The Solution

ZERUST^® Integrity Solutions^™, a global leader in corrosion management with over 50 years of experience, provides innovative solutions to prevent corrosion inside pipelines before construction or during downtime. Using advanced Vapor Corrosion Inhibitors (VCIs), ZERUST^® offers reliable and effective corrosion mitigation. ZERUST^® has everal cost-effective options using VCIs for protecting these pipe lengths during pre-construction, pre-commissioning, or during mothballing, layup, or abandonment.

Cost-Effective VCI Solutions for Pipeline Protection at Every Stage
• Preservation of pipe lengths during pre-construction
• Pipeline preservation post-hydrotesting
• Non-commissioned pipeline corrosion protection via misting pig
• Anti-corrosion for pipeline layup through liquid injection

Do you have a pipeline in the pre-construction or pre-commissioning stage for which you need anti-corrosion solutions? Contact us for your corrosion management needs.

 

Preservation of Pipe Lengths

ZERUST^® provides economical and efficient solutions for protecting pipe lengths during transportation and staging using Vapor Corrosion Inhibitors (VCIs). VCI sachets, containing both Vapor and Soluble Corrosion Inhibitors (SCIs), are placed inside the pipe with sealed ends to prevent internal corrosion caused by moisture and condensation.

Cutback Protection: 

• ZERUST^® Inhibitor Fusion Tape (ZIF Tape) protects external cutbacks and beveled pipe ends where welds are made.

Comprehensive Corrosion Coverage:

• VCI molecules adsorb onto bare metal surfaces, even in complex geometries, to provide long-term protection.

Simple and Efficient Application:

• VCI sachets are secured with a string to the end cap for easy removal.
• Provides corrosion protection for several months to years, depending on the application.

This reliable method ensures pipes remain corrosion-free during pre-construction and pre-commissioning, minimizing delays and rework.

 

Pipeline Preservation Post Hydrotesting

After hydrotesting, ZERUST^® offers a solution to prevent internal corrosion until commissioning, eliminating the need for dry air or nitrogen purging.

Inhibitor Slurry Application:

• ZERUST^® Zerion^™ Inhibitors mixed with water are pumped between two pigs (wiper and filming).
• The filming pig applies a thin layer of VCI slurry to internal surfaces.

Comprehensive Protection:

• SCIs neutralize contaminants and moisture on contact.
• VCIs protect gaps, valves, ports, and instrumentation.

Efficient and Effective:

• Compressed air moves pigs, coating surfaces without dried air or nitrogen.
• Proven effective for long pipeline lengths.

This cost-effective method ensures corrosion-free pipelines during pre-commissioning.

 

Hydrostatic Testing of Vessels & Pipelines

Hydrostatic testing, involving pressurizing vessels or pipelines with water, is crucial for ensuring safety and durability. However, residual hydrotest water can lead to corrosion, posing a risk to the asset's integrity. ZERUST^® offers a diverse range of products, including Soluble Corrosion Inhibitors (SCI's), Vapor Corrosion Inhibitors (VCI's), Chelating agents, and pH buffering agents, addressing various corrosion risks. Tailored solutions consider factors like asset geometry, configurations, service life requirements, and compliance with regulations. ZERUST^® hydrotesting formulations not only prevent flash corrosion but also enhance gas pipeline integrity, reducing iron oxide formation and optimizing odorant bloom times, resulting in significant cost savings for asset owners.

 

Non-Commissioned Pipeline Corrosion Protection - Misting

After hydrotesting, ZERUST^® offers an innovative solution to protect pipelines from internal corrosion until commissioning. ZERUST^®  Zerion^™ Inhibitors, mixed with water (often using a vacuum truck), are injected between a lead pig and a filming pig via a pig launcher.

How It Works:

• Compressed air moves the pigs, misting the slurry onto internal surfaces and forming a thin protective film.
• SCIs neutralize corrosive contaminants on steel surfaces, while VCIs protect gaps, valves, ports, and instrumentation.
• Inhibitors remain effective even after water evaporates, neutralizing contaminants and balancing pH.

Efficient and Long-Lasting:

• Suitable for long lengths of piggable pipelines.
• Sealed pipe sections stay protected for years.
• Proven effective on major pipeline projects.

This method provides cost-effective, long-term corrosion protection during pre-commissioning.

 

Anti-Corrosion for Pipeline Layup by Liquid Injection

Low-lying areas of non-piggable pipeline segments are prone to collecting residual water, leading to potential corrosion. ZERUST^® offers a liquid inhibitor injection process to protect these areas during layup.

How It Works:

• ZERUST^®  Zerion^™ Inhibitors are mixed with water, often using a vacuum truck, to create an inhibitor slurry.
• The slurry is pumped into ports at higher pipeline elevations and allowed to flow downward by gravity, treating standing water with SCIs.

Comprehensive Protection:

• SCIs neutralize contaminants and balance the pH of standing water.
• VCIs release vapor molecules that protect steel surfaces and neutralize atmospheric contaminants.

Efficient and Proven:

• Provides long-term corrosion protection for the pipe annulus until commissioning.
• This method ensures effective and reliable corrosion protection for non-piggable pipelines during layup.

 

Zerust Inhibitor Fusion (ZIF) Tape for CUI

ZERUST^® Inhibitor Fusion (ZIF) tape’s advanced features make it a valuable enhancement to the ZERUST^® pipeline protection solution.

• Enhanced Protection for Vulnerable Areas: ZIF Tape provides localized corrosion prevention for cutbacks, weld joints, and components susceptible to corrosion during pipeline staging, hydrotesting, or layup.
• Complement to VCI and SCI Systems: While Vapor Corrosion Inhibitors (VCIs) and Soluble Corrosion Inhibitors (SCIs) protect pipeline interiors, ZIF Tape shields external surfaces,  preventing moisture intrusion and mitigating Corrosion Under Insulation (CUI).
• Durability in Extreme Conditions: With a wide operating temperature range and UV stability, ZIF Tape ensures long-term protection in challenging environments.
• Quick and Easy Application: ZIF Tape’s self-fusing, residue-free design allows for fast deployment with minimal preparation, ideal for time-sensitive pipeline projects.

ZIF Tape is a versatile, durable solution that extends Zerust’s comprehensive corrosion protection systems, safeguarding pipelines and components throughout the construction, staging, and commissioning phases.

 

AVAILABILITY

• Available in 36-foot individual rolls, with width options of 2”, 4”, 12”, and 16”.
• Nominal thickness of approximately 20 mils when unstretched.
• Contact a ZERUST^®  representative for ordering information.