ZERUST® Corrosion Mitigation for Underground Pipe Casing with Residual Water Presence in Illinois, USA
ZERUST® Corrosion Mitigation for Underground Pipe Casing with Residual Water Presence in Illinois, USA
ZERUST solutions overcoming residual water challenges in underground casings
Project Details
Location: Illinois, USA
Date: December 2024
Contractor: TerraWorks LLC
Client: Confidential
Project Summary
ZERUST® Integrity Solutions (ZIS), in partnership with TerraWorks LLC, implemented a corrosion mitigation system for a 36-inch x 30-inch underground pipe casing. The project included site assessment, injection of a customized corrosion inhibitor solution, and installation of monitoring equipment. The goal was to extend the service life of the casing and provide ongoing monitoring capability.
Asset & Site Details
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Asset ID: Pipe Casing
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Casing Diameter: 36 inches (≈ 914 mm)
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Pipeline Diameter: 30 inches (≈ 762mm)
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Length: 198 feet (≈ 60.3 meters)
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Vent Pipes: Two 2-inch (Top orientation) (≈ 51 mm)
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Elevation Changes: Minimal
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Weather During Application: Visit 1: 17°F (-8°C), 45% humidity, Sunny. Visit 2: 43°F (6°C), 70% humidity, Fog, Cloudy
Solution Implemented
Products Used
• ZERUST® Zerion™ FVS Corrosion Inhibitor Powder
• ZERUST® Zerion™ PGH-300 Gel and PGH-400 Gel Powder
Monitoring
- Electrical Resistance (ER) Corrosion Monitoring Probe (CT-20, 20-ft cable length)
- Enardo Lever-Type Pressure Relief Valve
Implementation Details
Injection was delayed until excavation was complete. During the second visit, residual water was identified and treated with a 10% corrosion inhibitor solution formulated with ZERUST® Zerion™ FVS-S15 Corrosion Inhibitor Powder and ZERUST® Zerion™ PGH-300 and PGH-400 Gel Powders, injected in 250-gallon intervals using a 2-inch Eductor system. A total of 975 gallons (3,690 liters) was applied, displacing ~5 gallons (19 liters) of water. The ER Probe and Pressure Relief Valve were installed, and site personnel received IDS training.
Outcome
The corrosion mitigation solution was successfully implemented at adjusted concentrations. Monitoring equipment is now in place, and ongoing data collection from the ER Probe will enable continued performance analysis. The project positions the asset for extended service life and reduced corrosion risk.
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For More Information
Contact a ZERUST® representative regarding any questions about this report.
