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 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

Aberdeen Branch News

The third branch 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 a technical presentation of “Sour Service Testing of Carbon Steel Girth Welds” by Phil Dent, Element’s Global Corrosion Specialist, followed by a visit to the new H2S / Sour Service Laboratories.

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

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

Ian Farquharson, General Manager of Element Aberdeen and Edinburgh branches, introduced Element, and noted that is ranked as the 5th biggest materials testing and certification firm 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.
Phil Dent started his technical presentation by defining sour service conditions, followed by a description of the 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 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 the 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 also explained.

The corrosion testing laboratory visit was supervised by Paul Roberts, Corrosion and Chemistry Manager, who explained that 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 also 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 international testing standards and protocols such as those from ASTM, IP MIL and NACE. Paul summarised the procedures for the H2S sour service axial tensile test, high temperature / high pressure, electrochemical tests and strain gauging.

Element Laboratory Example of Serious SCC Type Cracking.

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 visit one of the major testing and materials qualifications bodies here in United Kingdom. Overall, it proved to be an excellent event in every respect.
The April evening meeting had 78 attendees, and followed on from a very successful visit to Aberdeen by the Marine Corrosion Forum.

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

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

George Gair of Subsea 7, started 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.

Very clearly the drive is to produce new and robust methods of harvesting sensor data, and subsea hardware suppliers are looking at increased in-situ 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.

Monzar Najami - Principal Inspection Engineer of Oceaneering International.

Monzar Najami – Principal Inspection Engineer of Oceaneering International.

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.

The presenters informed the audience that the greatest challenge to developing and implementing an asset integrity programme 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 delay in the implementation of these activities impedes the Integrity Management Programme (IMP) and increases the level of risk to the facilities in the operating stage.

Key stages in an IMP project were highlighted as:

a) 
Identify stakeholders early in the project (project team, operations, planners, site personnel)
b) 
Define strategies and processes and add activities to the construction plan (integrated project activity approach)
c) 
Analyse historical data (collect the available list of failures, anomalies and review root cause analysis)
d) 
Material fitness for new process (review threats assessment and existing material suitability)
e) 
Baseline inspections: Get in early (define scope and input your inspection requirements in the manufacturer’s ITP)
f) 
Brownfield revamp activities: Scrutinize output (repair recommendations were challenged and resulted in major cost saving, and change in material selection)
g) 
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)
h) 
Deployment of new and advanced inspection technologies (to achieve major cost savings)
A wide range of questions followed the very comprehensive presentation and all the 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. To sign up to the branch mailing list, go to, https://sites.google.com/site/icorrabz/home
ICorr Aberdeen will host its Annual Corrosion Awareness Event on Tuesday 14th August 2018. For further details please contact: Corrosion Awareness Chair, Steve Tate on, steve_f_tate@hotmail.com

Subsea Inspection – The Future by George Gair of Subsea 7 and Integrity Management of Brownfield Projects: Challenges and Rewards by Monzar Najami – Principal Inspection Engineer of Oceaneering International

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)

For copy of the newsletter please click link below:

Aberdeen Newsletter – April 2018 Meeting

 

 

 

 

Sour Service testing of Carbon Steel Girth Welds By Phil Dent Element Global Corrosion Specialist

An industrial visit to 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 a 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 Copy of the newsletter please click link below:

Aberdeen Newsletter – March 2018 Meeting.docx