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FEAT RE FEA ATURE


FACILIITI S MTIES MANAGEMEN T


NT


CORROSION RESISTANCE KEEPS UTILITY


CORROSION RESISTA TY INDUSTRY


Del


corrosion from EonCoat s,w ter, e


tricity, a


romgas distribution, drinking water, and sewer piping to electric transmission, distribution, and substation structures, to telecomtowers,much of the utility


F


industry’s carbon steel facility infrastructure is aging and nowbetween 40 and 100 years old. Consequently, the cost of corrosion is on a path to dramatically escalate. “Utilities, which supply gas, water, electricity, and telecommunications serv


rvices, account for the largest portion of annual industrial corrosion costs, with direct corrosion costs tota billion, according to NACE


International’s lling $47.9


report Corrosion Costs and Preventive Strategies in the United States.


The Electric Power Research Institute (EPRI), a non-profit scientific research organisation, estimates that corrosion cost the electric power industry $17 billion in 1998, of which “about 22 percent of the corrosion costs were consi dered avoidable.” Once corrosion starts, often through a breach in traditional barrier-type coatings such as epoxies or polyure coating can act like a gree


water, oxygen and other corrosion promoters. This allows the corrosion to spread quickly under the c which is difficult to inspec


to failure and costly premature


replacement. For these reasons, such coatings are routinely rea pplied at a sizeable cost in facility downtime, surface preparation, and coating application. “Corrosion is a never ending problemto utility facility infrastructure, and


everythingmade of steel is at risk,” says Scott Taylor, President of Taylor’s


Industrial Coatings, a LakeWales, Florida based industrial coatings contractor. “Steel structures are typically recoated every 7-10 years, depending on environmental factors such as rainfall, humidity, and proximity t o amarine environment. ”


Now a new generation of anti-corrosion coatings, called Chemically Bonded Phosphate Ceramics, is poised to cost- effectively stop such corrosion, improve


minimisingmaintenance a industry infrastructure and safety, and significantly ex


28 SPR 28 SPRIING 201


facility life while tend utility


nd downtime. 2017 | ENERG MANAGEMEN ENERGY MANAGEMENT


t, and can lead oating itself,


ll as telecomfacility infrastru ture RY RUNNI NG SMOOTHLY


Del Williams, a technical writer discusses how a new approach to corrosion from EonCoat, may be able to dramatically extend aging gas, water, electricity, as well as telecom facility infrastructure


a t chnicalwr er discusses howa newapproach t ay be able to dramati al


extend agi


TANCE K EEP S LY


because the carbon steel’s surface is turned into an alloy of stable oxides. Once the steel’s surface is stable (the way noble metals like gold and silver are stable) it will no longer react with the environment and cannot corrode.


Visible in scannin g electronmicroscop e photography, EonCoat does not leave a gap between the steel and the coating because the bond is chemical rather than mechanical. Since there is no gap, even if moisture was to get through to the steel due to a gouge, there is nowhere for the moisture to travel, which effectively stops corrosion in utility industry applications. The corrosion barrier is covered by a ceramic shell that resists corrosion, fire, water, abrasion, impact, chemicals, an d temperatures up to 400°F. Beyond this, the ceramic shell serves a unique role that helps to end the costlymaintenance cycle of replacing typical barrier type coatings every 7-10 years.


“If the ceramic shell and alloy layer is ever breached, the ceramic shell acts as a reserv


rvoir of phosphate to continually Figure 1:


Figure 1: EonCoat


nhouse, trapping thanes, the


eas


EonCoat a new tough, Chemically Bonded


at a new ew tough,


Chemically Bonded Phosphat


product ow


Phosphate Ceramic (CBPC) that helps stop corrosion,that ease application, and reduce production downtime


at helps stps stotop corrorosion, ase applica


ction downtime


ate Ceraramic (CBPC catation, and rereduce


PROTE T TECTIING UTILITY A G UTILITY ASSETS E TS


“Utilities are looking for better corrosion coatings that extend the usable lifespan of their facilities whileminimising the need for coating reapplication,” says Taylor. To address these issues, the company turned to EonCoat, a spray applied inorganic coating fromthe Raleigh, North Carolina based company of the same name. EonCoat represents a newcategory of tough, Chemically Bonded Phosphate Ceramics (CBPCs) that can stop corrosion, ease application, and re


reduce production downtime. In contrast to traditional polymer


coatings that sit on top of the substrate, the corrosion resistant CBPC coating bonds through a chemical reaction with the substrate, and slight surface oxidation actually improves the reaction layer is formed. Thismakes it


impossible . An alloy


for corrosion promoters like oxygen and humidity to get behind the coating the way they can with ordinary paints. Although traditional polyme r coatings mechanically bond to substrates that have been extensively prepared, if gouged,


moisture and oxygenwillmigrate under the coating’s filmfromall sides of the gouge. By contrast, the same damage to the ceramic-coated substrate will not spread corrosion in utility facility infrastructure


realloy the steel,” explainsMerrick Alpert, President of EonCoat. “This ‘self heals’ the breach, depending on its size, and stops the corrosion if necessary This capabilit y, along with the coating’s other properties, enables effective corrosion protection for the life of in-serv single application.” Because of the dua


. rvice


l layer of corrosion structures with a


protection and unique self-healing


capability of the alloy layer, the coating is expected to last aminimumof 30 years and carries a 30-year warranty. “The new anti-corrosion approach


essentially triples th e expected lifespan o f traditional coatings and ismuchmore cost effective in the long run for utility facility and infrastructuremanagers who want to protect their assets,” says Taylor. Such coatings consist of two non- hazardous components that do not interact until applied by a standard industrial plural spray systemlike those commonly used to apply polyurethane foamor polyurea coatings. Since CBPC coatings are inorganic and non-toxic, there are no VOCs no HAPs and no odo r. Thismeans the water soluble, non- flammable coatings can be applied safely even in confined spaces.


, Xchanging www.xchanging.com


www.xchanging.com +1 312-662-1859


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