ICorr London Updates

Institute News

In February, the branch welcomed Dr Mohammad Seyed Hosseini, Technical Director at London Petrotech Engineering Ltd and Principal Consultant at Subsea 7, based in London, who presented “Lessons-Learned from a Root-Cause Failure Analysis Conducted on a Subsea Sour Gas Pipeline.”

Dr Hosseini, is an accomplished materials and corrosion engineer with over 24 years of experience in the oil and gas industry. He has worked with some main EPCI contractors and major operators. In addition to his industry accomplishments, he holds an academic position in the UK, where he has spent years lecturing, researching, and supervising postgraduate students. He has also delivered several training courses to institutions and directly to oil and gas companies.

Dr Hosseini started by describing the subsea pipeline failure. It was transporting wet sour gas and experienced multiple failures within two years of the start of operation. The pipeline, constructed from DNV SAWL (longitudinally welded steel pipe manufactured using the Submerged Arc Welding process) 450 SD material, was thus subjected to a comprehensive three-stage investigation, including laboratory analysis, Root Cause Failure Analysis (RCFA) by the operating company’s expert, and an independent review by a contractor-appointed expert.

He then described the detailed examination conducted through laboratory investigations on the pipes retrieved from the seabed, which revealed several key findings. Visual inspection revealed ruptures in the base metal with extensive internal corrosion concentrated at the 10-2 o’clock position of the pipe sections. Despite chemical composition and mechanical properties (including toughness and hardness) meeting all required specifications, microstructural examination showed banded structures at mid-thickness with elongated inclusions. Ultrasonic testing detected several Hydrogen Induced Cracking (HIC)/Stepwise Cracking (SWC) indications at the mid-thickness, all located at the top of line (TOL). HIC/SWC tests confirmed acceptable results for most samples except one, which was taken from the parent material adjacent to the rupture point.

A holistic root-cause failure analysis was also performed based on BS 62740 using the Cause Tree Method (CTM). The relevant design, manufacturing, construction, installation, pre-commissioning, and operational data were reviewed. The RCA results showed that the primary root causes were material quality issues making the pipeline susceptible to HIC damage, with corrosion processes in wet H₂S environments leading to critical hydrogen absorption. Contributing factors included inadequate corrosion control strategies, infrequent pigging operations that allowed liquid accumulation, and higher-than-anticipated H₂S concentrations accelerating corrosion. Manufacturing inconsistencies and insufficiently rigorous HIC testing procedures further compromised the pipeline’s integrity.

The independent expert reviewed these findings and highlighted important enhancements needed in Root Cause Analysis methodology. It emphasised that RCA should be holistic and collaborative, with regular inter-stakeholder workshops to discuss interim results. The basis for selection of RCA techniques must be mutually agreed upon by all parties, and a minimum of two complementary techniques should be employed. Incorporating interviews with key personnel and utilising specialised RCA software tools were also recommended to improve investigation quality.

A pivotal conclusion emerged regarding the relationship between TOL corrosion and HIC. The analysis definitively established a sequential relationship where these mechanisms occur in series rather than in parallel. This means that TOL corrosion triggered HIC in the steel, which ultimately led to pipeline structural failure and rupture.

The expert also noted that microstructural imperfections like banding are unavoidable in thermomechanically-controlled processed steels but require careful management. These highlighted the lack of clear requirements in the current industry standards and  practices regarding acceptable banding structures for sour service applications. For severe sour service environments, the expert recommended using quenched and tempered (Q+T) or normalised steels where feasible, though acknowledged this approach was not applicable to this pipeline’s large SAWL pipes. Dr Hosseini concluded by noting that these comprehensive findings provide critical insights for preventing similar failures in sour service subsea pipelines through improved material selection, manufacturing quality control, and corrosion management strategies.

The branch held their AGM on Thursday, 13^th March. The chair summarised the past year and highlighted the upcoming events. The treasurer, Jim Glynn, presented the accounts, which showed we were able to run all the events and still return some of our allocated funds to Head Office. Acceptance of the accounts 
was proposed, seconded and approved. There were some changes to the committee; Ali Morshed resigned due 
to family commitments, Alejandra Fernandez-Vinas was going 
on maternity leave, and we had one new member, Berenika Syrek-Gerstenkorn. This new committee was elected for the 2025-2026 season.

Following the AGM, the chair gave a very interesting talk on “Work-Life balance”, he explained that after (potentially stressful) work, it is necessary to have another relaxing interest, e.g. a hobby, and in Paul’s case, it is bee keeping.

He explained the function of a colony of bees in a hive. Honeybees play a crucial role in pollinating crops and plants, ensuring the production of many of our fruits, etc. They produce beeswax which they use to build their hive. Going from autumn to winter, a hive has about 6-7,000 bees (worker bees and the queen) – during winter they are dormant and mainly generate heat by vibrating their wings while clustered around the Queen Bee, keeping her warm and fed, consuming the honey stored up during the previous summer.

For a bee hive to be successful, it must have 1,000s of worker bees and one queen bee and drones (male bees). The primary purpose of the Queen in a hive is reproduction, she is the only bee capable of laying eggs, essential for maintaining and expanding the colony , she  produces pheromones that help maintain the cohesion and stability of the colony , and is crucial the colony’s survival.

Drone bees are prevalent in colonies in the spring and summer months. As winter approaches, they are driven out of the nests or hives by the worker bees and left to perish in the cold. When a brood nest is large, the presence of drones helps to maintain heat, and it’s believed that a colony is more content with drones.

Worker bees are females which lack the reproductive capacity of a Queen and carry out the majority of tasks needed for the hive to function – they are by far the most numerous types of bee, smaller than drones and Queens, and have bodies specialised for nectar and pollen collection.  They perform different tasks around the hive progressively over their lifespans in a predictable order based on their age.

Worker bees gather pollen in the pollen baskets on their back legs and carry it back to the hive to feed the developing brood.  Nectar is sucked up through the proboscis, mixed with enzymes in their stomach, and carried back to the hive, where it is stored in wax cells, and evaporates into honey.  There are also Guard bees who stand at the front of the hive entrance, defending it from any invaders, such as wasps.

A beehive is analogous with a large company. The Queen is the CEO, the workers carry out all the tasks, and the drones are the seasonal workers, whilst the guards are the security, just as in our industry. There was an interesting discussion about the honey produced and the different flavours that are obtained. As is customary with the branch, the speaker received an ICorr pen as thanks for his talk.

In May, the branch will be holding a social event for members and their partners. Further details will be available on the ICorr website in due course.

Photo (right)
Dr. Mohammad Seyed Hosseini Delivering 
His Talk.

Photo: After a Very Interesting Q&A Session, the Chair Thanked Dr Hosseini for His Presentation, and Presented Him with an ICorr Pen, in Appreciation of His Talk.

Photo: Paul Brooks Delivering His Talk.

Photo: Honey Bee.

ICorr India Updates

Institute News

Following its successful launch and AGM of 28th January 2025, the ICorr India Branch recently hosted two insightful webinars focusing on advancements in corrosion protection technologies. These sessions featured renowned experts who delved into the historical foundations, modern techniques, and future directions of cathodic protection (CP) and digital twin implementation for offshore structures.

Technical Webinar: “200 Years of CP and OPC” Hosted on Tuesday 2^8th January 2025

Speaker: Professor Paul Lambert, BSc (Hons), PhD, CEng, CSci, FICorr, FIMMM, AMPP Corrosion Specialist

Professor Paul Lambert has over 40 years of experience in the investigation of structural durability and degradation and in the development of novel remedial techniques for civil and building structures, most recently as Head of Materials and Corrosion at Mott MacDonald. He became one of the three inaugural Mott MacDonald Fellows in 2023. Paul is Visiting Professor at the Centre for Infrastructure Management at Sheffield Hallam University where he carries out research into novel materials and repair technologies.

Professor Paul Lambert delivered an engaging and comprehensive presentation that traced the evolution of cathodic protection (CP) and ordinary Portland cement (OPC) over the past two centuries. His talk contextualised these developments within historical frameworks while addressing their contemporary applications and future potential.

Historical Context and Technological Evolution

Professor Lambert began by providing a historical overview, referencing key milestones that have shaped the development of CP and OPC:

1. 1824 – The Birth of Portland Cement: Joseph Aspdin, a bricklayer from Leeds, patented Portland cement. This formulation revolutionised construction and remains a cornerstone of modern infrastructure.
2. Early Understanding of Corrosion: Humphry Davy’s 1824 paper on corrosion prevention laid the foundation for cathodic protection. Initially focused on preventing the corrosion of copper sheeting on naval vessels, Davy’s work marked the beginning of electrochemical approaches to corrosion control.
3. Advancements in Anode Technology: The presentation highlighted the shift from early sacrificial anodes made of pig iron to modern materials such as magnesium and aluminium, which provide superior protection.

Practical Applications of CP in Modern Infrastructure

Professor Lambert discussed various real-world applications of CP, emphasising its importance in preserving infrastructure:

1. 
Marine Structures: CP has been instrumental in protecting submerged structures such as oil rigs, ships, and pipelines from corrosion.
2. 
Reinforced Concrete: CP is widely used in reinforced concrete structures to mitigate the effects of chloride-induced corrosion.
3. 
Historic Preservation: Techniques such as discrete anodes have been successfully applied to protect steel frames within historic buildings without compromising their aesthetic integrity.

Challenges and Future Directions

The session also addressed ongoing challenges and future developments in CP technology:

1. 
Hybrid Systems: Combining galvanic and impressed current systems offers enhanced protection and greater flexibility in diverse environments.
2. 
Regulatory Standards: Adherence to international standards (e.g., ISO codes) ensures consistency, quality, and reliability in CP system design and implementation.
3. 
Sustainability: Efforts are underway to mitigate the environmental impact of OPC production and to develop more sustainable materials and methods.

Webinar 2: “Implementation of a Digital Twin for an Offshore Structure” Hosted on 25th February 2025

Speaker: Eng. Esteban Amirante, CM BEASY Ltd.

He earned degrees in mechanical engineering and a master’s in business administration, enabling a successful career in developing new businesses. As International Business Development Manager at CM BEASY LTD, he has led global expansion of the UK firm’s industry-leading offerings and solutions. and spearheads the development of new products tailored to customer priorities. His leadership on defence projects worldwide showcases BEASY’s British technology innovation, working in many programmes.

In the second webinar, Engineer Esteban Amirante presented on the cutting-edge implementation of digital twins for offshore structure corrosion management. His presentation emphasised the transformative potential of digital twins in optimising cathodic protection (CP) system performance and asset integrity.

Understanding Digital Twin Technology


A digital twin is a virtual replica of a physical asset that integrates real-time data and simulation models to monitor, predict, and optimise performance. This technology is particularly valuable in managing complex systems like offshore structures where corrosion poses 
significant risks.

1. 
Data Integration: Digital twins combine inspection data with simulation models to create a comprehensive and dynamic representation of an asset’s CP system.
2. 
Accurate Modeling: BEASY’s proprietary boundary element solver provides precise electrochemical simulations that enhance the accuracy of digital twins.
3. 
Predictive Capabilities: By analysing real-time and historical data, digital twins enable predictive maintenance, allowing operators to anticipate and mitigate corrosion-related failures.

Implementation Process


Engineer Amirante outlined the step-by-step process of creating and utilising a digital twin for offshore structures:

1. 
3D Digitalization: The process begins with converting the physical structure into a detailed CAD model, including survey points and visual inspection data.
2. 
Calibration with Survey Data: Real-world measurements are used to calibrate the digital model, ensuring accurate representation of the CP system’s current state.
3. 
Simulation and Prediction: The calibrated model is used to simulate future performance and identify potential failures before 
they occur.
4. 
Identifying Discrepancies: Digital twins can detect inconsistencies between expected and actual performance, allowing targeted maintenance and resource allocation.

Benefits and Industrial Impact


The implementation of digital twins offers numerous advantages for offshore asset management:

1. 
Enhanced Accuracy: Combining real-time data with simulation models provides a more accurate assessment of CP system health.
2. 
Cost Efficiency: By predicting maintenance needs in advance, digital twins reduce operational disruptions and associated costs.
3. 
Decision Support: Digital twins facilitate informed decision-making by providing clear visualisations and data-driven insights.
4. 
Scalability: The technology is adaptable to various offshore structures, including pipelines, FPSOs (Floating Production Storage and Offloading units), and subsea facilities.

Future Outlook


Engineer Amirante concluded by discussing the future potential of digital twins:

1. 
AI Integration: Incorporating artificial intelligence and machine learning will enhance predictive accuracy and automation capabilities.
2. 
Broader Adoption: As digital twins become more cost-effective, their adoption will likely expand across industries beyond offshore oil and gas.
3. 
Standardisation: Developing standardised protocols for digital twin implementation will facilitate broader industry acceptance and interoperability.

Photo: A Slide from Professor Paul Lambert’s Presentation.

Photo: A Slide from Professor Paul Lambert’s Presentation.

Photo: Esteban Amirante.

Photo: 
(Right and Above). 
A Few Slides 
from Eng. Esteban Amirante’s 
Presentations.

ICorr Central Scotland
Updates

Institute News

ICorr Central Scotland Branch restarted its technical session in 2025 with two well-attended events in January and February. The Branch also held its Annual General Meeting (AGM) on 29^th January 2025 during the first Technical Meeting of the year. The new ICorr President, Dr Yunnan Gao, and immediate Past President, Mr Stephen Tate, were in attendance and witnessed the proposal and acceptance of the new Branch Committee. The Committee is comprised by:

The Committee held its first meeting on 20^th February 2025. Proposals such as improving coating, insulation and PFP expertise in Central Scotland, potential trainings and industrial visits were discussed.

In January’s hybrid Technical Meeting (facilitated via Zoom), a global audience benefitted from Nicolas Rossi’s detailed presentation on “Deep optimisation for Cathodic Protection: advanced technology for transformer rectifiers output current optimisation”. Nicolas, a Cathodic Protection (CP) Expert from Automa Srl, Italy, explained how new transformer rectifiers (T/Rs) and Artificial Intelligence are used in Smart CP systems to provide enhanced protection to assets such as gas pipelines. Field results demonstrating the optimisation of CP systems affected by DC interference from nearby infrastructure were presented.

On 26^th February 2025, Graham Greenwood-Sole, Technical Director at Corrocoat, delivered a well-received presentation on the topic “Cost-effective corrosion protection using two-pack epoxy coatings in an aerosol and protecting nozzles and flange faces, using alternatives to hand coating”. Graham’s explanation of how glassflake fillers assist in improving resistance inhibition of coatings and the benefits of glassflake technology was invaluable. He provided several case studies and showed how Epoxy Two Pack aerosols are now being used for fabric maintenance with minimal surface preparation, often by inspectors (at the time of inspection) rather than by separate fabric maintenance teams later.

Photo: Nicolas Rossi Presenting from Automa Srl, Italy.

Photo: Nicolas Rossi Presenting on “Deep optimisation for Cathodic Protection” to In-Person and Online Delegates, January 2025 Hybrid 
Technical Meeting.

Photo: Graham Greenwood-Sole Showing Examples of Harsh Environments Where Corrocoat’s Glass Flake Coatings are Applied.

Photo: Graham Greenwood-Sole Showing Examples of Harsh Environments Where Corrocoat’s Glass Flake Coatings are Applied.

Abstracts are welcomed for consideration for the 2025-2026 Technical Programme. Interested presenters can contact: cschair@icorr.org who will be happy to answer any questions at all.

Aberdeen Joint Event with the Energy Institute

Institute News

On Tuesday, 28^th January 2025 the Institute of Corrosion (ICorr) Aberdeen Branch held our annual joint event with Energy Institute. Dr Yifeng Zhang of Imperial College, London, gave a most interesting presentation on ‘Mon Ami – An Integrated Assessment Framework for Evaluating Inspection and Monitoring Strategies for Corrosion Surveillance.’

Yifeng Zhang is a postdoctoral research associate in the Non- Destructive Evaluation (NDE) group at Imperial College. He received his MEng degree in Aeronautical Engineering in 2018 and his PhD degree in Mechanical Engineering in 2022, both from Imperial College. In 2023, Yifeng was awarded the Institute of Physics Bob Chivers Prize for authoring the best research paper in physical acoustics. His research interests focus on the development of Structural Health Monitoring (SHM) systems and their applications in ensuring structural integrity, enhancing operational efficiency, and driving scientific innovation, particularly in the areas of chemical, electrochemical, and energy storage systems.

Synopsis: Corrosion poses a significant challenge to engineering structures, increasing the risk of service disruptions and safety incidents. Traditionally, ultrasonic Non-Destructive Evaluation (NDE) techniques for corrosion surveillance have relied on either periodic surface scans or continuous monitoring at a limited number of locations, which can prove unreliable. However, recent advancements in sensor technology and autonomous robotic systems have introduced innovative concepts, such as resident robots for asset inspection. These developments now enable the deployment of fleets of reconfigurable sensors capable of collecting spatially and temporally diverse data. To ensure the effectiveness of this new approach, thorough validation and comparison with established methodologies are essential.

The studies intend to assess the efficacy of different hybrid inspection/monitoring approaches. The proposed solution is a multi-stage framework for performance evaluation with 3 critical steps:

• Model 4D defect evolution in space and time.
• Performance assessment for different inspection and monitoring approaches in various scenarios.
• Simulate NDE measurement and associated errors.

In Stage 1 the NDE Group Model Uniform Corrosion

• Uniform corrosion is described as uniform thickness loss and change in surface roughness over time.

The NDE group can also model defect growth: Three contributing factors to the stochasticity of defect growth rate are:

• Dt 
• Pit initiation time 
•   Initial pit growth rate

Secondly, the NDE group model Spatial Aspect of localised defects which is the defect geometry and spatial footprint.

The measurement accuracy depends on factors such as:

• Location 
• Relative size
•         Surface roughness

A hemispherical shape is assumed, defined by pit aspect ratio (AR=diameter/depth) The defect spatial distribution is uniform (i.e. random) and the position of corrosion follows certain distributions (e.g. Concentrated frequently at 6 o’clock position of a pipe).

In matching real-life measurements, the NDE group generates a corrosion map that resembles in-field measurements at a specific point in time, and we calculate the thickness distribution and extrapolate its evolution both before and after.

In the 3^rd part of the process, the NDE group aims to understand measurement error due to the applied NDE techniques. An NDE filter is configured based on findings from previous studies of the effect of surface roughness on ultrasonic thickness measurements. Finally, the NDE group assesses the error associated with data acquisition procedures and applies that to the modelling.

Regular inspection is conducted by corrosion mapping or C-scan.

For spatial coverage, a full scan gives comprehensive information on asset conditions, while a partial scan by subsampling is often required due to access and cost constraints. Regarding inspection intervals, the data acquisition is programmed for selected time instances and is a time-based, risk-based or compliance-based inspection.

Alternatively, monitoring can be performed using permanently installed sensors. Data is then acquired via a small number of sensors ‘permanently’ installed on structures (potentially at the identified hotspots) to monitor thickness loss with enhanced temporal resolution.

Ultrasonic data can be used to match trends to those of chemical and operating data to give insights into rate of corrosion and causes.

The integrated framework allows for the assessment of various mixed inspection and monitoring scenarios, highlighting the potential benefits of the proposed hybrid approach. Furthermore, the framework has been developed into a stand-alone graphical user interface (GUI), offering researchers and industry professionals a versatile tool to evaluate degradation phenomena relevant to their applications.

Please contact the Aberdeen Branch Chair ABZchair@icorr.org if you wish to present at future events, or for any further information on upcoming events and check www.icorr.org/events/

Further information about the Aberdeen Branch, and past presentations, may be found on their Website page: Aberdeen Branch – Institute of Corrosion https://www.icorr.org/aberdeen/ under Local Technical Programme and to join the Aberdeen Branch mailing list, please contact: ABZchair@icorr.org

Photo: Dr Yifeng Zhang of Imperial College Presenting.
Photo: Degradation Phenomena.
Figure 1: Uniform Corrosion Modelling.
Figure 2: Defect Growth Rate.
 

Photo: The Use of Permanently Installed Sensors in Critical Areas.
Fig 3: Ideal Use of Permanently Installed Sensors.

 
Fig 4: Procedure to Assess the Efficacy of Hybrid Monitoring Approaches

Photo: ICorr Aberdeen and Energy Institute Aberdeen, Highlands and Islands Branch Committee Members with Dr Yifeng Zhang of Imperial College, London (4^th From Right).