PRESS RELEASE: Make the Shift to More Efficient Gearbox Preservation!

Gearboxes are critical to many industrial activities. While good maintenance during operation is needed to ensure continued reliable performance, proper care can be just as important when the gearbox is out of service. Cortec® shares several suggestions for efficient and effective preservation of gearboxes during shipping or layup.

Standard Layup ≠ Best Practice

The traditional method of gearbox preservation is to completely fill the gearbox with oil and hope it will create a sufficient barrier against oxidation. Unfortunately, it is not economical, environmentally friendly, or practical to use such a large amount of petroleum-based material. It is also unnecessary, since Vapor phase Corrosion Inhibitors offer more thorough preservation at a much lower dose.

gearboxes preservation

Protection That Goes Above and Beyond

Cortec® oil additives such as M-531 and M-535 HV protect in two ways. First, they fight corrosion on metals in direct contact with the treated oil. Second, they release corrosion inhibiting vapors into the gearbox cavity to form a protective molecular layer on metal surfaces above the oil level. This vapor-phase action means the gearbox does not need to be completely filled in order for all areas to be protected. Benefits include money saved, less oil wasted, and easier handling for workers.

Gearbox Preservation Process

Internals: Before preserving a gearbox that will be shipped or stored with gear oil inside, workers should contact Cortec® Technical Services to check additive compatibility with the oil they use. In addition to matching the right additive to the oil, Cortec® can help workers determine proper dosing based on gearbox internal volume and expected oil levels. If desired, gearboxes can even be shipped or stored completely empty by fogging a small amount of Cortec® additive inside.

Externals: Moving parts on the outside of the gearbox can be protected with temporary, (i.e., removable) coatings. VpCI®-369 leaves behind an oily corrosion inhibiting film and works well for moving components such as gear shafts. VpCI®-391 dries to a non-tacky film and is good for protection of static surfaces. If extra protection is needed for long-term/outdoor storage or overseas shipment, workers may wrap gearboxes in VpCI®-126 HP UV Shrink Film or MilCorr® VpCI® Shrink Film (extra heavy-duty) to get an external barrier with additional contact and vapor-phase protection.

Take the Easy, Effective Path to Preservation

Effective gearbox preservation is imperative to ensure that a gearbox is ready to use and continues to operate reliably for as long as possible. Cortec® VpCI® additives make this process easier, more effective, and more economical than the traditional method of filling the gearbox to the top with oil. Contact Cortec® if you need help making your gearbox layup more efficient.

Keywords: gearbox preservation, gearbox layup, efficient preservation, gearbox best practices, corrosion inhibitors, rust prevention, gearbox maintenance, gearbox storage, shipping solutions, Cortec

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PRESS RELEASE: Seasonal Layups Are Not Just for Boilers: Total System Protection

Spring boiler layup season is on its way to the Northern Hemisphere. Those who approach the task with the help of Cortec’s Boiler Lizard® or Boiler Dragon™ will reap the benefits next fall by avoiding many corrosion complications during startup. However, if only the boiler is treated, facility managers may be surprised by corrosion stemming from other parts of the system. In light of this concern, Cortec® reminds boiler operators and water treatment service providers that seasonal layup is not just for boilers.

Seasonal Layups Are Not Just for Boilers: Total System Protection

Why Worry About Corrosion?

Any part of the boiler system that handles water is at risk for corrosion during layup. This includes the deaerator/feedwater tank, steam line, heat exchangers, economizer, and condensate return lines. Unfortunately, a corrosion problem in one area can impact the others. For example, high iron levels may react with water treatment chemicals and make them less effective. Iron in the water also represents metal loss that could eventually lead to leaks and/or shortened service life. Furthermore, corrosion products can plug system components such as steam traps, reducing the efficiency of water recirculation and prompting costly repairs. Inhibiting corrosion in the entire system as part of the normal layup routine can therefore lead to valuable returns on investment.

A Corrosion Inhibitor for Every Component

Fortunately, Cortec’s water treatments are highly adaptable to multiple points of the boiler and steam system. Most traditional water treatments rely on corrosion inhibitors that only protect metal surfaces in direct contact with the treated water. However, technologies such as the Boiler Lizard® and Boiler Salamander™ also include Vapor phase Corrosion Inhibitors that diffuse throughout void spaces and adsorb on metal surfaces in hard-to-reach spaces that are partially or fully emptied.

Dry Layup: Dry layup with Vapor phase Corrosion Inhibitors works for every part of the system. Boiler Lizard® is the main go-to for the boiler water side. This water-soluble pouch of Vapor phase Corrosion Inhibiting powder protects 1,000 gallons (3.8 m³) of volume and simply dissolves when the boiler is refilled. Other options are the Boiler Gecko™ (protects approx. 100 gallons [380 L]) and the Boiler Dragon™ (one gallon protects approx. 1,000 gallons [1 L/1 m³]), Vapor phase Corrosion Inhibitor fogging fluids that can be sprayed into almost any component of a steam generation system:

  • Water side
  • Fire side
  • Deaerator
  • Economizer
  • Steam line
  • Superheater
  • Steam side heat exchangers
  • Condensate return

Wet Layup: Alternatively, some boiler components can be protected with technologies for wet-dry or wet layup. The Boiler Salamander™ works well for this purpose and can easily be added to feedwater or condensate lines and circulated without opening or draining the boiler. It protects surfaces below and above the water level and is effective at very low dosages for layup of high-purity steam boilers. While other parts of the system will inherently require dry layup, the Boiler Salamander™ is appropriate for wet layup of the following components:

  • Water side
  • Deaerator
  • Economizer
  • Condensate return

Invest Now—Reap Rewards Next Fall

Planning takes extra effort, but the corrosion prevention investment pays off in terms of the costs and headaches avoided. Those who have spent thousands of dollars on steam-trap or other corrosion-related repairs will be the most aware of how significant the ROI for comprehensive seasonal layup can be. Contact Cortec® for help to get total system corrosion protection this spring for a better startup next fall!

Keywords: seasonal layup, boiler layup, corrosion protection, corrosion inhibitor, boiler maintenance, dry layup tips, wet layup tips, Vapor phase Corrosion Inhibitors, Cortec, boiler efficiency

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PRESS RELEASE: Fight Corrosion in Concrete Potable Water Structures with MCI®!

What can be done when corrosion protection is needed in a reinforced concrete structure that holds drinking water or is located in an environmentally sensitive waterway? Due to the possibility of harmful chemicals leaching into water, contractors are limited on which products they can apply to concrete elements in contact with potable water. Fortunately, Cortec® Corporation offers a variety of Migrating Corrosion Inhibitor™ products that are certified to meet ANSI/NSF Standard 61 for use in drinking water system components.

Migrating Corrosion Inhibitors

How Migrating Corrosion Inhibitors Work

Migrating Corrosion Inhibitors (MCIs) can be admixed into new concrete and repair mortar or topically applied to existing concrete as a surface applied corrosion inhibitor (SACI). MCI® molecules migrate through concrete pores and are attracted to metal surfaces, such as rebar, where they form a molecular protective layer considered to be ambiodic, or mixed, meaning it inhibits corrosion reactions at both the anode and cathode of a potential corrosion cell.

MCI® Admixtures for Drinking Water Components

MCI® admixtures are sometimes desired for extra protection in potable water reservoirs, prefab pipe segments for transporting seawater to desalination plants, brine holding tanks, and seawalls in sensitive areas where there are leachate concerns. MCI® admixtures certified to meet NSF Standard 61 for use in drinking water system components include the following:

  • MCI®-2005 – A liquid corrosion inhibiting admixture. MCI®-2005 is a USDA Certified Biobased Product that can be mixed into new concrete on the jobsite or at the batching plant. MCI®-2005 retards set time, making it a welcome alternative to calcium nitrite on
    extremely warm days.
  • MCI®-2005 NS – A normal set version of MCI®-2005 that does not accelerate or retard set time.
  • MCI®-2006 NS – A powder MCI® admixture that does not accelerate or retard set time. It is often used in repairs.

MCI® SACIs for Drinking Water Components

MCI® SACIs are typically sprayed onto existing concrete and migrate deeper over time. They can be a great option when application errors in the construction of potable water holding tanks have left a thinner concrete cover than intended and additional corrosion protection is needed. They can also be used for periodic maintenance on structures (e.g., concrete water towers) that were not initially specified with MCI® admixtures but where there is a corrosion concern. The following SACIs are among those certified to meet NSF Standard 61 for use in drinking water system components:

  • MCI®-2020 – A water-based, highly concentrated dose of Migrating Corrosion Inhibitors.
  • MCI®-2018 – Migrating Corrosion Inhibitors combined with a 100% silane based water repellent (a waterproofing membrane should be used when the component will be under hydrostatic pressure).

Extend Service Life of Concrete Potable Water Structures

Corrosion in reinforced concrete structures leads to costly repairs, interrupting the intended use of the structure and potentially reducing its service life. Specifying an MCI® admixture in new drinking water system components at risk for corrosion or periodically applying a maintenance dose of MCI® SACIs to existing tanks and structures can be an excellent way to slow down the natural deterioration processes of corrosion in drinking water system components where higher safety standards exist. Contact Cortec® to learn more about using MCI® to protect potable water structures.

Keywords: alternatives to calcium nitrite, NSF Standard 61, corrosion inhibitors for drinking water components, corrosion inhibitors for potable water, concrete maintenance, from grey to green, Cortec MCI, rusted rebar in concrete, water tower maintenance, concrete admixtures

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