Category Archives: Cathodic Protection

Impressed Current Sled Anodes for Marine Structures – FAQs

Impressed current sled anodes to prevent corrosion of near shore marine structures such as docs, piers and jetties.
Impressed Current Sled Anode for Marine Structures

MATCOR is a leading manufacturer of impressed current sled anode systems and as such we tend to get asked a lot of questions about sled anodes.  Here are some frequently asked questions:

Does it matter whether sled anodes are to be installed in seawater, brackish water or freshwater?  What if the water salinity varies with the season or with tidal action?

These are two related questions, and both have to do with the conductivity (or resistivity which is merely the inverse of conductivity) of the water where the anodes will be located.  The conductivity of the water plays a critical role in determining the overall system resistance and current output of the system.  For freshwater locations, the relatively low water conductivity requires a significant quantity of anodes to keep the overall system resistance down.  In those instances, a sled anode may not be the best design option as sled anodes are most cost effective in brackish or saltwater environments. For environments where the conductivity can vary seasonally or with the tides, such as estuaries or tidal river boundaries, special consideration may be required such as constant current or auto-potential controlled power supplies.

Why would we use impressed current sled anodes as opposed to galvanic anodes? 

Depending on the application, there are compelling reasons for the use of each type of system. Galvanic anodes do not require an external power supply, are less subject to interference issues, and can be closely coupled directly to the structure. The impressed current sled anodes can greatly simplify installation, reduce overall costs, typically have a longer life, and can produce a lot more current from a lot fewer anodes. The choice of anode type is very much a site-specific consideration requiring a proper engineering evaluation during the design phase.

Are there any specific concerns with marine wildlife when evaluating cathodic protection systems?

Marine wildlife is generally unaffected by the presence of a cathodic protection system. Cathodic protection systems have been used in commercial aquariums and fish hatcheries without any impact on the marine life. At the structure, cathodic protection can result in a localized environment that reduces or inhibits the growth of barnacles while changes in the pH at the structure’s surface encourage the growth of calcareous deposits which reduce the current requirements and provide a form of protective coating for the steel structure.

The MATCOR sled anodes utilize a wooden base – are there any concerns with the deterioration of the wooden base releasing in chunks of wood that could damage intake structures?

We have not experienced any such problems – the wooden base is designed to sink into the mud along the sea floor and provide an anchor.  Wood holds up very well in this environment; however, over time the wood will slowly become food for cellulose processing bacteria and eventually will slowly be degraded. This process is a natural process and occurs over a long period of time.  There is no expectation that the wood base would break into pieces that could damage an intake structure. MATCOR can provide an inert non-metallic plastic base that would be like wood but not subject to natural biodegradation.

How do you protect the cabling from the Sled Anode back to the system rectifier?

MATCOR utilizes an HMWPE cable that has a very robust exterior jacket that is suitable for direct burial in soil or water environments. The cable is housed inside a 1” diameter flexible drilled PE pipe that provides mechanical protection for the cabling. We recommend the use of concrete weights to secure the cable along the seafloor. The drilled PE pipe holes facilitate the cabling sinking into the seafloor mud providing additional protection for the cabling.

What about dredging operations?

For locations that are subject to occasional periodic dredging operations every few years or so, MATCOR can provide a locator float and lifting lugs to allow for the anodes to be removed prior to dredging operations. If the frequency of the dredging operations is such that this would be a regular occurrence (multiple times per year), then consideration should be given to alternate designs that would not require anode removal on regular basis.


For information on MATCOR’s Sea-Bottom Marine Anode Sleds or for assistance with marine near shore cathodic protection system design, please contact us at the link below.

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Rethink Your Shallow Horizontal Anode Bed Design – The Case For Linear Anodes

A common cathodic protection system approach is the use of a shallow horizontal anode bed. These are typically defined as an anode system consisting of a series of multiple individual anodes installed either vertically or horizontally at a depth of less than 15m (50ft) and connected to a single power source. These are particularly effective in areas where drilling deep anode beds is not feasible or practical.

The typical anode used in shallow anode bed applications is an impressed current anode. These can be high silicon cast iron, graphite anodes or mixed metal oxide tubular anodes.  The anodes may be pre-packaged in a canister filled with coke backfill, or they can be installed in a vertically drilled/augured hole or a continuous horizontal trench with backfill installed around the bare anode. The anodes can be installed in parallel to a common header cable or can have individual leads all routed to a cathodic protection junction box and connected in parallel inside the junction box.

Shallow Horizontal Groundbed-Individual Anodes
Shallow Horizontal Anode Bed with Individual Anodes

A New Approach: Continuous Linear Anodes

Another approach that is gaining acceptance in the corrosion industry is the use of a single continuous linear anode as an alternative to multiple individual discreet anodes that are field connected to form an anode bed.  There are several advantages to using a single continuous linear anode to create a shallow horizontal anode bed:

Shallow Horizontal Groundbed-Linear Anodes
Shallow Horizontal Anode Bed with a Single Linear Anode

Advantages of linear anodes for shallow horizontal anode beds

  • Ease of installation
    The use of a single continuous linear anode assembly can significantly reduce installation time by eliminating numerous field splice connections of multiple individual anodes to a header cable.
  • Reliability
    The entire linear anode assembly is factory manufactured and tested with internal factory connections that are more reliable than a field connection.  The assembly is designed with an internal header cable for redundancy and can be manufactured with an integral external return header cable, eliminating all field splicing and connections.
  • HDD Installation
    The use of a linear anode for shallow anode bed design allows for the use of HDD (horizontal directional drilling) to install the continuous anode assembly.  This can significantly minimize the installation footprint and greatly reduce installation time and costs.  This also allows for a deeper installation to facilitate locations where surface activities such as deep tilling farming operations might preclude a shallower anode system installation.
  • Cost Effectiveness
    The use of linear anodes can be extremely cost effective, resulting in a much lower cost installation. This is especially true when considering the overall cost per amp year given the longer design life of mixed metal oxide based linear anode systems.

MATCOR has extensive experience designing and installing shallow horizontal anode beds, including the use of our HDD installation crews and state-of-the-art equipment to minimize surface impact in sensitive areas.


Contact us at the link below to find out if a linear anode cathodic protection system is right for your application.

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

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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Vapor Corrosion Inhibitors

Are Vapor Corrosion Inhibitors Magic Dust or a Viable Corrosion Prevention Tool?

This article is intended to provide a basic primer on vapor corrosion inhibitors for use in corrosion prevention for above ground storage tanks and address where this technology stands.

There has been a significant effort within the oil and gas world to either promote or repudiate the use of Vapor Corrosion Inhibitors (VCIs) for tank bottom plate corrosion control. As a leader in the above ground storage tank corrosion control industry, MATCOR has partnered with Zerust® Oil & Gas to make VCI options available to our customers that are interested in applying this technology as part of their corrosion mitigation approach.

How Vapor Corrosion Inhibitors Work – Video Courtesy Zerust® Oil & Gas


What are vapor corrosion inhibitors and how do they prevent corrosion?

Zerust Vapor Corrosion Inhibitors can be used in conjunction with CP systems.VCIs are chemical compounds that are released into a confined space, such as the underside of a tank bottom, and diffused through the sand pad material to reach the metal surface. These compounds are adsorbed onto the metal surface forming a strong bond that promotes and maintains a passive oxide layer on the metal and blocks other contaminant molecules from reaching the surface.

Are VCIs a non-permanent solution?

Corrosion protection using VCIs requires sufficient chemical concentration to thoroughly diffuse across the entire tank bottom surface area. The VCI has a finite life, after which it ceases to remain active. When this occurs, further chemical is required to replenish the spent VCI. The frequency of VCI replacement will vary depending a range of factors:

  • The rate of leakage through the tank chime
  • The operating temperature of the tank
  • The sand properties
  • The amount of chemical initially applied
  • Other factors

As VCI technology is still in the early phase of adoption, the typical replenishment frequency remains one of the big unknowns. A conservative estimate would be a minimum of 3-5 years’ service life before replenishment although a least one source has reported upwards of 15 years of effectiveness.

How is VCI applied initially for above ground storage tanks?

There are a variety of application technologies depending on the application and whether the tank is new construction, existing tank during inspection, a tank that is in-service or a double floor tank. Other considerations include the substrate material or concrete pad. The VCI chemical can be provided in a powder or liquid form. Whatever system is utilized to deploy the VCI, consideration should be given to how it will be replenished over the life of the tank.

Can vapor corrosion inhibitors be used in lieu of cathodic protection?

Practically speaking, most tank operators are not looking to replace cathodic protection but are considering VCI as a supplement to cathodic protection or as a short-term solution for inadequate or depleted CP systems until a replacement CP system can be installed.

Can VCI be used as a complement to cathodic protection?

This is where VCI provides an exciting opportunity to supplement cathodic protection. While cathodic protection has a proven track record in corrosion prevention for tank bottoms, there are limits to the effectiveness of cathodic protection. Cathodic protection only works when the tank bottom is in intimate contact with the sand bottom. Localized corrosion can occur wherever there are air gaps under the tank bottom. These can occur due to flexing of the tank bottom, imperfections in the plate steel, lapping of the plate steel, poor compaction of the sand bottom, presence of aggregate or non-conductive materials such as asphalt or oil, and at crevices in the tank ring wall. These are all areas where cathodic protection may not be effective and the proper application of VCI would be an excellent means of providing corrosion protection in these localized areas. Cathodic protection and vapor corrosion inhibitors are symbiotic. CP current distribution has been shown to improve in the presence of VCI.

How do I monitor that the VCI is working?

When applying VCI to a tank bottom, coupons, ER probes or UT probes installed under the tank are used to measure the effectiveness of the VCI and to alert the owner when the VCI requires replenishment. One of the concerns with using ER probes to measure corrosion rates under tanks is that ER probes provide an average corrosion rate and not localized pitting rates. It is understood that pitting corrosion is the dominant factor in tank bottom corrosion related failures and pitting rates can be significantly higher than average corrosion rates. There is a distinct correlation between average corrosion rates and pitting corrosion rates and the ER probes can be used to infer changes in the pitting rates.

Where do vapor corrosion inhibitors stand with industry standards and regulations?

According to API 651, there are several situations where CP is not recommended for specific tank foundation designs. In some of these designs, PHMSA recognizes that CP is not feasible.  In these cases, VCI can be a viable option. API 2610, the Tanks and Terminals standard outlines the use of VCI for tank bottoms in section 12.5. API 651, the CP standard, is being updated currently and VCI is being included as an option in this document. The State of Florida has identified that VCI can be used in tandem with CP or a standalone solution, for more than 6 years. NACE is currently working on publishing a standard “NACE TG543”, which is a comprehensive document on the application of VCI under tank floors. PHMSA is currently reviewing Special Permit requests for the use of VCI without a functioning CP system. If a non-regulated tank’s CP system is not meeting criteria, or has depleted, but the tank is still a few years from its next inspection, VCI can be applied to protect the floor until CP system repairs can be economically accomplished.

What independent published studies exist supporting VCI?

A 2018 study published by PRCI provides the strongest validation of the effectiveness of VCI and concluded that:

  • VCIs were found to be effective in mitigating pitting of steel exposed to corrosive sand but was not as effective as CP for reducing pitting corrosion. The study confirmed the importance of using the manufacturer’s recommended concentrations, as low levels of VCI was found to be ineffective.
  • ER Probes can be used to monitor the efficacy of VCIs
  • VCIs are compatible with impressed current cathodic protection; however, VCIs change the native potential of the steel and this must be considered when selecting CP criteria in accordance with NACE SP0193

Access the full study: PR-015-153602-R01 Vapor Corrosion Inhibitors Effectiveness for Tank Bottom Plate Corrosion Control

In conclusion, the application of VCI is a viable tool in our corrosion tool box that should be considered in conjunction with cathodic protection for critical service applications and as a standalone solution in some applications.


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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Have Extra 2019 Budget Monies?

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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AST Cathodic Protection System Tank Isolation Considerations

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

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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Helium Leak Testing for Cathodic Protection Anodes

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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Manufacturing Quality: What Does It Mean To Be Exceptional?

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?

Manufacturing Quality: ISO Certified

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 Remote Monitoring

This article provides a brief overview of the important role of cathodic protection remote monitoring systems in today’s pipeline operations. We will cover the CP equipment and features that can be monitored and how data is transmitted.

cathodic protection remote monitoring
Advanced cathodic protection remote monitoring systems are critical for today’s pipeline operator.

Modern pipeline operations face increasing pressures to incorporate advanced technologies to:

  • Drive down operating costs
  • Improve system reliability
  • Comply with regulatory requirements
  • Monitor the health of their pipeline networks
  • Monitor the critical systems that are integral to pipeline integrity

The use of advanced cathodic protection remote monitoring systems has become a critical component in the pipeline operator’s toolbox to meet these challenges.

CP remote monitoring (and control) has proven to be a reliable and cost-effective means to oversee the proper functioning of cathodic protection systems and AC Mitigation systems that are critical to assuring pipeline integrity and the proper protection against pipeline corrosion. Where operators in the past would have to send technicians out to remote pipeline locations to collect snapshot data on a frequent basis, the smart deployment of cathodic protection remote monitoring systems can provide continuous real time data that can be accessed from any cloud connected handheld or desktop device. Additionally, a remote monitoring unit for cathodic protection is well-insulated; this construction affords them excellent protection against lightning strikes. The financial, environmental and safety impact of eliminating hundreds of thousands of windshield hours is staggering across the vast pipeline industry.

Cathodic Protection Remote Monitoring – What can you monitor?

  • Cathodic Protection Rectifiers – the installation of RMUs with built in interruption capabilities should be standard on all new pipeline installations and retrofitting older units can provide significant cost savings and improve CP system reliability.
  • DC Cathodic Protection Test Stations – with today’s continuing advances in remote monitoring technology and costs, it is quickly becoming very cost effective to install remote monitoring units on all test stations. When combined with the ability to easily interrupt all of the influencing current sources on a pipeline, regularly scheduled testing of the CP system can be performed quickly and at virtually no cost.
  • AC and DC Coupon Test Stations – the latest NACE guidelines for AC Mitigation (SP21424-2018*) emphasize that the localized DC current density has a significant impact on AC corrosion and gathering data on both AC and DC current densities at areas of interest/risk is critical to a successful AC Mitigation strategy. Effectively doing so requires the ability to monitor these values over time as AC loads vary during the day and seasonally.
  • Critical Bonds – monitoring the effectiveness of critical bonds is necessary (and in many cases required by local regulatory bodies) to assure pipeline integrity.

NACE SP21424-2018 “Alternating Current Corrosion on Cathodically Protected Pipelines: Risk Assessment, Mitigation, and Monitoring”

How does a CP remote monitoring system transmit data?

remote monitoring unit cathodic protection
Mobiltex Cathodic Protection Remote Monitoring Unit (CP RMU)

Today’s operators have a range of options to assure that remote monitoring systems can regularly communicate data to their host data collection systems. The availability of conventional cellular networks combined with various commercial satellite systems assures pipeline operators of the ability to communicate with devices in even the remotest of locations. Your monitoring system provider can work with you to select the appropriate communications technology for each cathodic protection remote monitoring unit (CP RMU) location.

In addition to choosing how the communication is to occur, another key factor to consider is whether the communications are to be one way (monitoring only) or two-way (monitoring and control). For test station applications where data collection is the goal, one way transmission of the monitoring unit’s data is all that is required. For rectifier units, the ability to control the system output and/or the ability to initiate an interruption cycle for close interval surveys or test station polling purposes necessitates the ability of the remote monitoring unit to receive and act on communications as well as to transmit data.

Software Interfaces – Installing the appropriate CP RMU hardware is just one step in implementing a successful remote monitoring (and control) program. The data must be collected, stored, and accessible for the operator. Sophisticated cloud-based interfaces have been developed that incorporate critical features including firewall-friendly, password protected internet browser access. These systems allow for multiple client user accounts with configurable permission levels and automated alarm and status information including email and text alerts for designated alarm conditions.

In summary, the use of remote monitoring technology is a key component to the successful operation of any modern pipeline integrity management program. While MATCOR has extensive experience with all of the major RMU manufacturers, we have recently teamed up with Mobiltex, a leader in the field of remote monitoring, to bring state of the art technology to the pipeline and cathodic protection industry. Mobiltex’s CorTalk® line of CP RMU units combined with their CorView interface offers all the features necessary to implement a comprehensive, cost-effective, and highly robust cathodic protection remote monitoring program.


Please contact us at the link below if you have questions about cathodic protection remote monitoring, or if you need a quote for services or materials.

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