Joint Meeting with topic Subsea Inspection – The Future and Integrity Management of Brownfield Projects: Challenges and Rewards

The April Evening Event of 24th April 2018 with 78 attendees, followed on from a very successful visit to Aberdeen by the Marine Corrosion Forum, whose conference contained many informative papers.

George Gair of Subsea 7, commenced the evening session with a thought provoking theme ‘Subsea Inspection – The Future’ that considered many aspects of the current cost reduction environment, where there is a major focus now on how to reduce costs by incorporating new philosophies / technologies.

George Gair – Global Inspection Manager for Subsea 7 presenting to ICorr ABZ

Very clearly the drive is to produce new and robust methods of harvesting sensor data; subsea hardware suppliers are looking at increased in-suite equipment monitoring and intervention methods; the oceanographic community has developed remote seabed environmental monitoring systems. George highlighted many significant indicators that show a definite trend towards smarter systems, a key driver being to learn and incorporate inspection technologies from other industries such as Aerospace, Automotive, Medical and Power Generation, together with more efficient use of gathered data.

Significant Integrity Failure found by Advanced Subsea 7 ROV.

Monzar Najami and Hooman Takhtechian of Oceaneering International followed on with a similarly stimulating discussion on the theme of, ‘Integrity Management of Brownfield Projects: Challenges and Rewards’ highlighting the many important analysis and data gathering areas of modern RBI – Risk Based Inspection methodologies.

Monzar Najami – Principal Inspection Engineer of Oceaneering International

The presenters informed the large audience, that the greatest challenge to developing and implementing an asset integrity program during Brownfield development projects is the fact that project schedule and milestones often take primacy over integrity management processes, and in particular emerging vital integrity related interventions which can lead to conflict and disagreement.  Any delays in the implementation of these activities impede the Integrity Management Programme (IMP) and increase the level of risk to the facilities in the operating stage.

Key stages in an IMP project were highlighted as:

  1. Identify stakeholders early in the project (project team, operations, planners, site personnel)
  2. Define strategies and processes and add activities to the construction plan (integrated project activity approach)
  3. Analyze historical data (collect the available list of failures, anomalies and review root cause analysis)
  4. Material fitness for new process (review threats assessment and existing material suitability)
  5. Baseline inspections: Get in early (define scope and input your inspection requirements in the manufacturer’s ITP)
  6. Brownfield revamp activities: Scrutinize output (repair recommendations were challenged and resulted in major cost saving, and change in material selection)
  7. Tagging and RBA output alignment with the existing CMMS (understand the existing Computerized Maintenance Management System prior to your RBA to avoid major re-work)
  8. Deployment of new and advanced inspection technologies (to achieve major cost savings)

 

A wide range of questions followed the very comprehensive presentation and all presenters slides are available on https://sites.google.com/site/icorrabz/resource-center

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

 

 

Industrial Visit to Element New H2S / Sour Service Lab – Aberdeen Branch March Meeting

The third ICorr Aberdeen event of 2018 took place on Tuesday the 27th March, with 32 attendees representing major companies including: Aberdeen Foundries, ABR Engineering, Atkins, Axiom NDT, CAN Offshore Ltd, DNV GL, ICR Integrity Ltd, Lloyds Register, Lux Assure Ltd, Maersk Oil (now TEP UK Ltd), Oceaneering, One Subsea, Plant Integrity Management Ltd, PROSERV, Shell UK Ltd, Sonomatic and Wood plc.

The event was an industrial visit to the premises of Element Materials Technology in Aberdeen to attend the technical presentation of “Sour Service Testing of Carbon Steel Girth Welds” by Phil Dent, Element’s Global Corrosion Specialist, followed by the visit to the new H2S / Sour Service Laboratories.

An introduction was delivered by Ian Farquharson- General Manager of Element Aberdeen and Edinburgh branches, who declared that Element is ranked as the 5th biggest materials testing and certification firms in the world following its recent merger with EXOVA. He also mentioned that Element Aberdeen is a UKAS and ISO/IEC 17025 accredited laboratory which offers one of the most comprehensive ranges of metallurgical materials testing and analysis services in the UK including mechanical testing, fracture toughness testing, engineering critical assessments (ECA), metallurgy and materials characterization, failure investigation, chemical analysis, corrosion testing and welding engineering services to multi-sector clients around the world.

Phil Dent of Element started the technical presentation by a definition of sour service condition followed by description of various types of sour service cracking mechanisms and the environmental factors affecting the susceptibility of materials under sour service regimes. The sour service cracking mechanisms which were presented by Phil included Sulphide Stress Cracking (SSC), Hydrogen Induced Cracking (HIC), Stress Orientated Hydrogen Induced Cracking (SOHIC), and Soft-Zone Cracking  (SZC). The various test methods such as Four Points Bend test (NACE TM0316), C-Ring test (NACE TM0177, Method C), Full Ring test (BS 8701), and Uniaxial tensile test (NACE TM0177, Method A) were explained by the presenter.

Phil Dent, Element’s Global Corrosion Specialist explains SSC Phenomenon

The corrosion testing laboratory visit was accomplished under supervision of Paul Roberts – Corrosion and Chemistry Manager after a brief introduction of the safety points. The corrosion testing services cover a full range of environmental testing simulations, including pipeline corrosion testing for sour and non-sour applications, hydrogen testing, pitting, full ring tests, as well as SCC tests.

Element Laboratories in Aberdeen, specialise in materials qualification for sour service applications and offer standard HIC, SSC tests and also more specialised Full Ring and SOHIC tests and follow such international testing standards and protocols as ASTM, IP MIL and NACE. The summarised information about the facilities and test procedures for H2S sour service axial tensile test, high temperature / high pressure, electrochemical tests and strain gauging was delivered by Paul.

Element Laboratory Example of Serious SCC Type Cracking

The questions raised by attendees during the technical presentation and laboratory visits were well responded to by the Hosts. This event attracted a high interest within the professionals and executives of major oil and gas operators, engineering consultancies, and service companies in Aberdeen, to attend and take the benefits by visiting one of the major testing and materials qualifications bodies here in United Kingdom. Overall, it proved to be an excellent event in every respect.

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

ICorr International Training Courses

IMechE Engineering Training Solutions are able to offer a range of Institute of Corrosion (ICorr) approved courses internationally.

Delivered by our UK trainers in a range of locations, delegates will be able to access our ICorr courses without the cost and inconvenience of travelling to the UK. The full list of available courses are below:

Course dates

Location Course Date
Chennai, India ICorr Insulation Inspector
ICorr Fireproofing Inspector
21 – 25 May
Perth,
Western Australia
ICorr Insulation Inspector
ICorr Fireproofing Inspector
18 – 22 June
Johor Bahru, Malaysia ICorr Insulation Inspector
ICorr Fireproofing Inspector
16 – 19 July
Perth,
Western Australia
ICorr Insulation Inspecor
ICorr Fireproofing Inspector
ICorr Hot Dipped Galvanizing Inspector
12 -20 November

“An excellent course and appreciated by a range of candidates from Craft Operatives to Engineer grade”
William attended Paint Inspector Level 1 (ICorr), September 2017

Course information

For more information about our ICorr courses, click here. Please note the course dates listed on the course pages are for the UK only.

Course and examination enquiries

If you are interested in any of our international ICorr courses or would like to express an interest in courses being delivered in your region, please email trainingsolutions@imeche.org

For more details, please click link below:

https://trainingsolutions.imeche.org/training/coating-inspection/international-icorr-training

The Paul MacIntyre Award

The Paul MacIntyre award 2018, has been awarded to Dr John Broomfield for his services to the corrosion protection industry by the Institute of Corrosion President Sarah Vasey at the Corrosion Engineering Division working day in Warrington.

The award is presented to a senior corrosion engineer, who, as well as being a leading practitioner in their field, has advanced European collaboration and International standards development (in keeping with Paul’s areas of interest).

The criteria for the recipient of this award are as follows:

  • They have established an international reputation in the field of corrosion engineering.
  • They have demonstrably advanced European collaboration and international standards development in the field of corrosion engineering.
  • They must be living and working in the European corrosion community.
  • They must be a member of a corrosion related body in the European area (e.g. NACE UK, The Institute of Materials, or the Institute of Corrosion, or another European corrosion society).
  • They must not be a current member of the Council of the Institute of Corrosion.
  • They must be aged over 30.

 

Dr Paul McIntyre graduated from the University of Newcastle upon Tyne with a 1st class honours degree. He spent his early career in the steel industry. In 1978 he moved to the Central Electricity Research Laboratories in Leatherhead as group leader of EAC studying stress corrosion, localised corrosion and corrosion fatigue in conventional and nuclear power plants. Later he was involved in asset management and remaining life assessment of components including development of remedial methodologies such as RAM (reliability, availability and maintainability) and RCM (reliability centred maintenance). From 1996 until 2006 he was Editor or the British Corrosion Journal (which became CEST). For six years from about 2004 until 2010 he worked as consultant in the electrochemistry and corrosion group at NPL. His scientific insight and depth of engineering experience was critical to successful analysis of a wide range of failure investigations including fracture of wind turbine bolts, corrosion pitting in a desalination plant as well as providing informed corrosion control guidance to industry. Paul wrote almost 60 published papers and over 200 internal reports. In addition to his career in industry Paul had almost thirty years of participation in corrosion standardisation within BSI and ISO committees. These included being past chair of ISO/NFE 8 Corrosion of metals and alloys, and UK representative on the equivalent ISO committee TC 156 and within that being secretary of WG2 Stress Corrosion Cracking and member of WG 7 Accelerated Corrosion Tests. He made an immense contribution as Scientific Secretary of the EFC. He was also on the Council of the Institute of Corrosion from the early 2000s specializing in standards work and pan European activities. In 2003 Paul was awarded the T B Marsden prize of IOM3 for his considerable achievements in promoting standards, education and publishing in corrosion and materials. The chair of ISO TC 156 stated at the award citation “Paul has provided more input into the development of ISO standards in the corrosion field than any other individual”. Paul was invariably polite and accommodating to everybody. But he had core of steel and dry sense of humour. In 2010 he was diagnosed with secondary liver cancer and very sadly passed away in 2012

Function – Related Dosage of Corrosion Inhibitors The Development of an on-site Operator Deployable Technology

The February event focused on internal corrosion management Issues, particularly corrosion mitigation by chemical control and optimization.    A very enjoyable and informative presentation was given by Emma Perfect, CEO of LUX Assure Ltd, who described the development of an onsite technique for measuring dosage of corrosion inhibitors used in the protection of pipelines. This advanced technique was developed as there was a perceived need to identify more quickly, and more accurately, when dosing levels of inhibitor were either below or above the threshold for protection, and hence allow an operator to adjust levels to better protect equipment from corrosion or have options to lower the dosage level to reduce costs of inhibitor supply.

A well supported event at Palm Court Hotel

Development of the LUX Assure Control Concept commenced in 2008 and the company has been supported by key energy industry players including Chevron, ConocoPhillips and Statoil Technology Ventures, along with the Scottish Investment Bank and Archangels / Private Investors. The technique relies on the fact that corrosion inhibitors form micelles in the body of the fluid once all available sites for absorption are occupied. This is essentially a saturation point, and the micelles formed increase in concentration as inhibitor is supplied in excess of optimal levels.

With access provided to suitable trial sites, the development of the technique and a suitable kit for onsite monitoring progressed over a period of 3-4 years until it was fully commercialized in 2013.  LUX Assure gathered data to show operators that this technique could be used to test fluids and identify the Critical Micelle Concentration (CMC) of a surfactant above which micelle formation occurs. But the real challenge for LUX Assure was to develop a kit, (now known as CoMic TM) which operators offshore could use to sample and analyse fluids in the field in relatively uncontrolled environments without precise preparation. The specialised kit includes detection reagents and an optical analyser. Final data processing evaluation of the sample is still currently performed back at the offsite laboratory and results and advice swiftly communicated back to the field, but a full onsite service is currently being progressed

The presentation, which was well received, went on to describe case studies and discuss when samples may not be suitable for testing, and also the correct use and interpretation of the data for the test situation. It is hoped that in the near future that all data interpretation can be made by the test operator if a practical and proven site assurance system can be developed.

For Copy of the article please click link below:

Aberdeen Branch February 2018 Meeting – Newsletter Vol.1.R1