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

The branch kicked off 2018 with 3 well attended events

The branch kicked off 2018 with 3 well attended events

The branch kicked off 2018 with 3 well attended events with an average attendance of over 60 people, beginning with a special cathodic protection evening on the 30th of January. In the first of two presentations, Edgar Rodrigues of TAQA gave an excellent talk on “Impressed Current Cathodic Protection Retrofit Strategy in the North Sea”.

TAQA’s fixed drilling and production installation was installed in the North Sea in 1980 in 161 metres water depth approximately 110 miles north-east of Lerwick in the Shetlands.   The platform jacket has 8 legs and was installed with traditional stand-off galvanic anodes, but its sacrificial CP System is now beyond its original design life.   Surveys from 2010 to 2013 indicated a reduction in corrosion protection from the CP system, and plans were implemented to upgrade this. A remote impressed current CP (ICCP) anode sled system was selected, installed and commissioned in early 2016. This presentation discussed the CP design process and the many challenges in choosing what was at the time, the largest ever CP retrofit, both in terms of delivered current capacity offshore, and the CP current demand of the structure required to maintain external corrosion protection.  All retrofit CP systems however require regular CP data to validate CP performance and this can often be erratic and costly to obtain, typically involving ROVs, as was discussed in the second presentation of the evening.   

Andy Smerdon of Aquatec Group continued the evening with a very interesting and complimentary presentation on “Retrofit CP Monitoring to Reduce Inspection Frequency”.   Aquatec was founded by the current managing director in 1990 as a specialist consultancy in oceanographic instrumentation design.  This presentation described a CP toolbox within a UK North Sea case study, comprising monitoring and communications modules that were used to provide high quality CP potential and CP current data sets, accessed remotely from diving vessels and platforms.    The cost of CP monitoring equipment when simultaneously installed with retrofit CP systems, is relatively low and normally recovered by dispensing with just one conventional subsea inspection campaign, in favour of remotely retrieved data.

The branch’s second event in January, took place at the School of Mechanical Engineering at Aberdeen University, where a Corrosion Awareness training session was held. In the packed two hour event, there were 6 presentations covering corrosion theory and failure mechanisms, principles of corrosion management, materials and coatings selection, risk based inspection, cathodic protection, chemical and corrosion monitoring, all of which prompted a number of interesting questions from the enthusiastic audience.

Retrofit CP Monitoring

In recent years, ICorr Aberdeen has established a strong working relationship with the Aberdeen branch of IMECHE and in particularly its Young Engineer Panel, and a further more extensive Corrosion Awareness event will follow in August 2018, details will be announced in the May/June magazine, and on the branch website.

The February event focused on internal corrosion management Issues, particularly corrosion mitigation by chemical control and optimisation. 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.

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 CoMicTM) 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. 

CoMic Testing Kit

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 information about all forthcoming Aberdeen branch activities, please contact, Dr Yunnan Gao, ICorrABZ@gmail.com, alternatively a calendar of local events of interest to corrosion professionals in the Aberdeen area and the opportunity to sign up to the branch mailing list is available at https://sites.google.com/site/icorrabz/home

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

 

 

 

Aberdeen Joint Event with Mining Institute of Scotland (MIS) and IOM3  Oil and Gas Division

Aberdeen Joint Event with Mining Institute of Scotland (MIS) and IOM3 Oil and Gas Division

The Branch continued its successful 2017-2018 session with a high turn-out (68 attendees) at its joint event with the Mining Institute of Scotland (MIS) and IOM3 Oil and Gas Division, (Over the last few years MIS has established a strong working relationship with the Aberdeen branch and holds an annual joint technical evening that is funded alternatively).

The key topic under discussion was Corrosion under Insulation (CUI).  This is a major issue for not only the oil and gas sector, but industry in general, with an estimated annual cost to the UK of £28 billion. The event started with a buffet and a poster presentation from Tianyang Lan, a MSc student from Northampton University, who presented the experimental work that he had been undertaking, assessing both physical and electrochemical techniques for measuring CUI.  Two physical methods and two electrochemical methods were used in this test work, Eddy Current Testing (ECT), IR Thermography (IRT), Electrochemical Impedance Spectroscopy and Electrochemical Noise Method (ENM). The samples used to conduct the experiments were carbon steel panels at different corrosion stages, used to simulate the pipe condition, with standard maintenance organic coatings and insulation tapes representing the pipe insulation. Results have indicated that ECT/IRT could not discriminate rusting beneath a coating when it was greater than about 250microns thick however the electrochemical methods showed immense promise. Insulation of course covers all signs of corrosion.

MIS, with IOM3 Oil and Gas Division, had arranged two technical presentations. The first was given by Rebecca Allison of the Oil and Gas Technology Centre, (OGTC, a public / private initiative), who introduced the topic of CUI and the role of the OGTC in addressing the challenges of CUI.  Rebecca provided an overview of new technologies being supported by the OGTC and got comprehensive feedback from the audience on these, however she highlighted that addressing CUI is not just about technology, a holistic approach including working practices, procedures, competency, human factors and data management is required.

Bill Brown and Mike Dixon of The Rope Access Company (TRAC) then built on the overview provided by Rebecca with a presentation providing results from their field and yard trials assessing the latest tools and techniques available to measure and analyse CUI, which included developments with pulsed eddy current and digital radiography.   Field and yard work highlighted key issues for practitioners to be aware of.   

The Oil & Gas Industry has experienced many challenges when inspecting for Corrosion under Insulation (CUI), assessing the condition of steel components under Engineered Composite Wraps and the minimum remaining wall thickness under surface scabs / blisters. The aim of their OGTC supported project is to try and determine the limitations of the available NDT methods relative to each application. TRAC plans to share the ongoing research and development overview obtained to date.

At closing, a warm vote of thanks to all the presenters was made by the new MIS President Bob Laird for their valuable contributions which were very much appreciated by all those in attendance.  Next year’s joint meeting is already scheduled for 27 November 2018 at the Palm Court.

Information about all forthcoming Aberdeen branch activities can be found on the diary page of the magazine and on the Institute website, a calendar of local events of interest to corrosion professionals in the Aberdeen area and the opportunity to sign up to the branch mailing list is available at https://sites.google.com/site/icorrabz/home. Aberdeen Branch have also established their new Media Centre on LinkedIn, which can be found at https://www.linkedin.com/in/aberdeen-icorr/recent-activity/

The 2017-2018 ICorr Aberdeen Sponsors currently include: Aberdeen Foundries Ltd, Atkins, CAN Offshore Ltd, CORRPRO Companies Europe Ltd, Cosasco, Deepwater, ICR, IMG Composites, IndCorr, LR, North East Corrosion Engineers, Oceaneering International Services, Permasense, Pipeline Technique Ltd, Plant Integrity Management, Spencer Coatings, Rosen, R&R Corrosion Ltd, Total E&P and TRAC.