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?