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Zerust® Mitigates Corrosion on Valves, Flanges, and Welded Joints

  • During Operation

Who?

Oil & Gas Company in Mexico

What?

Zerust® Flange Saver® protects Valves, Flanges, and welded Joints from the corrosion effects generated by tough environment conditions with the presence of acid gases.

Why?

The customer requested Zerust® put together a product trial to evaluate the effectiveness of Zerust® Flange Saver® corrosion protection on five valves and flanges on a selected site as part of a gas line pilot field test.

How?

Zerust® Flange Savers® are specially designed modules that have been impregnated with proprietary Zerust® inhibitor formulations that provide superlative corrosion protection for flanges, valves, and welded joints.

Flange Saver
Flange Saver
Flange Corrosion

The objective of this test demonstrates the efficiency of Zerust® Flange Savers® anti-corrosion protection system for valves, flanges, and welded joints, to protect their physical and mechanical integrity from the corrosion effects generated by tough environment conditions with the presence of acid gases. The test was carried out in compliance and in accordance with the customer’s guidelines regarding “Procedures to incorporate new technologies and best maintenance practices”.

To evaluate the effectiveness of  Zerust® Flange Savers® corrosion protection on five valves. The Flange Savers® were installed on a selected site as part of a gas line pilot field test. The flange (PTP6) was located on the SVMP-1 Vertical separator because of the presence of acid vapors and its contrast with the external temperature (this area of the pipe and flange is always wet and generates moisture and obviously presents serious corrosion problems).

To measure the rate of corrosion, we used three external and three internal metal coupons (1010 Steel) as witnesses, three of them were enclosed in the valve and flange body and another series of three witnesses were left exposed outside.

At the end of the trial period (3 months), all the coupons were recovered and cleaned in our laboratory, the weights of the interior and exterior controls of each case were compared with its initial weight, and the weight difference of the coupons permits determinate the annual corrosion rate at which each valve and/or flange is exposed, and the protected witnesses showed the corrosion protection degree of that Zerust® Flange Savers® valve protectors and flanges provide.

Test Ambient Conditions:

  • Relative Humidity Range: 50% to 95%
  • Temperature: 10ºC to 37ºC
  • Cl and traces of H2S y SO2 present in the environment.

TEST RESULTS: Three Months Later:

Flange Corrosion

Metal Plate Analysis: Anual corrosion rate.

  • With Zerust® Protection =  170 mm/year
  • Without Zerust® = 190 mm/year
  • 25 Times valve life expectancy in tough environment conditions.

Zerust® Flange Savers® provide corrosion protection
For up to 2 years on flanges


Zerust® Flange Savers® provide corrosion protection
For up to 2 years on valves


Customer Satisfaction
100%

Results

Zerust® Flange Savers® proved to be a very efficient aid to reduce the level of corrosion on valves, flanges and welded joints at the customer’s facilities and they maximized the life expectancy by 3 – 10 times, this translates in cost reductions by eliminating:

  • Valve or flange costs
  • Replacement bolts nuts and seals
  • Welding process and costs
  • Production loss
  • Hydrostatic tests
  • Waste disposal
  • Labor costs

In need of a corrosion consultation in Mexico? Contact:

Raul Ducoing Arjona
Director De Ventas y Mercadotecnia Mexico y Latino America
Northern Technologies International Corporation NTIC
Tel. 55 91541805  Cel. 044 55 54515071
rarjona@ntic.com

The Zerust® Flange and Valve savers have an in-use life expectancy of two years, the cost is insignificant compared to the related costs that changing a valve or a flange involve, and they increase the reliability of the equipment by permitting easy access to valve and flanges that operates at its best.
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