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

  • During Operation

Who?

Oil & Gas Company in Mexico

What?

ZERUST® Flange Saver® protects flanges, valves, and welded joints from the corrosion effects generated by harsh environmental 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®’s 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 excellent corrosion protection for flanges, valves, and welded joints.

Flange Corrosion
Flange Corrosion
Flange Corrosion

This test aims to demonstrate 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 harsh environmental 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 presents serious corrosion problems).

To measure the corrosion rate, we used three external and three internal metal coupons (1010 Steel) as witnesses; three 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 are present in the environment.

TEST RESULTS: Three Months Later:

Flange Corrosion

Metal Plate Analysis: Annual corrosion rate.

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

Flange Corrosion

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 in reducing the level of corrosion on valves, flanges, and welded joints at the customer’s facilities. They maximized the life expectancy by 3 – 10 times. This translates into 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:

ZERUST® Mexico
Teléfono: 01 (81) 1247-5949
E-mail: mexicosales@ntic.com

The ZERUST® Flange and Valve savers have an in-use life expectancy of two years. In addition, the cost is insignificant compared to the related expenses that changing a valve or a flange involves, and they increase the reliability of the equipment by permitting easy access to the valve and flanges that operate at their best.
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