protect your pipe: invest in the next 100 years · invest in the next 100 years. jeff blakely sr....
TRANSCRIPT
Protect Your Pipe: Invest in the Next 100 Years Jeff Blakely Sr. Sales Engineer May 3, 2017
Outline
Introduction
Corrosion Review
Corrosion Protection of DIP
• V-Bio Polyethylene Encasement
• Zinc Coating System
Questions
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INTRODUCTION
INTRODUCTION
Jeff Blakely
• B.S.M.E. from UND
• With AMERICAN for 7 years
AMERICAN
• Founded in 1905
• 2000+ Acres
• Our Divisions
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CORROSION REVIEW: MIC & GALVANIC
Corrosion Mechanisms
Microbiologically Induced Corrosion (MIC)
• Sulfate Reducing Bacteria = H2S
• Acidithiobacillus Bacteria = H2SO4
• Graphitic Corrosion / Pitting
Galvanic Corrosion
• Need – Anode, Cathode, Electrolyte, Current Path
• Break the Cycle = Stop Corrosion
• Galvanic Series
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CORROSION PROTECTION: V-BIO ENHANCED POLYWRAP
V-Bio Polyethylene Encasement
What is it?
• Three Layer Co-Extruded Polyethylene
• Fused into on 8 mil Thick Film
• Inner Layer Infused w/ VCI & Biocide
How Does it Work?
• Eliminates Organisms (MIC)
• Controls Galvanic Corrosion
• Volatile Corrosion Inhibitor
• Prevents Electron Flow Between Cathode/Anode
• Molecular Barrier Between Iron and Electrolyte
• Not a Consumptive Process
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CORROSION PROTECTION: ZINC COATING
History of Zinc Coatings 1670’s – Indian Armor Dipped in Molten Zinc
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1837 – Stanislas Sorel Patented Galvanizing
1958 – Zinc Coated CI Pipe Manufactured in Europe
1982 – AMERICAN Supplied its First International Zinc Coated Order
1984 – DIP Manufacturers in the U.K. Standardized on Zinc Coating
1995 – Zinc Under Bitumen Paint Typical in Europe
History of Zinc Coatings
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Today All Domestic DIP Manufacturers Supply Zinc with Asphaltic Topcoat
International Manufacturers Supply Differing Zinc Formulations and Multiple Topcoat Options (Polyurethane, Epoxy, etc.)
ISO Standards
ISO 8179 - External Zinc-Based Coating
• Part 1: Metallic Zinc with Finishing Layer
• Part 2: Zinc Rich Paint with Finishing Layer
99.99% Zinc by Mass (Part 1)
Applied Via Arc-Spray
Minimum Average Mass = 130 g/m2
• AMERICAN uses 200 g/m2
Minimum Local Mass = 110 g/m2
Finishing Layer
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How is the Zinc Applied?
Pipe Surface Cleaned & Preheated
Arc Spray Process
• High Purity Zn Atomized
• Clean Air Propels Droplets on to Rotating Pipe
• Zn Cools and Adheres to Surface
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Frequently Asked Questions
How much longer will the pipe last?
• Situational but Substantial
• Data from Europe Suggests Hundreds of Years
• 1991 DIPRA Study - Everglades, FL
• 44 Years w/ Zn & w/0 Polywrap
• Zero Measurable Corrosion with Zn & Poly
What Happens if the Coating is Scratched?
• Creates Galvanic Couple
• Zinc Reacts and Leaves Protective Compounds
• “In this process, corrosion by-products known as zinc salts or zinc patina, form a dense, tightly adherent layer between the annealing scale and the finishing topcoat. This layer creates a rugged and long-lasting protective barrier between the iron pipe and the surrounding environment.” (American Galvanizers Association, 2011)
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Frequently Asked Questions
How Much Does Zinc Coating Cost?
• Typically 15% More Than Pipe
• Minimal Compared to Overall Project
Why Do I Need Zinc Without Corrosion Issues?
• Still Extends the Life of DIP
Should I Still Spec Polywrap?
• Economical Insurance – 3% of Pipe
• V-Bio = More Preventative Measures
• Dielectric Barrier
• Reduced Friction in Seismic Event
Can I use Zinc with CP/Can Zinc Replace CP?
• Yes / Depends on Situation
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Frequently Asked Questions
Can I Use Megalug/FastGrip Gasket with Zinc?
• Yes
Are Zinc Coated Fittings Available?
• Yes. Type Depends on Supplier.
How Do I Handle Damaged Zinc?
• Small Areas OK
• Larger Repaired with Zinc Paint
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What You Need to Know
Zinc Coating is a Life-Extension Product
• Proven Track Record (Service/Studies)
• Standardized Product/Application
Becoming the “New Normal”
• Cement Lining (1922)
• DIP vs. CIP (1950’s)
• Push-On Joint vs. MJ (1950’s)
Enhances Already Durable Product
Reduces Life-Cycle Costs
• Pressure Class & Zinc vs. Thicker Wall
• Zinc Coating in-lieu of Cathodic Protection
• Cost of Zinc vs. Overall Project = ROI
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QUESTIONS?