosion management.

Corrosion poses a significant threat to infrastructure and equipment across industries, from pipelines to storage tanks. VCIs offer a solution, using advanced chemical technology to protect metal surfaces and prevent costly damage.

zerust-vci-molecule

As a leader in the above-ground storage tank corrosion control industry, MATCOR has partnered with Zerust® Oil & Gas to provide innovative VCI solutions for customers seeking advanced corrosion mitigation strategies.

What are Vapor Corrosion Inhibitors?

Vapor Corrosion Inhibitors (VCIs) are advanced chemical compounds that prevent corrosion by diffusing through confined spaces and bonding with metal surfaces. This process creates an invisible yet highly effective barrier that blocks water, oxygen, and other contaminants from initiating degradation.

Key features:

  • Create a passive oxide layer that inhibits chemical reactions
  • Can be applied in various forms, including powders, liquids, or impregnated materials.
  • Long-lasting protection for months or years, depending on conditions.

Why Choose VCIs?

Vapor Corrosion Inhibitors (VCIs) stand out among corrosion prevention solutions due to their ease of application, flexibility, and proven effectiveness. Compared to other methods like wax, VCIs offer several key advantages:

  1. Ease of Installation: VCIs are easy to apply, requiring no heating—just simple mixing with potable water and injection through vent pipes, ensuring efficient distribution.
  2. Broad Compatibility: VCIs work seamlessly with other corrosion prevention methods, such as coatings and cathodic protection, enhancing overall protection strategies.
  3. Cost-Effectiveness: By extending the lifespan of assets and reducing the need for frequent maintenance, VCIs provide a high return on investment over time.
  4. Allows Monitoring: VCI effectiveness can be monitored in real time using coupons, ER probes, or UT probes, with the option for remote monitoring units (RMUs). In contrast, wax requires in-line inspection (ILI) runs for evaluation.
  5. Non-Invasive: Unlike some traditional methods, VCIs do not require disassembly for application, making them a convenient choice for hard-to-reach areas.
  6. Versatile Applications: VCIs are available in various forms, including films, papers, powders, liquids, and emitters, making them adaptable to a wide range of industrial needs.
  7. Removability: VCIs can be easily washed out and removed if necessary, offering flexibility for future maintenance or operational adjustments.
  8. Environmentally-Friendly: VCIs are an environmentally friendly solution for corrosion prevention, offering biodegradable formulations, non-toxic options for sensitive industries, and contributing to sustainability by reducing waste and extending asset life.
  9. Industry-Approved Solution: VCIs are recognized and approved by leading authorities, including the Association for Materials Protection and Performance (AMPP) and the U.S. Department of Transportation’s Pipeline and Hazardous Materials Safety Administration (PHMSA).

Through our partnership with Zerust® Oil & Gas, MATCOR delivers these benefits with proven products backed by extensive research and industry expertise.

Applications of Vapor Corrosion Inhibitors Across Industries

  • Oil and Gas: Protects internal surfaces of pipelines after hydrotesting and safeguards tanks bottoms from localized corrosion. Learn more about pipeline corrosion risks and prevention methods in our Pipeline Corrosion and Prevention—A Comprehensive Guide.
  • Manufacturing and Industrial Equipment: Shields components during storage, shipping, or idle periods.
  • Marine and Offshore: Mitigates corrosion from saltwater and high-humidity environments.
  • Aerospace and Automotive: Protects critical systems like engines and fuel tanks during long-term storage.
  • Infrastructure and Utilities: Prevents corrosion in water pipelines, bridges, and utility equipment.

Monitoring and Maintenance

To ensure the long-term effectiveness of VCIs, regular monitoring is essential. Techniques include:

  • Coupons: Small metal pieces placed in the protected environment to assess corrosion rates.
  • ER Probes: Monitor changes in electrical resistance to track corrosion over time.
  • Replenishment: Determined based on environmental conditions and the observed depletion rate of VCIs. Factors influencing replenishment frequency include:
    • The rate of leakage through the tank chime.
    • Operating temperature and environmental conditions.
    • Properties of the substrate, such as sand or concrete.
    • The initial amount of VCI chemical applied.

Typically, VCIs provide effective protection for 3–5 years, though some applications may last longer under optimal conditions. Proper monitoring ensures VCIs maintain consistent protection and helps operators identify the appropriate timing for replenishment to sustain corrosion prevention.

VCIs and Industry Standards

Vapor Corrosion Inhibitors (VCIs) are gaining recognition in industry standards as a flexible and effective corrosion prevention tool. While they are often used to complement cathodic protection (CP), they are also being acknowledged as standalone solutions in scenarios where CP may not be feasible.

  • API 651 and API 2610: Standards such as API 651 include VCIs as an alternative for situations where CP systems are unsuitable, and API 2610 outlines their use under tank bottoms.
  • Regulatory Adoption: Organizations like PHMSA and the State of Florida have endorsed VCIs for their versatility, particularly in cases where CP systems are not functional or economical.

These endorsements highlight the growing recognition of VCIs as a versatile tool for corrosion prevention, whether as a standalone solution or a complement to existing systems like CP.

Independent Studies Supporting Vapor Corrosion Inhibitors

The effectiveness of Vapor Corrosion Inhibitors (VCIs) is well-supported by independent research, including a comprehensive 2018 study published by PRCI (Pipeline Research Council International). This study offers critical insights into the capabilities and limitations of VCIs:

  • Effectiveness in Corrosive Environments: VCIs were found to effectively mitigate pitting corrosion in steel exposed to corrosive sand. However, the study noted that VCIs are not as effective as cathodic protection (CP) for reducing pitting corrosion in certain conditions.
  • Importance of Proper Application: The study emphasized the need for following manufacturer-recommended concentrations, as inadequate levels of VCIs were shown to be ineffective.
  • Monitoring Compatibility: ER probes can be used to monitor the efficacy of VCIs, providing valuable data on corrosion rates and the need for replenishment.
  • Compatibility with Cathodic Protection: VCIs are compatible with impressed current cathodic protection systems. However, they can alter the native potential of steel, which must be considered when selecting CP criteria in accordance with NACE SP0193.

For more details, access the full study: PR-015-153602-R01 Vapor Corrosion Inhibitors Effectiveness for Tank Bottom Plate Corrosion Control.

Vapor Corrosion Inhibitor Case Studies: Real-World Success with VCIs

Pipeline Preservation with VCI in West Texas

MATCOR and Zerust® collaborated on a pipeline preservation project in West Texas, injecting over 24,000 gallons of VCI solution into pipeline manifolds. This approach provided effective corrosion protection during construction and harsh environmental conditions.

For more details on how VCIs address pipeline-specific challenges, visit our Pipeline Internal Corrosion Prevention with VCI page.

Casing Repair with VCI

MATCOR conducted a casing repair for a high-pressure natural gas line that had settled, losing contact with its protective casing. The solution included sealing the casing and injecting VCIs through the vent pipe, providing effective corrosion protection without excavation.

Learn more about this project in our Casing Repair & VCI Case Study.

Q&A: Common Questions About Vapor Corrosion Inhibitors (VCIs)

Are VCIs a permanent solution?

No, VCIs have a finite lifespan. Their effectiveness typically lasts 3-5 years, depending on factors like environmental conditions, application methods, and leakage rates. Regular replenishment is needed to maintain protection, with some applications lasting up to 15 years under ideal conditions.

How are VCIs applied to above-ground storage tanks?

VCIs can be applied as powders or liquids, depending on the tank type (new,in-service, or under inspection). The method varies based on substrate material (ie. sand or concrete), but long-term replenishment planning is essential to sustain protection.

Can VCIs replace other corrosion prevention methods?

VCIs are not typically used as a standalone replacement for other methods but are effective for short-term corrosion protection or in scenarios where other solutions are not practical.

Can VCIs enhance other corrosion prevention methods??

Yes, VCIs work well alongside existing methods by addressing localized corrosion in hard-to-reach areas like gaps, crevices, and irregular surfaces. This complementary approach strengthens overall protection.

How is VCI performance monitored?

VCI effectiveness is monitored using coupons, ER probes or UT probes. These tools measure corrosion rates and help identify when replenishment is required. While ER probes track average corrosion rates, they can also infer localized risks like pitting.

What standards and regulations support VCI use?

VCIs are recognized by standards such as API 651 and API 2610 for specific applications, and they are included in the upcoming NACE TG543 guidelines. Regulatory bodies like PHMSA also acknowledges VCIs as a valid corrosion prevention tool, especially when other methods are infeasible.

Conclusion: The Future of Corrosion Prevention with VCIs

Vapor Corrosion Inhibitors (VCIs) are transforming the landscape of corrosion prevention across industries. From pipelines and storage ranks to marine and aerospace applications, VCIs provide a versatile, cost-effective, and environmentally friendly solution for protecting metal assets. Their ability to adapt to various environments and integrate with other corrosion prevention methods makes them a critical tool for modern infrastructure and equipment management.

Through our partnership with Zerust® Oil & Gas, MATCOR delivers proven VCI solutions backed by extensive research and industry recognition. Whether you’re seeking to enhance existing systems or explore standalone VCI applications, our team is ready to help you develop a customized strategy to protect your assets and reduce long-term maintenance costs.

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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Careers, MATCOR

MATCOR is Hiring!

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Please spread the word that MATCOR is hiring!

2019 has been a year of tremendous growth and development in the corrosion industry. Thank you for the huge part you’ve played in MATCOR’s continued success. We are committed to helping you achieve your corrosion prevention goals by providing the best services and products in the cathodic protection business. To keep up with increasing demand, we’ve expanded our footprint in the Gulf, Permian and Rockies, acquired additional drilling rigs, Mud Puppy filtration systems and water trucks, and are looking for new team members.

Click here for a list of MATCOR job postings

AC Mitigation, Anodes, Cathodic Protection, Linear Anodes

Have Extra 2019 Budget Monies?

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MATCOR can help.

This is the time of year when thoughts turn to Thanksgiving and Christmas vacations, using up all your remaining vacation and wondering what to do with any leftover 2019 cathodic protection budget monies.  More than likely, it is too late to schedule and complete new projects.  MATCOR along with most of our competitors have full construction schedules and adding additional commitments is quite difficult.

So what to do with that leftover budget monies that may reset in 2020?  Many of our clients look to stock up on materials for their anticipated 2020 projects.  It is not too late get MATCOR’s Mitigator® Engineered AC Mitigation System, SPL™ Impressed Current Linear Anodes, Durammo® Deep Anode System, MMP™ Prepackaged MMO Canister Anodes and other ancillary materials into this year’s budget.

Click HERE to get in touch with your MATCOR account manager for more information, to ask a question or get a quote. Or, complete our contact form at the link below and we will respond by phone or email within 24 hours. For immediate assistance, please call +1-215-348-2974.

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AC Mitigation, Pipeline

Case Study: AC Mitigation Design Criterion – It Matters

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This case study highlights some of the challenges associated with choosing AC mitigation design criterion for a new pipeline construction project.  The specific project consisted of approximately 200 miles of pipeline with another 35 miles of lateral lines and included compressor stations, metering valves and a valve station.  The final approved right of way consisted of 41 identified transmission lines spanning 5 different utility owners.  MATCOR’s scope of work included designing both the CP system and modeling and designing an AC Mitigation system to address the extensive HVAC colocations.

For the AC Mitigation effort, MATCOR performed extensive field data collection along the right of way and MATCOR sent requests for utility operating data for AC Mitigation Design purposes.  After 6 months of requests from the various utilities, the results were inconsistent with some utilities providing only emergency and peak data, others provided seasonal average data and one utility would not provide any data.  Ultimately, modeling was performed based on actual data wherever possible, supplemented by assumptions based on experience from other AC Mitigation designs projects.

While this engineering project was being started, NACE was adopting its latest version of SP 21424-2018-SG “Alternating Current Corrosion on Cathodically Protected Pipelines: Risk Assessment, Mitigation, and Monitoring”.  This latest version presented an updated criteria standard based on DC Current Density.  Basically, if you can assure that the CP Current Density along the length of pipeline is controlled to below 1 A/m2 then you can tolerate a much higher AC Current density threshold of 100 A/m2 requiring less AC mitigation.  If you are unable to control CP Current to the 1 A/m2 level, then the acceptable AC current density drops to a much lower 30 A/m2 threshold often requiring more extensive mitigation.

For the initial AC modeling effort, MATCOR based the AC Current Density limit to the lower, more stringent, 30 A/m2 criteria that assumes that the CP Current Density could not be controlled to below 1 A/m2.  The modeling, given all the assumptions that we had to make, came back with:

  • Numerous locations where Step and Touch Potential concerns required mitigation
  • No concerns over fault current given the separation distances and fault currents presumed
  • A very significant mitigation requirement to bring the induced current densities below the 30 A/m2 criteria including approximately 81 miles of parallel mitigation and 8 x 600ft deep grounding wells.

These results warranted additional review given the extensive AC Mitigation requirements from the initial modeling.

After some sensitivity assessments, a second modeling effort would be taken based on some revisions to the HVAC operating data based on updated information and some revisions to the input assumptions.  This new modeling effort would also be run using 50 A/m2 as the AC Current Density limit.  Additionally, based on input from operations, it was determined that all deep grounding wells would be limited to 200 ft depth.  The new modeling effort resulted in a significant reduction in AC Mitigation required eliminating almost 50 miles of parallel mitigation.

The dual modeling efforts showed that there were numerous locations that were only slightly above the 30 A/m2 threshold but below that of 50 A/m2.  In those areas, the owner opted to install additional monitoring systems but forego the initial installation of AC Mitigation and instead focus on those higher risk AC Interference areas by installing AC Mitigation.

This case story highlights the role of AC mitigation design criterion selection and the complexity around the current criteria that correlates CP Current Density levels, which are not typically controlled, to the AC current design threshold to mitigate the induced corrosion AC Interference risk.  With judicious design decisions and a healthy amount of monitoring systems, there is significant value in your modeling criteria.

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.

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Cathodic Protection, Storage Tanks, Tank Bottoms

AST Cathodic Protection System Tank Isolation Considerations

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cathodic protection tank isolation considerationsEvan Savant, EnLink Midstream reached out to the MATCOR Technical Team asking about AST cathodic protection system tank isolation:

“Can you advise on the importance of isolation for a new AST connected to a Pipeline, and can you advise on the need to isolate the tank cathodic protection from the tank grounding?

MATCOR’s Director of Engineering, Kevin Groll PE, NACE CP4 responded:

I am unaware of any papers or technical documents on the subject, but I will summarize as follows:

  1. Why can a lack of isolation hurt your cathodic protection?
    When trying to protect any type of structure from corrosion, cathodic current loss to nearby structures is always a concern. Losses can occur when the structure in question is directly bonded to other structures which may “steal” current. Offending metal structures that are close to the cathodic protection anode and structures with better resistance to earth (e.g., bare copper grounding, bare driven piles, etc.) will more likely take a significant amount of current.
  2. How do you obtain isolation without losing overvoltage protection?
    To prevent current loss, your target structure must be electrically isolated from the offending structures.  However, once you isolate a structure, you will lose grounding (if it was purposefully grounded) and you will lose protection against overvoltage events, AC faults, and lightning strikes.  Therefore, to obtain DC isolation but maintain AC continuity and overvoltage continuity, we use solid state decouplers (SSDs) and polarization cell replacements (PCRs). The primary difference between these devices is how much surge current they will carry.
  3. Tank cathodic protection design considerations.
    When we design an under-tank CP system with concentric rings, we assume that we will not have isolation from grounding and facility piping, and we also assume that most of the current will get to the tank bottom because of the proximity of the anodes.  This is not always the case, as we saw in a recent project, but for the most part concentric ring systems can be powered high enough to overcome the lack of isolation.

Horizontal directional drilling installed linear systems show approximately 1.5 to 2 times as much current is required as a concentric ring system due to current losses.  Again, we usually factor in enough current capacity to overcome these losses.

Deep anode systems and semi-deep anode systems suffer the worst losses. These systems will sometimes require isolation of the tanks to prevent critical current loss.  If a system is already in place, testing can be performed to determine how much loss there is to existing structures by measuring the current returned on ground rods and pipes. This is accomplished by using clamp-on current meters around wires/rods and Swain meters around pipes.

It is important to note that tank terminal isolation and grounding are factors in these complex tank terminal applications that must be considered in the proper design of Cathodic Protection.  MATCOR’s experienced team of engineers can evaluate your specific application and make the appropriate recommendations.

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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Cathodic Protection

Oil Cooled Cathodic Protection Transformer Rectifiers: Why, when and where…

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Oil Cooled Cathodic Protection Transformer RectifiersThis article describes the components of a cathodic protection rectifier, and when to use oil cooled cathodic protection transformer rectifiers vs. air cooled rectifiers.

When it comes to cathodic protection power supplies, conventional transformer rectifier circuits have long been employed by the cathodic protection industry for impressed current CP systems.  These power supplies (commonly referred to as rectifiers in the CP world) consist of three main components; the transformer, the rectification stack, and a cabinet to house these components.  The transformer takes the input AC voltage on the primary side and controls the output AC voltage on the secondary side.  The rectification stack, typically silicon diode stacks which have largely replaced older less efficient selenium stacks, convert the AC input wave form into a DC wave form by cycling the AC flows in one direction and blocking in the other.  Additional components typically include circuit breakers, fuses, voltage and current output meters, lightning arrestors, surge suppressors, transformer tap bars, and monitoring systems.

Air-cooled Rectifier
Typical Air-cooled Rectifier

The majority of these Rectifiers are housed in air-cooled NEMA 3R enclosures – these enclosures are typically constructed of hot dipped galvanized steel, aluminum, stainless steel or painted steel.  NEMA 3R enclosures are intended for outdoor use.  They provide a degree of protection against falling rain and ice formation but are not completely water tight or weather proof and could be subjected to beating rain or streams of water, under certain conditions, entering the enclosure.  This is the most common type of rectifier enclosure in the industry.

When and Where to Use Oil Cooled Cathodic Protection Transformer Rectifiers

Oil Cooled Rectifier
Oil Cooled Rectifier

For some applications; however, the use of air cooled NEMA 3R enclosures is not recommended or not suitable.  The three most common reasons not to use air-cooled NEMA 3R enclosures are:

  1. Rectifier transformer size is too large to support an air cooled enclosure. For a small percentage of impressed current CP systems where the power requirements (measured in DC Watts) are sufficiently high that the cooling capacity of the enclosure is insufficient for the heat generated by the transformer (typically anything more than 12kW for single phase and 18kW for three phase.)
  2. Severe environment locations where high humidity, dust or other situations could shorten the life of a standard air cooled rectifier. Marine and near shore applications often fall into this category.
  3. The enclosure must be in a hazardous classified location requiring Class 1 Div. 2, Group D compliant enclosure – commonly referred to as Explosion Proof.

Oil Cooled Rectifier for Hazardous Locations
Oil Cooled Rectifier for Hazardous Locations

For these applications, oil cooled cathodic protection transformer rectifiers are typically specified.  As implied in the name, the oil cooled rectifier utilizes an enclosure that has a sealed reservoir which houses the transformer and transformer tap bars and is filled with a special transformer oil.  The transformer oil provides better heat transfer and dissipation and the larger case facilitates improved heat removal.

It is very important to note that standard oil cooled rectifiers are NOT explosion proof.  For an oil cooled rectifier to be considered Explosion Proof, the components that are not immersed in the transformer oil reservoir must be housed in special Explosion Proof fixtures.  Simply specifying oil cooled when ordering a rectifier does not satisfy the requirements for locating the rectifier in a hazardous Class 1 Div.2 location without also including the additional provisions required for the explosion proof fittings.

To get in touch with our team of cathodic protection experts for more information, to ask a question or get a quote for cathodic protection materials or related construction services, 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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Anodes, Cathodic Protection

Helium Leak Testing for Cathodic Protection Anodes

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MATCOR is pleased to announce that we are now capable of performing Helium leak testing on our full range of linear anode products as an optional testing service. This is a common practice among companies and product developers that provide products that could potentially leak gas or that require water tightness. Products commonly leak tested include refrigeration lines, vehicle brake lines, and devices that contain potentially harmful or deadly substances. Helium is the second smallest element (Hydrogen is the smallest), which means that it is valuable for leak testing. Smaller molecules naturally can find smaller gaps or defects from which to leak. Unlike hydrogen, however, helium is a noble gas and is therefore unreactive due to its complete valence electron shell. As a result, helium is the most viable gas for use in leak testing.

Helium leak testing is now available for all MATCOR linear anode products, however our Kynex connection technology has zero reported failures since it was introduced a decade ago.
Helium leak testing is now available for all MATCOR linear anodes, however our patented Kynex technology has zero reported failures since it was introduced a decade ago.

MATCOR has enjoyed an outstanding record as the world’s leading supplier of MMO anodes/Titanium linear anodes with over 25 years of linear anode experience supplying our industry leading SPL™ family of linear anode products for pipelines, tanks and other applications around the world. Our patented automated injection molded Kynex® connection technology has an outstanding track record with no known connection failures since this technology was introduced in 2009.

We do, however, see some client specifications calling for 100% connection testing and helium leak testing is the most effective means to test an entire anode assembly.

For more information, please feel free to contact your local MATCOR representative or contact us at the link below.

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Equipment Fleet

More than just a new truck smell!

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As we roll out our new fleet of construction equipment across our operating regions, that grin on our crew members’ faces is not from the new car smell in their truck – it’s that feeling of rolling up to the job site with state-of-the-art new construction equipment that looks great and performs even better. We’ve invested heavily in improving our construction fleet and listening to our crews and our customers.

New Drilling Rigs

Our new drilling rigs are bigger and faster and incorporate the latest technologies to assure that we have the right equipment for the job. Outfitted for both air and rotary mud drilling operations, these rigs are ready to rumble. The impact for our crews and customers includes:

  • A safer work environment
  • Reduced installation time
  • Eliminating unnecessary downtime

With our new rigs on the job, our customers won’t have to sit around and wait as an idle rig is being repaired or waiting on parts to proceed with the installation.

New Water Trucks

Our new fleet of water trucks were specifically designed by MATCOR for deep anode installation projects. These new trucks enable us to reduce our crew footprint and consolidate our vehicle count by combining our water truck, coke pump and material truck into a single multi-purpose vehicle. Reduced vehicle traffic greatly lowers impact on the customer site and access roads. It also reduces our environmental emissions impact while eliminating one additional driver/crew member. Innovative equipment design makes us safer and more competitive.

Mud Cleaning and Handling System

Portable pits are the pits – MATCOR is moving towards a new state of the art mud cleaning and handling system that eliminates the need for earthen pit or portable pits. Our new MudPuppy® solids control system efficiently removes drilling cuttings while conditioning and cleaning our circulating mud to improve drilling effectiveness. It also provides the added benefit of reducing wear and tear on the drill pump and drilling equipment. For our customers, this means a much cleaner, fully-contained drill site with significantly reduced solids disposal requirements. MATCOR is an early adopter of this technology in the cathodic protection industry.

We are investing heavily in the best equipment because we understand that a well equipped crew is the first step in a well-executed, safer and cost-effective installation.

To get in touch with our team of cathodic protection experts for more information, to ask a question or get a quote for cathodic protection or AC mitigation related construction services, 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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AC Mitigation, Anodes, Cathodic Protection, Quality

Manufacturing Quality: What Does It Mean To Be Exceptional?

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Manufacturing Quality for Anode SystemsAt MATCOR, we pride ourselves on being a world class manufacturer of unique cathodic protection systems and AC mitigation systems. Our anode systems offer you longer life, lower total installed cost, and are safer and easier to install than many conventional anode solutions. We have earned a reputation for exceptional manufacturing quality—but all companies say their products are world class and have exceptional quality, right? What makes MATCOR different? What does it mean to be exceptional?

At our state of the art Chalfont, Pennsylvania manufacturing facility we have developed a culture of quality. That is not to imply that we are perfect or that we don’t occasionally make a mistake; we are not perfect. However, we HAVE embraced, through our ISO Certified Quality Management System, a systematic approach towards excellence. So, while everyone aspires to do a quality job, our manufacturing team’s quality culture is based on perspiration—we work relentlessly to do a quality job for YOU by embracing the key tenets of quality.

Through our Manufacturing Quality Management System, we:

  • Document procedures for what we do
  • Train our team on the proper processes
  • Hold ourselves and our suppliers to high quality standards
  • Self-audit to ensure we are doing what we say we will do
  • Measure our performance daily through KPIs (key performance indicators)
  • Strive to continuously improve
  • Collect and act on YOUR feedback, comments and complaints

We’d love to hear from you about our manufacturing quality, please comment or contact us at the link below.

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