In the past 2 months, the Aberdeen Branch has provided 2 excellent presentations showcasing the changing world of Inspection. On Tuesday 25^th March they welcomed a well-attended talk on Digital Approaches to Enhance Integrity Management by Kevin McDonald (Sonomatic).

About the Speaker

Kevin is a principal integrity engineer within Sonomatic’s integrity team. He is a mathematician with a PhD in computing science. He has extensive experience in data analytics and inspection planning, co-authoring the non-intrusive inspection (NII) recommended practice. As well as integrity consultancy, he is involved in technical capability development for the integrity team. Developments focus on novel applications of statistics to the analysis of inspection data implemented following both topside and subsea inspection campaigns.

Digital Approaches to Enhance Integrity Management

Integrity management of equipment relies heavily on inspection to ensure the asset remains fit for service. Inspection can take several forms, each requiring planning to ensure the inspection is efficient and effective, plus post-inspection analysis to ensure the most informed integrity management decisions are reached.

Sonomatic have developed and regularly deploy a suite of software tools to enhance each stage of the integrity management process.

In the pre-inspection planning phase, digital tools – such as a digital twin or similar component model – can be used to better visualise inspection plans and to keep an accurate record of requested inspection locations.

This model can then be deployed during an inspection campaign, allowing data to be populated to facilitate easy visualisation for multiple stakeholders. Data would remain within the model for evaluation and analysis, which, again, allows easy explanation and presentation to stakeholders.

Integrity management relies heavily on inspection to ensure the asset remains fit for service.

Inspection can take several forms for identifying internal degradation risks: corrosion mapping (CM), internal visual inspection (IVI), non-intrusive inspection (NII), remote internal inspection (RII) and spot-point readings (Manual UT/Radiography).

A digital twin is a virtual representation of real-world entities and processes, synchronised at a specified frequency and fidelity, using real-time and historical data to represent the past and present and simulate predicted futures.

Sonomatic have developed digital twins specifically geared to inspection use.

Non-Intrusive Inspection

Non-Intrusive Inspection (NII) is a 4-stage process applied to pressure vessels in which inspection is aimed at replacement or deferment of internal visual inspection (IVI). NII involves assessing if the vessel is suitable for NII, developing a work scope to ensure the inspection meets a specific set of criteria, inspecting the vessel according to the work scope, then evaluating and analysing the inspection results to ensure the inspection met the requirements.

Figure 1 Non- Intrusive Inspection (N1) Process Overview

Figure 2 Ni Evaluation and Conformance

Coating Correction

Algorithms can account for varying coating thickness between repeat inspections. They can calculate the most accurate growth rates for input into integrity management decisions. Kevin illustrated this with an example. Repeat inspection, by a third party, on a critical item with significant internal corrosion.

Figure 3 Coating Correction for UT Measurement

Post-Inspection Evaluation

Post-inspection evaluation using digital tools can extract maximal value from inspection data, providing significant enhancements to most current processes. Crucial to the integrity management process are calculations on corrosion rates and remaining life estimates. However, when there is a large catalogue of previous inspection data, there is often little consideration given beyond the two most recent results. A digital approach, where all inspection history can be housed in an easily accessible platform, allows the use of corrosion rate calculation using a longer-term statistical trend. This makes use of all previous data and provides the most representative corrosion rate possible. In addition, when calculating corrosion rates, emphasis is generally placed solely on changes to the minimum values. When more expansive inspection data has been recorded, such as a corrosion map, it is rare that growth of other corrosion features of a shallower depth than the minimum is considered, but this is often where corrosion growth is most pronounced. To assess such trends, an accurate like-for-like comparison is essential, looking at areas common to both inspection campaigns; digital tools are crucial in assisting with
this analysis.

Crucial to this topic is quality data that is representative of the current state of the inspected component. Sonomatic’s deploy propriety algorithms that can differentiate between internal corrosion, external corrosion and inclusions as well as providing insights into potential coating breakdown.

Summary

Digital tools improve consistency, accuracy, understanding, repeatability and decision outcomes.

Digital tools facilitate detailed analysis of inspection data critical to reliable integrity decision-making. Growing need for data analytics capability in integrity teams.

Digital solutions include 3D mini-digital twins, digitised flowcharts and calculations, and batched and automated reporting. Digitisation allows integration of simple and complex tools.

On Tuesday, 29^th April 2025, the Aberdeen Branch were kindly hosted by Bilfinger for a most interesting industrial visit to their workshops at the Bridge of Don.

Bilfinger is an international industrial services provider serving many areas of manufacturing. The aim of the group’s activities is to increase the efficiency and sustainability of customers in the process industries and to establish itself as the number one partner in the market for this purpose. Bilfinger’s comprehensive portfolio covers the entire value chain from consulting, engineering, manufacturing, assembly, maintenance and plant expansion to turnarounds and digital applications.

Process industry customers come from sectors that include energy, chemicals and petrochemicals, pharma and biopharma, and oil and gas. With its ~30,000 employees, Bilfinger upholds the highest standards of safety and quality and generated revenue of €4.5 billion in financial year 2023. To achieve its goals, Bilfinger has identified two strategic thrusts: repositioning itself as a leader in increasing efficiency and sustainability and driving operational excellence to improve organisational performance.

The company delivers its services in two key service lines: Engineering and Maintenance and Technologies. Bilfinger are primarily active in Europe, North America and the Middle East. Its new Bridge of Don facility houses extensive offices and workshops. Bilfinger is a leading provider of maintenance, modification and operations services to clients in the offshore oil, gas and wind markets in northwest Europe. Through integrated service offerings, innovative products and multi-skilled teams, the company aims to enhance the efficiency of assets, ensuring a high level of availability and reduced maintenance costs. Bilfinger has over 40 years’ experience in all phases of operations, including inspection, repair, maintenance and decommissioning. Following an overview presentation, ICorr Aberdeen guests were treated to a full facility tour, including demonstrations of PA-CAT, Creaform, Eddy Current Array and Advance NDT technologies. This department is under the overall management of Scott Westwater, a long-standing Bilfinger employee. 

Advanced NDT Demonstrations by Matthew Hale, NDT Engineer

With the recent shift from conventional NDT methods to advanced (ANDT), Bilfinger NDT services can now accurately detect, size, and locate defects with remarkable precision.

Special thanks are due to the staff of Bilfinger who stayed late to make our visit possible. The Aberdeen branch was very proud to facilitate these informative presentations, for which there were extensive question-and-answer sessions. Feedback to date has been extremely favourable for its 2024-2025 technical season.

Branch Information

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

Our online event recordings are uploaded to the ABZ ICorr YouTube Channel at ICorr YouTube Channel

 

CED Teesside Event – Celebrating ‘Innovation and Collaboration’ in Corrosion Engineering.

On 24^th April 2025, a broad spectrum of corrosion professionals came together at the Net Zero Industry Innovation Centre (NZIIC) for the INSTITUTE OF CORROSION – Corrosion Engineering Division (CED) Working Day and Symposium – an event that proudly coincided with World Corrosion Awareness Day 2025 founded by the World Corrosion Organization (WCO).

It was a timely reminder that our work as corrosion engineers is not just technical – it’s vital. Corrosion may often be invisible, but its impact on infrastructure, safety, and sustainability is anything but. Raising awareness of these. Challenges are essential if we are to support the global energy transition. This year’s theme, “Innovations in Corrosion Engineering for Sustainable Energy Systems”, captured the importance of uniting our expertise to build a more reliable, low-carbon future.

With over 40 attendees from across industry and academia, we shared technical insights, celebrated collaboration, and honoured excellence in the field.

A Day of Learning, Innovation and Shared Purpose – Key Highlights Throughout the day, we heard from speakers across LBBC Baskerville, University of Leeds, TWI, OGC Energy, Scottish Power Renewables, and Corrpro Europe – each providing insights into how corrosion engineering is evolving to support sustainable energy systems.

Opening Remarks from Gari Harris – Net Zero Industry Innovation Centre.

Gari Harris, Director of the Net Zero Industry Innovation Centre, opened the day by setting a powerful and thought-provoking context around the global climate crisis and Teesside’s critical role in addressing it.

• Gari highlighted the stark message from the IPCC’s most recent reports — that we are now at a “final warning” stage, and swift, bold action is essential.

• Gari then explained the concept of transitional, physical, liability and reputational risks that businesses face if they don’t adapt to climate and carbon targets.

• He showcased Teesside’s incredible positioning as a hub for hydrogen production, CCUS infrastructure, and renewable energy innovation, backed by government Track 1 support. https://www.spglobal.com/commodity-insights/en/news-research/latest-news/energy-transition/100324-uk-government-awards-gbp22-bil-to-track-1-ccus-blue-hydrogen-projects

• Delegates learnt about NZIIC’s world-class labs, research collaborations, skills development work, and its mission to support both SMEs and large industries in scaling up decarbonisation.

• The presentation also outlined how NZIIC is leading on everything from green shipping corridors to direct air carbon capture (DAC), circular economy labs, and digital twin models for net-zero infrastructure.

Gari’s talk was a strong reminder that climate adaptation is no longer optional – it’s a strategic opportunity and Teesside, thanks to its geography, geology, and growing collaborative ecosystem, is uniquely placed to lead.

Technical Talk 1
Corrosion Testing Challenges in CCUS – Danny Burkle – LBBC Baskerville

Danny talked about the complexities of corrosion in dense-phase CO₂ environments and the urgent need for collaboration to improve testing methodologies, material selection, and predictive models. It is evident that no single organisation can solve this alone — we must work together to deliver safe and resilient infrastructure.

• Discussed corrosion challenges in Carbon Capture, Utilisation, and Storage (CCUS) environments.
• Highlighted failure risks, including hidden corrosion threats, and the critical role of autoclave testing
• Emphasised the importance of understanding localised corrosion, erosion-corrosion, and predictive modelling.
• Proposed new-generation autoclave testing solutions integrating real-time monitoring and AI-enhanced modelling.
• Stressed that collaboration across industry, academia, and equipment manufacturers is essential to meet the complex corrosion challenges faced in CCUS environments.
• Encouraged knowledge-sharing initiatives and closer partnerships to accelerate innovation and ensure the development of reliable corrosion mitigation strategies.
• Highlighted that no single organisation can solve these challenges alone, and collective effort will be critical to supporting the transition to a lower-carbon future.

Technical Talk 2
Investigating CO₂ Corrosion in Carbon Steel – Amber Sykes – University of Leeds

• Amber shared new findings on FeCO₃ protective layer formation using advanced electrochemical techniques, contributing to better corrosion rate predictions.
• Presented research on FeCO₃ protective layer formation and its impact on CO₂ corrosion rates.
• Used electrochemical techniques (EIS, LPR) to monitor corrosion under realistic conditions.
• Identified a significant reduction in corrosion rates due to FeCO₃ formation.
• Highlighted gaps in current mechanistic models and opportunities for further research.

Technical Talk 4
Technical Talk 4 – Lessons from Energy Transition Projects – Tuncay Kurtulan – OGC Energy

• Tuny brought case studies from CCS and hydrogen projects, showing how real-world impurity profiles and tailored corrosion assessments are reshaping the standards we use — and how to avoid “copy-paste” specifications.
• Presented case studies from major CCS and hydrogen projects (e.g., Porthos CCS, NZTC H₂ Backbone Link).
• Discussed pioneering corrosion risk assessments and standards contributions.
• Emphasised the need for bespoke material integrity strategies based on real operating data.

Technical Talk 5
Technical Talk 5 – Offshore Coatings Innovation – Pedro María Alonso Muñoz – ScottishPower Renewables

• Pedro introduced sustainable coating systems using recycled cork and low-VOC materials. These new systems offer both corrosion protection and alignment with net-zero goals through reduced maintenance and carbon impact.
• Focused on sustainable coatings for offshore corrosion protection.
• Introduced innovative coatings using recycled cork and low-VOC components.
• Shared testing methodologies and promising results from abrasion, salt spray, and offshore exposure tests.
• Aligned innovations with UK Net Zero goals and offshore maintenance cost reductions.

Technical Talk 6
Cathodic Protection for Renewables
– Zsolt Ronafalvi – Corrpro Europe

• Zsolt explored the emerging challenges of cathodic protection in hydrogen facilities, solar farms, and offshore wind.
• Shared practical insights into managing the significant AC/DC interference and corrosion risks through updated standards and smart monitoring.
• Discussed new challenges faced by cathodic protection systems in renewable energy sectors, including hydrogen plants, solar farms, and offshore wind.
• Addressed AC interference issues from new electrical infrastructure and their mitigation.
• Highlighted corrosion issues in solar farms, such as chlorine concentration, pH imbalance, and copper earthing effects.
• Proposed cathodic protection solutions like sacrificial anodes, ICCP systems, and use of decouplers.
• Examined offshore wind structures’ corrosion risks and the importance of ISO 24656:2022 and DNV standards.
• Shared design considerations, including MMO anodes, reference electrodes, TR units, armoured cables, and remote monitoring systems.
• Emphasised proactive monitoring and tailored CP designs to meet evolving net-zero infrastructure needs

Facility and Lab Tours

Two separate Tours showcased testing capabilities for carbon capture, hydrogen, smart energy systems, and recycling innovations.

Group 1: Tour of NZIIC facilities with Gari Harris.

Group 2: Tour of TWI laboratories with Chris Graham.

Recognising Excellence: The Paul McIntyre Award

A very special moment of the day was honouring Chris Williams PhD CEng FIMMM FICorr, as the 2024 Paul McIntyre Award recipient.

With over 30 years in corrosion engineering, Chris has made significant contributions to both international standards and the mentoring of future engineers. His reflections on proactive corrosion management and sustainable practices were a highlight of the day.

This award was presented by: ICorr President – Dr Yunnan Gao (PhD CEng CSci FIMMM FICorr) and honoured the legacy of Paul McIntyre, emphasising his impact on corrosion engineering standards and collaboration.

Yunnan introduced the 2024 recipient: Dr Chris Williams (bp).

Looking Ahead

As we face the challenges of climate change and energy transition, corrosion engineering plays a critical role in securing the future of sustainable energy systems. It was especially meaningful that our CED Working Day coincided with World Corrosion Awareness Day 2025, an arrangement that we hope to follow in future years.

This essential annual reminder underlines why events like ours are so important – not just to share technical innovations, but to raise broader awareness of corrosion challenges and the vital part corrosion management plays in infrastructure resilience, safety, and sustainability. If we are to build a lower-carbon world, we must also build a world that is protected, reliable, and enduring. Raising awareness across industries, governments, and the public is fundamental to this mission.

There’s more to come: Keep an eye out for the next edition of the ICorr Corrosion Management Journal, where a full write-up of the day’s discussions will be published.

Presentations from the event will also be uploaded soon to the ICorr members’ area on the website – a fantastic resource for those who want to revisit the content in more detail. https://www.icorr.org/corrosion-engineering-division/

I left the event feeling incredibly optimistic about what can be achieved when we come together as a community. Thank you once again to all the speakers, sponsors, organisers, and attendees who supported us and who made the day so special and especially our Event Sponsors: METEC Group, Corrocoat, Corrpro Europe, Duvine Ltd.

 

 

 

 

 

 

 

 

 

The Engineering Council is delighted to announce that the Institute of Corrosion (ICorr) has become a licensed professional engineering institution with approval to assess its members for professional registration as Chartered Engineer (CEng), Incorporated Engineer (IEng) and Engineering Technician (EngTech) on the Engineering Council’s national Register.

Founded in 1959, ICorr has been a Professional Affiliate since 2001. ICorr serves the corrosion science, technology and engineering community in the fight against corrosion. Central to this is ICorr’s promotion of good corrosion management practice, the advancement of corrosion control measures and awareness at all stages of design, fabrication and operation across various sectors.

Engineering Council CEO, Paul Bailey, said: “The Licensed Professional Engineering Institutions represent engineers and technicians from across all industries. As the UK’s leading professional organisation dedicated to the science and engineering of corrosion control and prevention, I’m delighted that members of the Institute of Corrosion will now have the opportunity to have their engineering competence and commitment to upholding safe, ethical and sustainable practices formally recognised. The award of the Engineering Council licence recognises the Institute’s strong commitment to promoting best practice and standards development in the field of corrosion management and we look forward to working with ICorr in the promotion of professional excellence.”

ICorr President, Dr Yunnan Gao, commented: “The Institute of Corrosion is honoured to have been granted licensed status by the Engineering Council, enabling us to independently assess and recommend our members for inclusion on the Engineering Council’s Register at all levels: EngTech, IEng and CEng.

This significant milestone reflects the increasing recognition of corrosion science and engineering as essential to the integrity, sustainability, and safety of the built environment. It further reinforces ICorr’s vision to advance the science and engineering of corrosion prevention for the public benefit. We look forward to playing a greater role in supporting professional excellence and upholding the highest standards within the engineering community.”

Further information on currently licensed professional engineering institution can be found on the Engineering Council website

For EngC Registration through ICorr:

Please contact: Anthony Setiadi (Chair)

Email: ECReg@icorr.org