Oil and gas line pipe

June 16th, 2022

Oil and gas line pipe

Problem

Surplus oil and gas line pipe, ranging in diameter from DN50 to DN200, was left surplus after a project. Externally the pipe had been coated with 700 to 1250 microns of paint and a corrosion inhibitor. The client wished to store the line pipe outdoors but needed to ensure the inside of the pipe also had a corrosion inhibitor applied.

Solution

To protect the internals of the line pipe a VCI corrosion inhibitor powder was blown in from either end and then the pipe ends sealed. End caps were then fitted to enable easy lifting of pipe in the future.

Protection of 3+ years is provided.

Benefits

  • long term corrosion protection
  • quick and easy to apply VCI powder and seal pipes

Barrel Strip

June 16th, 2022

Barrel Strip

Barrel strip is a flexible plastic tube made with vapor corrosion inhibitor (VCI) technology.

It provides targeted corrosion protection for gun barrels, either on long guns or pistols.

Ideal for use as part of a long term storage and presevation regime it comes in two sizes:

Standard caliber: 0.20″ (5.08mm) ideal for 22 rfiles and psitols

Large caliber: 0.25″ (6.35mm) for larger caliber firerams

Zerust Tube Strip

Pontoons

June 16th, 2022

Pontoons

Issue

Two pontoons that provide vital infrastructure access to a mine site needed internal corrosion protection. Each pontoon uses fresh water as ballast as well as containing an air space.

The client required corrosion protection for both the air space and the ballast water.

Solution

The solution was to use GVP100 VCI powder. GVP100 can be used in either a wet or dry layup and is ideal for this application.

A dose rate of 100 gm per cubic metre was used for the air space and 1 kg per cubic metre for the water. For the air space the VCI powder was fogged in, whilst for the water a slurry mixture was made and poured in to the ballast water.

Testing needs to occur at yearly intervals to ensure the VCI concentration is sufficient.

Benefits

  • easy process to protect both the air space and the water.  Can be done by unskilled labour
  • provides long term protection
  • easy process to measure VCI concentration and ensure ongoing protection

Machinery Relocation

June 16th, 2022

Machinery Relocation

Problem

An inexpensive solution was required to protect machinery that was being relcoated from Australia to an overseas destination. The client needed to protect the mqachinery from the elements but also provide corrosion protection.

Solution

The solution was to use X-Rust outdoor VCI film. This VCI film comes in a 5.4 metre width meaning that large items of machinery can be wrappped quickly. The film is UV stabilised and comes with two way shrink, so easily conforms to the item being wrapped when heat is applied.

Electrical cabinets were provided with targeted protection by using vapor capsules.

Photographs show how machine tie downs are incorporated with the VCI film.

Benefits

  • Quick wrapping process due to width of VCI outdoor film
  • Heat shrinkable and quickly conforms to equipment shape
  • Tough and durable as made from 200 micron UV stabilised plastic
  • Corrosion protection as well as protection from the elements
  • Allows equipment to be shipped on deck, reducing freight costs

Heat Exchanger/Boiler Preservation

June 16th, 2022

Heat Exchanger/Boiler Preservation

Problem

A heat exchanger/boiler in an industrial facility needed to be preserved during a plant shutdown.

Solution

VCI powder was used to preserve the internals and a wet layup process was used where the VCI powder was disolved in water. Being environmentally friendly the wet layup solution can be reaidly disposed of.

A dry layup process could also have been used where VCI powder is fogged in to the boiler/heat exchanger.

Benefits

  • Minimal effort in achieveing corrosion protection using wet layup
  • Equipment preserved for an extended period of time
  • Disposal of the water solution

Pumps

June 16th, 2022

Pumps

Issue

Pumps used by the military are refurbished after a period of service. The military require pumps to be operationally ready when pulled from stores.

Solution

Following their refurbishment they are preserved from corrosion using a mix of Mil Spec and commercial off-the shelf (COTS) materials.

In this case the pump has been protected aganist corrosion using the following components:

  • vapor capsule inside the electrical control box
  • plastabs inside junction boxes
  • high performance desiccant inside the package to absorb water
  • barrier film to Mil Spec on the outside

Benefits

  • pump is preserved in the same state as it is after refurbishment
  • operational ready
  • no rework required

Firearms

June 16th, 2022

Firearms

Issue

Firearms are prone to corrosion due to the nature of the materials used in their manufacture.  Whilst desiccants like silica gel can remove moisture from your gun safe they need regular replacing and only work in a passive fashion.

Solution

By using a vapor capsule in your gun safe it provides ACTIVE corrosion protection and only needs replacing every year. The vaopor corrosion inhibitor (VCI) finds its way in to every crevice and protects all metal items. This includes protection for electronic ranging sights or the like.

VCI technology is used by leading manufacturers such as Browning, Remington and Winchester to protect their inventory.

Vapor capsule on the top shelf provides active protection from corrosion for one year

For longer term storage you can use X-Rust gun bags or firearm tube. These products are made from VCI plastic and provide active corrosion protection for 2+ years. Table 1 provides visual evidence of corrosion protection with and without VCI packaging as tested to TL 8135-0002 standard

GreenVCI Polymer Tested to TL 8135-0002
Control sample (without VCI) Protected samples with VCI product

Benefits:

  • inexpensive, quick and easy corrosion protection for gun safes. One vapor capsule will protect a standard single door safe for one year
  • leaves no coating on optics, no effect on fine timbers
  • VCI plastics, in either bag or tube form, offer 2+ years corrosion protection
  • no need to vacuum seal, just close tightly to eliminate air movement.

Specialised Packaging

June 16th, 2022

Specialised Packaging

Problem

The long term secure storage of assets is required. Assets need to be protected from the weather, corrosion and kept secure.

Solution

The items to be protected where packaged in Valsem Titan film. Titan allows for crate free packaging whilst keeping the item secure from both the elements and from tampering.

Benefits

  • Secure packaging film
  • UV resistant
  • Easy to apply and use

Packaged items can also be tracked using Internet of Things (IoT) technology. IoT tracking allows the following parameters to be determined:

  • real time location (GPS, Wi Fi, cell tower)
  • shipment environment (temperature and humidity)
  • shipment integrity (shock, vibration, orientation)

Oil Drilling

June 16th, 2022

Oil Drilling

Problem

A major oil drilling company was looking for an environmentally friendly way of providing lubrication and corrosion protection to wire lines used in their drilling rigs.

Solution

After extensive testing by their inhouse laboratories a biodgeradbale lubricant was selected. Whilst being more expensive than what it was replacing it provides numerous benefits to drilling crews in the field as it acts as a cleanmer, lubrianct and preservative across a wide temperature range.

Benefits

  • Cleans, lubricates and preserves wire lines
  • Biodegradable with ultimate biodgeradbaility (Pw1) within 28 days as per ASTM D-5864 Aerobic Aquatice Biodegradation of Lubricants
  • Reduced environmental cost should a spillage occur.

Electrical and Electronic Equipment

June 16th, 2022

Electrical and Electronic Equipment

Problem

Electronic systems are vulnerable to corrosion with both silver, copper and solder elements susceptible to corrosion.  These metals tend to tarnish rather than rust which results in hot spots forming and the risk of the electronic device failing.  A specialised communication provider of equipment to both Government and military clients globally were seeking to protect various electronic systems.

Solution

Vapour capsules provide targeted, long life corrosion protection.  Easy to install, non toxic and leaving no residue the vapor capsule ensures that the equipment continues functioning as it should with no tarnish or corrosion present.  Protection is offered for either a one year or two-year period. Ideal for use where reliability is of the utmost importance.

The table below shows test results under MIL-STD-3010 method 4031 for vapr inhibitor ability. Evidence of corrosion on the control sample is clearly visible and distinct to the samples protected by VCI

Product Sample Results Test Material Results
Control Grade 0, corrosion present
(S) Sample Grade 2-3, 3, 3 Little to no corrosion

Benefits

VCI vapor capsules offer the following benefits:

  • Longer equipment life and sustained reliability
  • Eliminates hot spots and reduces the risk of electrical fire
  • Reduces operating and maintenance costs due to improved conductivity
  • Reduced downtime and fewer repairs
  • Maintains a clean, high-quality surface with no need to apply circuit board coatings making test and trace activities simple
  • Multi-metal protection including ferrous and non-ferrous metals (silver, copper)
  • Equipment in storage is ready for instant use with no need to pre-prepare asset for deployment