ICorr Aberdeen Branch – Corrosion Awareness Day 2018, (Emerson Automation Solutions)

The Annual Aberdeen CAD Event this year took place at the Training Centre of our Key Sponsor – Emerson Solutions Automation, who generously provided numerous Training Materials, expert Technical Demonstrations and of course some first class Catering.
Our Attendees (45 in all) came from across many different Industries and from many areas of the UK, skilfully co-ordinated by Denise Aldous and Gwynneth Moore at ICorr HQ.
As in previous years, all our Aberdeen Branch Sponsors were invited to send 2 representatives each and there were additionally 20 fee paying attendees who confirmed the event as being excellent value for money

Delegates and Trainers of the 2018 Aberdeen Corrosion Awareness Day, at the Emerson Training
Facility, Dyce with Andy Young (Site Team Manager at Emerson Automation Solutions) in centre.

The Event had 2 Key Objectives:
1). To assist in the development of those unfamiliar with Corrosion Prevention Issues.

2). To raise funds for ICorr, to maintain its ongoing Education Programmes / Events.

In what was a very busy programme, delegates were treated to an excellent mix of Theory and Practical Demonstrations, along with many Exhibits of failed Metallic Components, Coatings and of course a few more modern, Non-Corrodable options.

List of Speakers:

1 – Dr Odagboyi Philip Enegela, Ceng, MIMMM, MICorr, (Repsol Sinopec).

2 – Dr Muhammad Ejaz, CEng FIMMM, MICorr, MPIE, (PIM).

3 – Dr Carol Devine, BSc, PhD, (ICR Integrity).

4 – Dr Nigel Owen, B.Sc D.I.C, Ph.D, MIMMM, (Aberdeen Foundries).

 5 – Stephen Tate, MBA, PG. Dip. Eng, MICorr (CAN/TEPUK).

6 – Hooman Takhtechian, MSc, CEng, MIMMM, (Oceaneering).

7 – Chris Burke, BEng (Hons), MIET, (Emerson Automation Solutions).

8 – Fiona Butters, BA (Hons), (Emerson – Roxar), supported by Ionut Cadar (Emerson Corrosion Solutions Central & Eastern Europe).

 9 – John Thomson, (Emerson – Rosemount).

10 – Steven Healy, (Emerson – Flow Solutions).

11 – Chris Burke, BEng (Hons), MIET, (Emerson – Permasense).

A short CAD Test closed the day, with all delegate’s achieving over 75% pass rate.
Members of the ICorr Aberdeen Committee provided all the morning lectures, with a comprehensive programme covering, Principles and Costs of Corrosion, Corrosion Modelling, Bacterial Corrosion, Cathodic Protection, Materials and RBI – Risk Based Inspection.

The afternoon session was purposely designed to complement the morning session, with demonstrations of all types of Process Control Instrumentation by the Emerson Technical Team – Compositional, Flow, Pressure and Temperature Measurement (for Corrosion Modelling Inputs), Intrusive Corrosion Monitoring Devices of all Types and Non-Intrusive Clamp-on and Magnetic NDT Devices for Wall Thickness Monitoring. All the above instruments provide valuable data for CRA’s – Corrosion Risk Assessments and RBI / Schemes of Examination.

The range of Metallic Materials and Non-Metallic Substitutes on Display, including In-service Failed Components from UK Offshore Production Facilities and many Onshore Applications

Preceding the Demonstrations was a very interesting talk on the full range of Automation Solutions, many now available as APPS for Mobile Devices.
It was very evident, that increasingly the trend is towards data being supplied directly to the Corrosion Engineer, giving them far greater control than was ever possible previously and the development of software programmes that support risk assessments and FFS – Fitness for Service activities. These new ways of working are still supported when required, by data feeds and longer-term trends from conventional DCS – process control systems / panels.

Dr Philip Enegela (Repsol Sin0pec) enthusiastically opened proceedings with insights into Natural Corrosion Behaviours

Dr Muhammad Ejaz (Plant Integrity Management) captured all the key aspects of CO2, H2S and O2 Corrosion Modelling

Dr Carol Devine (ICR Integrity), introduced us to the fascinating world of Bug Growth and Microbial Management

Dr Nigel Owen (Aberdeen Foundries) took us further into the Marine World with his specialist knowledge of CP Systems Supply and the ‘day to day’ operations of an Alloy Foundry.

Stephen Tate (CAN/TEPUK), co-ordinated the 2018 CAD Event on behalf of the Aberdeen ICorr Committee and presented on the theme of In-Service Materials Failures and Site Detailing.

Hooman Takhtechian (Oceaneering), took us into the complex World of Corrosion Risk Management and RBI – Risk based Inspection

Chris Burke (Emerson – Permasense) introduced us all, to Modern Process Automation and Measurement Methods

Fiona Butters (Emerson – Roxar) and Ionut Cadar (Emerson Corrosion Solutions Central & Eastern Europe) neatly explained the concepts of Advanced Intrusive Corrosion Monitoring

Advanced Process Instrumentation and Flow Measurement being demonstrated by Steven Healy (Emerson – Flow Solutions)

John Thomson (Emerson – Rosemount) explained, the many options and principles of Pressure and Temperature Process Control

Afternoon – One to One Discussions in the Emerson Workshops with Chris Burke (Emerson – Permasense)

The day finished with Certificates of Appreciation being issued to all the contributing speakers and CPD Certificates being issued to all attendees followed by a vote of thanks to our excellent hosts Emerson, to whom ICorr Aberdeen is extremely grateful for all their financial support, to its 2018 CAD Event.

At the Close of Play, thanks were given to all of the days Speakers, Dr Carol Devine (ICR Integrity) receives her Certificate of Appreciation from CAD Chair Stephen Tate (CAN/TEPUK)

All the day’s slides may be found under “2018/2019 ICorr Aberdeen Presentations” Folder on our Site.
https://sites.google.com/site/icorrabz/resource-center

ICorr Committee have also obtained all the shared photographs from the day and saved them under ICorr Aberdeen Event Online Album at:
https://photos.app.goo.gl/8F7QkQHpBrCqCj81A

Next year’s Aberdeen CAD Event is now in preparation and will take place at the Palm Court Hotel next year, kindly sponsored by Rosen, (now incorporating Macaw).

Meanwhile, Emerson Permasense will present on the theme ‘Optimising Plant Integrity and Solids Control through Continuous Non-Intrusive Wall Thickness Monitoring’ at Robert Gordon University (RGU) Garthdee Road, Aberdeen, AB10 7AQ, 6pm on 30/10/2018.

ICorr Level 2 Cathodic Protection Senior Technician Marine Metallic Structure Course 22nd to 26th October 2018

Why attend this course?

Certification of cathodic protection personnel competence is a requirement for the cathodic protection industry throughout Europe in accordance with BS EN 15257 (soon to become an ISO Standard). This includes all personnel i.e. Technicians, Senior Technicians/Junior Engineers, Field Engineers, Designers and Consultants carrying out cathodic protection duties such as survey, design, installation, testing, monitoring and maintenance within the UK and Europe. With the ISO this will be international.
This course and examination, for Level 2 Senior CP Technicians, is in compliance with BS EN 15257 and suitable for candidates with a minimum Level 1 experience in cathodic protection, or with Dispensation from ICorr based on education, professional qualifications and experience to bypass Level 1, but note that full Certification to Level 2 by ICorr requires a minimum of four year’s approved marine CP experience (less with a higher level education). The course is likely to be of particular value to, in addition to Level 1 Technicians in this or other sectors:
• Level 2 Senior Technicians Certificated in the Buried or Steel in Concrete sectors
• Engineers in the offshore Oil and Gas sectors involved in cathodic protection
• Engineers and Inspection and Maintenance personnel in the Offshore Wind industry
The location of the course provides special interest allowing for practical measurements to be taken on site at the Harwich International Port Ltd. Particular thanks are due to Dean Tatum, Port Engineer.

Course content:

The topics of this course are fully set out and described in BS EN 15257 for Level 2 at Annex B1 and B3 and cover the application of cathodic protection (CP) to the following marine structures:
• Harbours
• Wharves, pilings and walls
• Jetties
• Subsea structures
• Offshore Wind Foundations
• Offshore pipelines (submerged and buried)
• Offshore platforms
• Ship external hulls

Copy of the brochures, please click link below:

Level 2 CP Senior Technician Course Revised web page entry bsw 290818

A Letter from John P. Broomfield on his Paul McIntyre Award

It is a great pleasure and privilege to receive the Institute of Corrosion, Corrosion Engineering Division Paul McIntyre Award.  Paul was a group leader at the Central Electricity Research Laboratory (CERL) when I joined in 1979.  He was leading a group on fracture mechanics and I worked with him and his team on grain boundary segregation using the techniques I has recently mastered in my DPhil work at Oxford University Materials Department and AERE Harwell.  I also worked on the denting corrosion problem in PWR steam generators, oxide dating as a tool for failure analysis and then on the durability of the reinforced concrete foundations of the supergrid towers.

This led me away from power generation corrosion issues to corrosion of steel in concrete and to Taywood Engineering, the laboratories and consultancy arm of Taylor Woodrow Construction, which was building the prestressed concrete pressure vessels for the Advanced Gas Cooled Reactors.  Taywood diversified into concrete durability which meant that I was fortunate enough to lead the group that designed and installed some of the first impressed current cathodic protection systems on reinforced concrete structures in the UK, Hong Kong and Australia.

Cathodic protection of steel in concrete had been pioneered by the late Dick Stratfull of Caltrans who took the concept of a high silicon iron anode in coke breeze backfill and “flattened it out” to apply to bridge decks.  Using pancake anodes and a coke breeze blended asphalt he created an anode that could be used on trafficked surfaces.  In North America they were not using waterproofing membranes on decks which led to massive potholing problems due to de-icing salt ingress leading for reinforcement corrosion and consequent cracking and spalling of the concrete cover.  Stratfull and others also developed the half-cell or reference electrode technique for measuring the corrosion risk of steel in concrete leading to the development of ASTM C876.

In the UK, Europe and the rest of the world our corrosion problems were different.  As waterproof membranes were applied to bridge decks, the problem was the deicing salt run-off onto substructures.  We were also finding problems with calcium chloride used as a set accelerator on buildings.  Trials were carried out on exposure slabs at Taywood’s Labs for the Transport Research Laboratory and then the first trials were apllied on bridge substructures on the Midland Links Gravelly Hill Interchange.  As these were substructures, conductive organic coatings were used.  Taywood worked with one of the leading technical coatings suppliers, Blundell-Permoglaze, to trial and optimise a suitable coating that has the adhesion, permeability and conductivity to be a suitable anode system for reinforced concrete structures.   Meanwhile we had another trial in a building at Marylebone Station with calcium chloride set accelerator and then the VAT office in Southend where it was applied to the calcium chloride ridden first and second floors.

Anode systems continued to develop, first with the mixed metal oxide titanium mesh and titanium ribbon anodes and then with the probe anodes in grids of drilled holes.  The publication of the NACE Standard RP 0290 swiftly followed by the European standard BS EN 12696 formalised the design, procurement commissioning and operation of impressed current cathodic protection systems for steel in concrete.  One of the most important items was the consensus that the 100mV decay criterion was suitable for steel in concrete.  This mean that the accurate calibration of reference electrodes was not essential and if they drifted with time they could be used as long as they were stable over the polarisation or depolarisation period.  It has been shown that it is impossible to recalibrate a reference electrode embedded in concrete so measuring a shift meant that drift was not important.  An excellent report on the background and theory with a section on its application in concrete is given in NACE Report 35108.

I went to present my early work at a NACE conference in 1987 in San Francisco.  The proceedings of the symposium on corrosion of steel in concrete were published as a book by NACE and has been on sale until recently when all papers became available on line.  On my way back from San Francisco, I stopped in Washington DC to meet the start-up staff of the Strategic Highway Research Program (SHRP), which was spending $150 million on highway research, mostly on durability and $50 million specifically on the assessment and remediation of reinforcement corrosion on highway bridges.  I ended up at Technical Contract Manager for that research and worked with some of the leading researchers and engineers in the USA and Canada working on concrete durability at that time.

On returning from the USA in 1990 I set up my own consultancy and I have worked on corrosion problems in reinforced and prestressed concrete all over the world from the National War Memorial in Wellington to a container port in Zanzibar and design and installation of impressed current cathodic protection during construction on a massive building in the Middle East.  I worked on durability modelling for reinforced concrete with the Building Research Establishment and helped in the development and promotion of resistivity and polarisation resistance meters for reinforced concrete.

I have also been active on National and International Standards bodies which I know was close to Paul McIntyre’s heart.  He and I would see each other occasionally at such meetings as CERL was closed down with the privatisation of the electricity industry.  His death in 2012 was a sad loss to the industry.  I have chaired the committee that revised BS EN 12696 on cathodic protection of steel in concrete and then oversaw its conversion to BS EN ISO 12696.  I also chaired committees that produced the NACE and CEN standards on electrochemical realkalization and chloride extraction of steel in concrete as well as chairing and participating in development of a number of other NACE standards, test methods and reports on corrosion of steel in concrete and early 20th century buildings.

It has been an interesting career so far working with very diverse teams. The projects have ranged from applying cathodic protection to early 20th century steel framed buildings such as Selfridges Department Store on Oxford Street to Spaghetti Junction in Birmingham and a recent fascinating project involving the design, installation and commissioning of a retrofitted galvanic cathodic protection system with a 50 year design life on a dock wall. There have also been interesting tunnel projects in the UK, USA and Canada and basements in the Middle East and the UK.

Click below for copy of the letter:

2018.07.17 PMcIntyre ArticleR1

ICorr Aberdeen AGM meeting & Industrial Visit to Sonomatic- Presentations and Showcasing Kit and Facilities on overcoming and Identifying Corrosion/Integrity Challenges

The 5th branch event of 2018 took place on Tuesday 29th May 2018 with 46 attendees and with 29 CPD Certificate’s issued on conclusion of the Event.

The evening opened with a short AGM and election of a new committee for 2018-2019 session.

Next year’s Technical Meetings will be held at a new venue – The Robert Gordon University (RGU).

In terms of the committee members, Aberdeen Branch have secured continued commitment from all the existing 2017/2018 members. In addition, we have elected a new committee member, Ms. Zahra Lotfi (MICorr, CEng) who will service the branch from the 2018/2019 session.

Also the branch welcomed back a former committee member, Dr. Muhammad Ejaz who took a sabbatical year in the 2017/2018 session and has returned for the 2018/2019 session.

The established formation of ICorr Aberdeen 2017/2018 committee is now as follows:

Officers:

  • Chair: Dr. Yunnan Gao
  • Vice Chair: Mr. Stephen Tate
  • Corrosion Awareness Chair: Bryn Roberts
  • Secretary – External: Mr. Stephen Tate
  • Secretary – Internal: Dr. Nigel Owen
  • Treasurer/Finance Officer: Mr. Alistair Seton
  • Event Co-ordinator: Mr. Amir Attarchi
  • University Liaison and CPD Officer: Ms. Zahra Lotfi

 Ordinary Committee Members:

  • Bryn Roberts
  • Hooman Takhtechian
  • Muhammad Ejaz
  • Philip Enegela.

This month’s meeting  was a very informative Industrial Visit to Sonomatic (ABZ), with many Presentations and showcasing Specialist Equipment and Facilities for Overcoming / Identifying Corrosion and Integrity Challenges.

It was a wonderful opportunity to witness so many different inspection technologies on display together and it was greatly appreciated by all who came along. It was also very interesting to hear about the Links between Industrial NDT as used extensively in the Oil and Gas Industry and Medical applications of these advanced techniques.

The applicability of the use of NII and possible time saving’s, was explained in the context of the main NII Grading’s of Table 4-1 of G103:

  • Type A – No Corrosion likely and Minimum Inspection Requirements / Coverage.
  • Type B – Predictable Corrosion Locations / Moderate Rates and Medium Inspection Requirements / Coverage.
  • Type C – Unpredictable Corrosion Locations / High Rates and 100% Inspection Requirements / Coverage.

A wide range of Non-Intrusive verification methods were demonstrated, along with discussion of Non-Intrusive Codes such as DNVGL-RP-G103 as further developed by HOIS Joint Industry Project and others.The need for close working co-operation between Inspection Teams and Corrosion Engineers was stressed. Also the importance of post inspection analysis / data review and statistical analysis. When correctly calibrated and deployed, these specialist techniques provide an extremely useful 3 dimensional record of the completed inspection with all high risk areas highlighted / colour coded according to depth of corrosion penetration / pitting.

A full tour of the Sonomatic facilities was kindly provided along with an excellent buffet.

The use of LRUT as an effective screening tool was explained in detail to the audience. Weld locations maybe clearly visualised as high amplitude peaks, as illustrated below. When used properly, LRUT flags up areas showing corrosion activity which require further investigation. This does not necessarily stop at the specific location(s) of the indication(s) detected, but it triggers the operator to perform a higher level of investigation. For instance, if defect indications are detected in sections of straight pipe, adjacent elbows or other fittings may warrant inspection using a complementary NDT technique, e.g. CHIME.

CHIME is a semi-quantitative tool used to inspect pipe material located between two UT probes, which can be up to 1m apart. This is ideal method for pipe supports. LRUT indicates only where there is an indication but CHIME® classifies indications into categories of:

a. No corrosion. b. < 10% wall loss, c. 10% to 40% wall loss d. >40% wall loss

Later in the evening the DRS – Dynamic Response Spectroscopy demonstration showed how modern composite coatings / wraps such as Coal Tar Enamel, Neoprene and Multi-Layer Polypropylene could be effectively inspected, highlighting variations in thickness, the ability to detect internal pitting to +/- 0.5mm and any significant coating defects. DRS uses lower test frequencies to deal with these thicker type coatings.

 

 

At the end of the evening, a vote of thanks was given to all the Sonomatic staff, who contributed to this very successful event.

Throughout the evening, wide range of questions followed the very comprehensive presentations and all the presenters’ slides will be available soon on,https://sites.google.com/site/icorrabz/resource-center

Other event photo’s are available on: https://photos.google.com/share/AF1QipO2x5hHaJom3g5ZXwhs6CCqk8sW37gVZjCicIU8HoOVqBTpsiLHuQ9p4t4Y_iK34Q?key=YkduRGtLQzNxcjVRMDlRUnd6NmE1Ujlucmh0dHV3

For information about all forthcoming Aberdeen branch activities, please contact, Dr Yunnan Gao, ICorrABZ@gmail.com.  To sign up to the branch mailing list, go to https://sites.google.com/site/icorrabz/home