Category Archives: Corrosion

April 24 is Corrosion Awareness Day

Did you know that corrosion costs us an astounding 2.5 trillion dollars globally?

Not to mention corrosion can cost lives and jobs…

Today is corrosion awareness day, so we thought it would be a good idea to reiterate the importance of the NACE IMPACT (International Measures of Prevention, Application, and Economics of Corrosion Technologies) study released in 2016.

According to the study, most corrosion failures, and nearly all catastrophic corrosion failures are preventable. And nearly $875 billion can be saved through the right prevention and risk analysis efforts.

Through the IMPACT study, NACE determined that in order to reduce the astronomical cost of corrosion, we would have to change how decisions are made regarding corrosion. We must not only continue to develop corrosion control methods and technology, but we must utilize organizational management systems and risk tools throughout all levels of an organization to achieve the greatest success in saving lives, jobs and money.

You can learn more by visiting impact.nace.org.

Best Cathodic Protection Paper and Excellence in Corrosion Science at CORCON 2016

We recently joined fellow Brand Energy company SGB Scaffolding and Industrial Services as Silver Sponsors of CORCON 2016. CORCON, held in September in Delhi, is NACE International Gateway India Section’s premiere event in India and NACE International’s 2nd largest conference.

Please join us in congratulating two of our colleagues recognized during CORCON:

Corrosion Awareness Award

Mr. Shailesh Javia, division head for SGB in India, was awarded the NIGIS Corrosion Awareness Award, presented to individuals and institutions for their contribution to corrosion awareness and developments in the field of corrosion science and technology in India.

Best Paper – Cathodic Protection Track

Mr. Ted Huck was awarded Best Paper in the cathodic protection track for his presentation entitled AC Interference Modeling And Mitigation Materials.

In addition to Mr. Huck’s award-winning paper, we presented four additional technical papers at CORCON:

  • Impressed Current Cathodic Protection of Internal Submerged Surfaces of Carbon Steel Water Storage Tanks, presented by Mr. Shailesh Javia, SGB and E. Gopal, MATCOR
  • Atmospheric Corrosion Inspection of Above Ground Piping, presented by Mr. Jeffrey L. Didas, MATCOR
  • Impressed Current Anode Systems for Jetty Piling Protection, presented by Mr. Shailesh Javia, SGB
  • Corrosion Prevention of Aging Pipelines with Deteriorated Coating by Application of Linear Anode ICCP System, presented by Mr. Ted Huck, MATCOR

To learn more about MATCOR’s cathodic protection systems and AC mitigation materials, please visit matcor.com/products. If you have questions or need assistance please complete our web form to connect with our corrosion experts.

To learn more about SGB, please visit sgbgroup.com.

MMO Anode Technology: The latest in Cathodic Protection

MMO anode technology has taken over the cathodic protection industry and MATCOR has been on the forefront for the last 20 years. Ted Huck, our VP of International Sales was interviewed at the recent NACE Corrosion Conference. In this video he discusses MMO anode technology for cathodic protection systems and the importance of reliable anode to cable connections.

MMO Anode Technology

MMO anodes, or mixed metal oxide anodes are the latest technology in the corrosion industry. Mixed metal oxide anodes are lightweight and durable with a very low consumption rate. 

MMO anodes are a mix of metal oxide electrocatalysts. In the presence of a DC voltage source they cause an electrical reaction that generates cathodic protection current. Unlike conventional impressed current anodes that physically consume as part of the cathodic protection reaction (at rates measured in kg/amp-year), MMO anodes are dimensionally stable and do not consume. Instead, they have a long and predictable catalytic life. MMO anodes consist of a thin coating of the MMO catalyst over an inert lightweight titanium substrate and are available in a wide range of shapes and configurations.

Why Cathodic Protection Systems Fail

Waterproof Anode to Cable Connection to protects MMO anode cathodic protection systems
Kynex® Patented, Waterproof Anode to Cable Connection

The most critical component to any cathodic protection anode system is the connection of the anode to the cable that runs back to the power supply. Because the cable is part of the anode system, if it has any nicks or defects or is not water tight, that cable can become part of the anode and will very quickly consume. When that happens, the anode fails. So, with cathodic protection systems it is imperative to have the highest quality connections.

Typically, when a cathodic protection anode system fails, it is not the anode that fails, it is the anode connection that fails. MATCOR has developed a proprietary technology for connecting wire anodes to cable, called Kynex®. Wire anodes are the heart of a lot of our products and this proprietary anode technology is a huge leap forward in the reliability of these connections.

Cost-effective, Reliable Cathodic Protection Solutions

At the end of the day, for our clients, it’s all about delivering value. It’s providing a cost effective solution that’s going to serve them for a very long time. As a designer and manufacturer of cathodic protection anode systems, we are able to specifically address client needs with customized corrosion prevention solutions that provide:

  • Long life
  • Great economic value
  • Superior reliability

MATCOR Products and Services

MATCOR is one of the world’s leading cathodic protection companies. We design, manufacture, install and service cathodic protection systems for clients worldwide. MATCOR provides services to the pipeline, midstream and oil & gas industries, protecting assets such as pipelines, storage tanks, and compressor stations. We also do a lot of work in the power industries, petrochemical, and chemical industries. Anywhere where you have buried steel structures, we are there to stop corrosion.
We encourage you to contact MATCOR through our website where our corrosion specialists and engineers can provide a solution tailored to your needs.

MATCOR Profiled in India Corrosion Publication

MATCOR Profile in Coatings and Anti-Corrosion Engineering Review, Apr/May 2015 issueThank you to Abraham Mathai at Coatings and Anti Corrosion Engineering Review for the profile about MATCOR and our 40th anniversary in the April/May 2015 issue!

MATCOR was founded in 1975 by William R. Schutt when he set out to develop a high quality, reliable source for cathodic protection products and equipment. The company designed and provided the first commercial cathodic protection system for reinforced concrete bridge decks that same year. The company has grown to offer a broad portfolio of proprietary cathodic protection and AC mitigation products, in addition to complete corrosion engineering services.

In March of 2015, MATCOR was acquired by Brand Energy & Infrastructure Services (Brand). Brand also owns CP Masters, Inc., a leader in the design and construction of cathodic protection and corrosion control prevention in the North American energy markets.

READ THE COMPLETE PROFILE

MATCOR Celebrates 40 Years Protecting the World’s Infrastructure from Corrosion

Chalfont, PA (Jan 16) – MATCOR, Inc. the trusted full-service provider of proprietary cathodic protection products, systems, and corrosion engineering solutions is celebrating its 40th anniversary throughout 2015.

matcor-40th logoIn 1975, William R. Schutt founded MATCOR, setting out to develop a high quality, reliable source for cathodic protection products and equipment. That same year, the company designed and provided the first commercial cathodic protection system for reinforced concrete bridge decks. Today, Mr. Schutt serves as MATCOR’s Chairman.

MATCOR has built a broad portfolio of proprietary products. The company received its first patent in 1984 for its deep anode cathodic protection system, the predecessor to today’s Durammo™ Deep Anode System. Other patented products include Kynex® waterproof anode to cable connection technology, the SPL™-INT-Anode for internal pipeline cathodic protection, the ORB™ Marine Anode and a precast anode plate system for use in steel-in-concrete applications.

In 1987, MATCOR experts served as part of the White House delegation to the Soviet Union under Ronald Reagan, invited for their expertise in concrete and construction infrastructure. The company has also received numerous safety, technical and industry awards in its 40-year history.

The company has grown from manufacturing and supplying cathodic protection products to offering a full array of turnkey cathodic protection and AC mitigation services and products.

William Schutt Web-1MATCOR is located in a state-of-the-art ISO 9001:2008 certified facility in Chalfont, PA. With a service office in Texas since 2006, an office opened January 2015 in India and a growing list of international distributors, MATCOR has established global reach in the corrosion industry. In 2014, the company delivered products and services to over 25 countries.

MATCOR Chairman William Schutt said, “MATCOR’s 40th anniversary is a tremendous milestone for the company. We’ve succeeded not only in our vision to become a reliable source of cathodic protection products; MATCOR has become a trusted global leader for both products and engineering services throughout the corrosion industry.”

ABOUT MATCOR

 

MATCOR to Present Two Technical Papers at Mumbai, India Corrosion Conference

Chalfont, PA – November 4, 2014, MATCOR, Inc., the trusted full-service provider of proprietary cathodic protection products, systems and corrosion engineering solutions, will present two technical papers at CORCON, NACE International Gateway India Section’s premier conference, taking place at the Hotel Grand Hyatt in Mumbai, India November 12 – 15, 2014.

Continuous MMO Wire Deep Well Anode System

Shailesh Javia
November 13, 9:00 – 11:00
Hall A, Cathodic Protection 1, Paper CP11

This presentation examines a self-contained deep well anode system for cathodic protection of cross country pipelines, city gas pipelines, plant piping and well casings, ideal in congested areas where land is a constraint. The system utilizes a titanium wire with a mixed metal oxide thermally applied coating as the active anode element. The continuous anode element is factory assembled with continuous integral vent pipe and lowering rope to simplify installation.

Learn about MATCOR’s deep anode solution.

Pipeline Integrity Management – International Overview

Ted Huck & Shailesh Javia
November 14, 2014, 14:00 – 15:30

Hall D, Structural Integrity and Reliability Assessment, Paper SI11
This presentation will provide an overview of Pipeline Integrity Management programs utilized in the United States and around the world highlighting some of the key aspects of a successful program including; initial pre-assessment efforts, collecting and managing indirect survey data, the importance of direct examinations, risk assessment and reporting practices.

Learn about MATCOR’s Pipeline Integrity Management Services.

ABOUT THE AUTHORS

Mr. Ted Huck, Vice President International and Practice Lead for MATCOR is an electrical engineer and a recognized expert in cathodic protection, authoring over a dozen articles in a wide range of publications and speaking at corrosion conferences worldwide.

Mr. Shailesh Javia is an electronics engineer and NACE certified Cathodic Protection Technologist with 22 years of experience focused on corrosion engineering and cathodic protection. His diverse portfolio includes the design of cathodic protection systems and managing turnkey projects for cross country pipelines, plants, tank bottoms, tank and vessel internal cathodic protection, city gas pipelines, post commissioning surveys and handling complex interference problems on cross country pipelines.

ABOUT MATCOR

New Energy Report Underscores Need for Cathodic Protection Systems to Prevent Corrosion

Energy Report - Gas Regions in US
Source: U.S. Energy Information Administration

In a recent update to its drilling productivity energy report, the Energy Information Agency revealed that there are now three US oil fields that are producing more than one million barrels of oil a day (BPD). In North Dakota, the Bakken Shale has been a major economic boon for the region while in Texas the Permian Basin and Eagle Ford Shale have both exceeded predictions. As oil and natural gas continues to expand in these regions, the need for cathodic protection systems to prevent corrosion grows.

The three fields are so prolific that they now account for at least a third of the total US daily oil production. In fact, Mark Perry of the American Enterprise Institute found that the output of the three combined fields now surpasses 4 million BPD.

Each of these regions has seen rapid growth that is nearly unprecedented in the United States. The Bakken oil production was less than 200,000 barrels per day in 2008 and is now producing around 1,100,000, an increase of 450% in just over five years.

Meanwhile, in Texas, Eagle Ford’s natural gas production has tripled in the last three years and oil production has also flourished in recent years. The region was producing less 100,000 BPD in 2010 to more than 1,400,000 BPD in 2014.

Finally, wells that had been previously drilled in the Permian zones have found new life with the development of horizontal drilling techniques. Historically, wells had a 34 percent recovery rate, but that benchmark is being challenged with new technologies.

“This Energy Information Agency report is yet another reminder that oil and gas production in the United States will continue to flourish in the years to come,” said Chris Sheldon, utilities practice lead at MATCOR. “With such rapid growth, however, it’s vital that infrastructure is built to accommodate the changes. That means building it fast, but also building it right.”

“Cathodic protection systems, like those produced by MATCOR, ensure the safety of oil and natural gas production and delivery assets.”

Learn More About Cathodic Protection Systems

MATCOR is a corrosion prevention firm that engineers, manufactures, installs, commissions and maintains a proven range of turnkey proprietary cathodic protection and AC mitigation systems worldwide for the oil & gas, power, water/wastewater and other infrastructures industries.

Contact a MATCOR corrosion expert by completing our contact form or calling +1-215-348-2974.

Elite oil fields redefine meaning of crude’s ‘Big Three’,” CNBC, July 27, 2014.

Bakken Oil Production Boom Could Result in Greater Cathodic Protection Needs

Bakken Oil ProductionAfter eight years of extensive oil exploration to define the Bakken formation boundaries, oil production companies are ramping up drilling operations to “harvest” the Bakken oil formation.

There are currently more than 10,000 producing wells in North Dakota, with the majority in the Bakken region. The expansion of oil production has grown at an exponential rate and the area will soon be producing 1 million barrels a day.

While there’s currently a well located on nearly all of 8,000 spacing units, there remains plenty of opportunity to increase well density in the region. In 2013, the permit applications were limited to four wells on a single 1,280 acre unit, but the maximum is expected to increase from eight to 20 wells per unit, depending on the local geology.

As oil companies drilling in the Bakken formation continue to increase well density, the region could see another phase of this oil boom.

“The Bakken area has enjoyed great success over the last decade, and with more opportunities for companies drilling in the Bakken oil field, it’s vital that they protect their assets,” said Glenn Shreffler, executive vice president, engineering at MATCOR.

“Protecting future investments from the devastation caused by the corrosion of pipelines and storage tanks is paramount as the Bakken region continues to see expansion of oil production,” said Shreffler. “Cathodic protection is among the most cost effective means and efficient ways to halt corrosion activity.”

In business for almost 40 years, MATCOR specializes in providing customized corrosion engineering and cathodic protection systems to oil and gas industries nationwide.

Oil lands claimed, the focus shifts now to ‘harvesting it,” The Bismarck Tribune, February 25, 2014.

MATCOR to Participate in Middle East Corrosion Conference and Exhibition

Chalfont, PA – February 2, 2014, MATCOR, Inc. the trusted full-service provider of proprietary cathodic protection products, systems and corrosion engineering solutions, announces the company’s participation in the 15th Annual Middle East Corrosion Conference and Exhibition in Bahrain from February 2th through 5th.

“MATCOR has a long history of providing proprietary anode solutions to clients around the world including North Africa, the Middle East and Asia,” said Douglas Fastuca, president of MATCOR. “We are pleased to be sending a representative to participate in this region’s largest corrosion conference.”

MATCOR is a respected innovator in the development of impressed current cathodic protection anode systems and has received numerous patents for its custom anode solutions that protect buried gas and water pipelines, above ground storage tanks, near shore marine structures including piers, docks and sheet pile walls, and reinforcing steel in concrete structures.  Featured as one of Forbes’ Magazine’s fastest growing small companies, MATCOR continues to expand its presence in markets globally while maintaining its leadership position as an industry innovator.

MATCOR Iron Gopher® HDD Cathodic ProtectionMATCOR’s most recent innovation is the patented Iron Gopher®, the industry’s first linear anode product developed specifically for horizontal directional drilling (HDD) installation.  For further technical and product information about Iron Gopher or any of MATCOR’s innovative cathodic protection products, or to contact your MATCOR Account Manager, visit www.matcor.com or call (US. & Canada) 1 800-215-4362 (Worldwide) +1-215-348-2974.

ABOUT MATCOR

MATCOR is a full-service, ISO 9001:2008 certified provider of customized cathodic protection systems to the oil & gas, power, water and other infrastructures industries. Cathodic Protection is a technique used to control the corrosion of a metal surface through the application of electric current. MATCOR has an array of proprietary cathodic protection products and systems combined with high-quality corrosion engineering, installation and maintenance services.

In business for 40 years, MATCOR is considered the technology leader in the cathodic protection and corrosion engineering fields. MATCOR is headquartered in Chalfont, PA, has a service office in Houston, TX and recently established a presence in Ahmedabad, India. The company provides turnkey services throughout the United States and has a growing list of international distributors. MATCOR has been named to the Inc. 5,000 list of fastest growing companies in 2011, 2012 and 2013.

Pipeline Petroleum Transport Investment May Predict Growing Cathodic Protection Needs

If Warren Buffet’s investment strategy is any indication, pipeline efficiency is going to start playing a bigger role in moving crude oil and natural gas in the United States.

The Berkshire Hathaway luminary is pipeline-efficiency-cathodic-protectionspearheading a swap of about $1.4 billion in shares of Phillips 66 for full ownership of the energy company’s pipeline petroleum transport services business. The business unit’s focus is polymer-based additives that are used to move crude oil and natural gas through pipelines more efficiently by reducing drag.

The shift in Berkshire’s investment strategy comes amid a boom in U.S. crude oil and natural gas production. Since many liquids pipelines in the United States are operating at capacity, producers can use the pipeline petroleum transport additive to quickly increase capacity without immediately growing pipeline infrastructure.

Although future pipeline projects may be in the works to meet the sharp increase in demand, the process of gaining approval for new pipeline projects can be slowed by permitting.

A greater reliance on existing pipelines for transporting liquids means that producers and pipeline owners need to pay even more attention to cathodic protection management, according to Kevin Groll, project management director for MATCOR, a Pennsylvania-based company that specializes in cathodic protection products and services.

“Any time you have pipeline you have to protect it from corrosion,” Groll said. “And that’s especially true when you increase the value of a pipeline by increasing its capacity. If that pipeline were to develop a corrosion problem you’d be facing a situation where your profitability could suffer significantly.”

“With pipeline owners using additives to push greater volumes of liquids it becomes imperative to use cathodic protection products such as impressed current anodes and cathodic protection rectifiers to protect the increased capacity and profitability of the pipeline infrastructure.”

Further Reading

Berkshire Swaps $1.4 Billion in Phillips 66 Stock in Deal,” Bloomberg, December 31, 2013.