The Institute of Corrosion (ICorr) and the Hydrocarbon Passive Fire Protection Network (PFPNet) will be launching their market leading training programme

The Institute of Corrosion (ICorr) and the Hydrocarbon Passive Fire Protection Network (PFPNet) will be launching their market leading training programme

The Institute of Corrosion (ICorr) and the Hydrocarbon Passive Fire Protection Network (PFPNet) will be launching their market leading training programme

Please find below an invitation to the launch of the new PFP Inspector training programme; “ICorr/PFPNet Fire Protection Coatings Inspector Training Programme (Ref: ICorr/PFPNet CITP)”

About this Event

The Institute of Corrosion (ICorr) and the Hydrocarbon Passive Fire Protection Network (PFPNet) will be launching their market leading training course specifically aimed at the training of Inspectors who inspect installation of hydrocarbon passive fire protection materials. The training course is targeted at both epoxy and cementitious intumescent materials and we ask you to join us for the launch of this training programme which is a step-change towards improved competence in this safety critical area of our industry.

The hydrocarbon passive fire protection training course is aimed at Inspectors responsible for the installation of product, but could equally benefit Engineers and others who wish to understand the reason why passive fire protection is important and the processes involved in it’s installation.
The launch will include commentary from a number of key notables in the industry and its your opportunity to ask the organisers detail about the course and its global delivery.

We hope you are able to join us on one of the time slots on the 23rd September but please note numbers are limited.

How to Register

This will be an online event and we would ask you to complete the Eventbrite registration:

We will then send you an invitation to the live Teams event on the time slot of your choice.
As this is a global launch and you will note that we have posted 3 events through the day in order to meet the different time zones; 09.00, 12.00 and 16.00 (UK time)

We look forward to seeing you on the 23rd September.

PFP Training – A Global Event

PFP Training – A Global Event

Who Will Benefit from PFP Training, and How Can You Get On Board?

In previous articles, we have discussed the financial cost of getting passive fire protection wrong and why PFP is critical for health and safety and asset integrity.

We’ve uncovered the need for improved standards in training, knowledge and expertise to prevent damaging and costly accidents occurring, especially in dynamic environments; for example, where modification to existing structures may require removal of or damage to the original PFP installation.

Simply put, well-designed, properly applied, and comprehensively inspected PFP protects people, assets and businesses. If the application process is not controlled and aligned with QA/QC standards for the coating used, you risk:

  • The final system not meeting the design’s fire specification
  • Flaws in the coating system leading to corrosion underneath the coating which is not externally visible and has consequent impact on fire performance
  • Degradation of the coating over time due to severe environmental effects

Market dynamics are directing a new approach to PFP inspection

Market dynamics are directing a new approach to PFP inspection. This approach is industry-led rather than mandated by legislation.

As margins have reduced for manufacturers of PFP coatings, the free-of-charge on-site technical service personnel provided by manufacturers are no longer extensively offered. In addition, the oil and gas industry has sought to keep project costs down, with the effect that nobody in the contract chain wants to pay for PFP specialist qualified inspection services. The result is little or no inspection from individuals who can identify and prevent problems with PFP installation.

The knock-on effects of this reduction in expertise for the oil and gas and hydrocarbon processing industries, where PFP is critical, are expensive complications further down the line:

  • The cost of substandard PFP can be experienced in the tragic loss of human lives
  • The financial cost of rectifying problems is many, many times the cost of initial application

Consequently, there has been a strong desire from companies and individuals in the industry to develop best practices, navigate regulations, and improve standards that remove confusion and conflict. This has culminated in the development of new PFP training courses designed to accredit individuals who are involved in PFP installation and inspection.

Who will benefit from PFP training?

Driven by industry needs and defined by industry experience, the new and unique Institute of Corrosion/PFPNet Fire Protection Coatings Inspector Training Programme will qualify inspectors of epoxy intumescent and cementitious PFP coatings used to protect against hydrocarbon fires. The course is designed to provide evidence of distinctive competence to properly understand and inspect PFP installation in new construction or retrofit situations.

In brief, there are three categories of operator who will benefit from this training:

  • The owner operator/engineering house who will need to build the course into specification, to ensure that PFP is fully considered and that the design and application of PFP meets improving standards and industry best practices
  • The fabricator/applicator who will need to have their inspectors competently trained, demonstrating that they are committed to maintaining improved standards of application and inspection
  • The inspection houses who will need to have trained inspectors ready to meet the market requirement

Gain PFP expertise through blended learning

Blended (sometimes called ‘hybrid’) learning combines online training with traditional ‘classroom’ training to maximise effectiveness. The decision to present this PFP course in this manner was easy to make. It also means that COVID-19 risks are minimised, as you’ll be doing around 10 to 20 hours of study online.

The online part of the course will prepare you for the classroom learning. In the classroom, you’ll benefit from working in a group, gaining different perspectives, and improving the effectiveness of learning. The classroom sessions are delivered over four and a half days.

When you have completed the classroom sessions there will be a half-day exam, with peer review completed within 28 days.

Who is delivering the training?

Training of this status deserves to be delivered by the best of training establishments. The Institute of Corrosion is pleased to have been selected as a partner, and training will be delivered via IMechE Argyll Ruane.

In addition, you will also be able to access this training via the PFP manufacturers. In alphabetical order, these are:

  • Carboline
  • International Paint
  • Jotun
  • PPG
  • Sherwin-Williams

The official launch of this exciting new training is set to take place on 23rd September, via a Teams meeting to be delivered in the East and then delivered in the West later the same. At this launch, you’ll also be introduced to some of our expert course presenters for this PFP training.

To register for the launch, or to discuss which of the three training mechanisms will be best for you, contact either John Dunk at PFPNet or David Mobbs at ICorr.

Innovative Products – New Combustible Gas Detector

Innovative Products – New Combustible Gas Detector

Blackline Safety Corp. a leader of gas detection and connected safety solutions, has announced a partnership with NevadaNano, a developer and manufacturer of microelectromechanical systems (MEMS)-based gas sensors, to add their MPS™ Flammable Gas Sensor technology to its line-up of cloud-connected G7 wearable detection systems.

According to the company, where traditional LEL sensors fall short, the MPS Flammable Gas Sensor detects gas mixtures as accurately as it does a single gas, eliminating false alarms with built-in environmental compensation, poison immunity, fail-safe design, and a real-time conversion factor. Now a member of Blackline’s G7 gas sensor portfolio, the MPS sensor delivers the industry’s most linear response for the LEL of individual and mixed gas compositions for the 12 most common combustible gases, including hydrogen, methane, ethane, propane, ethylene, xylene. Across this wide range of gases, the MPS sensor maintains accuracy for over five years and incorporates internal diagnostics to automatically detect issues with the sensor itself.

PFP Training – A Global Event

PFP – Critical for Health & Safety and Asset Integrity

Mitigating Installation Risk to Keep Assets and People Safe

Asset integrity, health and safety, and PFP (passive fire protection) should be comfortable bedfellows, because PFP primarily works in two ways:

  • Employing construction elements to contain fire or limit its spread
  • Fire protection to structural elements to protect from the heat of a fire causing those structures to fail and collapse

By protecting structures from fire using PFP, you protect the integrity of an asset and this helps you achieve what is your first concern – the safety of your people.

PFP – Protection for people

Passive fire protection, such as intumescent epoxy or cementitious coatings, provides protection for people because it provides protection for structures and maintains structural integrity. In an ideal world people who live or work in a building or other installation should be able to escape hazard such as fire.

Indeed, individuals who work in commercial office buildings have become used to unannounced fire drills to test how quickly and effectively they are able to exit the building to a safe location on hearing the fire alarm.

However, what do you do when you can’t simply get away? Imagine an offshore oil and gas installation, most likely hundreds of miles from dry land with the working and living areas of the structure possibly hundreds of feet above the sea, which in cold climates may be cold enough to cause death by hypothermia for anyone entering that environment within a very short time.

In these cases, containment of the fire within the area that is burning and protection of the surrounding structure to allow an orderly abandonment by lifeboat is indeed a matter of life and death.

Unfortunately, over the years a number of offshore fires and explosions have taken the lives of offshore workers, and whilst valuable lessons have been learned on how to prevent fires and put in place rigorous safety practices, these tragic events still occur.

Types of PFP

There are several types of PFP to protect assets and people.

For example, defend-in-place strategies seek to limit the spread of fire and smoke to other compartments. Installations may be designed to restrict the ability of fire and gas to move beyond their point of origin.

In oil and gas installations, steel is treated with PFP products to protect it against hydrocarbon fires which are rapid temperature rise fires that can raise the temperature of unprotected steel to beyond its point of collapse within a few minutes. Epoxy intumescent coatings are commonly used. They need to be adhesive, hard but flexible, tough, and protect against corrosion. When they are exposed to heat, they need to create an insulating carbonaceous char to protect the steel.

In comparison to paint used for anticorrosion, PFP coatings are more complex and may have stages in their application, such as the installation of reinforcing mesh, where specific controls and skills are vital to ensure that the final installation meets design requirements for the lifetime of the asset.

Failure to control the application process and follow the appropriate QA/QC standards for the coating in question can lead to many problems, including:

  • The final system will not meet the design fire specification in the event of a fire
  • Flaws in the coating system such as voids, uncured material or other defects can lead to corrosion underneath the coating which is not externally visible
  • Degradation of the coating over time due to severe weathering which is common in certain environments

Application, maintenance, and safety

Issues with PFP installation can occur well into the lifetime of the asset, as oil and gas installations are often dynamic environments where modification to existing structures and addition of services such as cabling and piping may require removal of or damage to the original PFP installation.

Frequently, those carrying out such works are not aware of the original design PFP requirements. In some cases it has been shown that maintenance staff are not aware that they have removed a fire safety-critical item during modification works.

Thus, having individuals well trained in PFP to supervise and ensure remedial works are carried out to a high standard is extremely important.

Applicators often have no knowledge of PFP

Materials used for PFP are highly regulated in terms of their quality and performance, which is independently verified, but the application and inspection of PFP is less well regulated.

At the time of writing, owner operators typically specify that inspectors of PFP coatings should be Paint Inspector Level 2 qualified – but anticorrosion coatings knowledge and experience is not adequate when it comes to PFP coatings. This is an issue that is putting the integrity of assets at risk, and, most importantly, means that people within high-risk installations have a higher risk to their health and safety. 

The Passive Fire Protection Network (PFPNet), together with the Institute of Corrosion, is developing and delivering PFP training courses designed to accredit individuals who are engaged in PFP installation and inspection. The courses may well also be of interest to engineers and professionals who need to have an understanding of the practical elements of PFP installation and maintenance.

Training will be provided by qualified individuals, and an important part of the overall programme is accreditation of the course along with qualification of the individuals who successfully conclude the training. Within the training, there will be elements that cover health and safety while at work – meeting CSCS H&S requirements for UK-based work.

This new training has been developed by drawing on the experience and needs of the industry, and will ensure that best practices are followed to and above current regulations. We expect the PFPNet Competency Framework to be mandated by asset owners and other stakeholders as a requirement for projects and operations.

For more information, contact either John Dunk at PFPNet or David Mobbs at ICorr.

Standards Up-date

ISO

The following documents have obtained substantial support within the appropriate ISO technical committees during the past two months and have been submitted to the ISO member bodies for voting, or formal approval

ISO/DIS 1463 Metallic and oxide coatings — Measurement of coating thickness — Microscopical method (Revision of the 2003 standard)

ISO/FDIS 2409 Paints and varnishes — Crosscut test (Revision of the 2013 standard)

ISO/FDIS 2810 Paints and varnishes — Natural weathering of coatings — Exposure and assessment (Revision of the 2004 standard)

ISO/DIS 3613 Metallic and other inorganic coatings — Chromate conversion coatings on zinc, cadmium, aluminium-zinc alloys and zinc-aluminium alloys — Test methods (Revision of the 2010 standard)

ISO/DIS 4518 Metallic coatings — Measurement of coating thickness — Profilometric method (Revision of the 1980 standard

ISO/FDIS 8502-15 Preparation of steel substrates before application of paints and related products — Tests for the assessment of surface cleanliness — Part 15: Extraction of soluble contaminants for analysis by acid extraction

ISO/FDIS 11463 Corrosion of metals and alloys —Guidelines for the evaluation of pitting corrosion (Revision of the 1995 standard)

ISO/FDIS 15156-1, 2 and 3 Petroleum and natural gas industries — Materials for use in H2S-containing environments in oil and gas production — Part 1: General principles for selection of cracking-resistant materials ; Part 2: Cracking-resistant carbon and low-alloy steels, and the use of cast irons ; Part 3: Cracking-resistant CRAs (corrosion-resistant alloys) and other alloys (Revisions of the 2015 standards)

ISO/FDIS 22232-2 Non-destructive testing — Characterization and verification of ultrasonic test equipment — Part 2: Probes

ISO/FDIS 22858 Corrosion of metals and alloys — Electrochemical measurements — Test method for monitoring atmospheric corrosion

New international standards published during the past two months

ISO 7539-10:2020 Corrosion of metals and alloys — Stress corrosion testing — Part 10: Reverse U-bend method

ISO 11844-1:2020 Corrosion of metals and alloys — Classification of low corrosivity of indoor atmospheres — Part 1: Determination and estimation of indoor corrosivity

ISO 11844-2:2020 Corrosion of metals and alloys — Classification of low corrosivity of indoor atmospheres — Part 2: Determination of corrosion attack in indoor atmospheres

ISO 15528:2020 Paints, varnishes and raw materials for paints and varnishes — Sampling

ISO 21062:2020 Corrosion of metals and alloys — Determination of the corrosion rates of embedded steel reinforcement in concrete exposed to simulated marine environments

ISO 21809- 3:2016/Amd 1:2020 Petroleum and natural gas industries— External coatings for buried or submerged pipelines used in pipeline transportation systems — Part 3 Field joint coatings — Amendment 1: Introduction of mesh-backed coating systems

ISO 22410:2020 Corrosion of metals and alloys — Electrochemical measurement of ion transfer resistance to characterize the protective rust layer on weathering steel

SSPC

SSPC, The Society for Protective Coatings, has revised one guide and one joint standard practice

SSPC-PA Guide 11, Protecting Edges, Crevices, and Irregular Steel Surfaces by Stripe Coating.

The 2020 revision adds definitions for some previously undefined terms and provides guidance to specifiers for

• Determining when the stripe coat is applied (before or after a full-coat application)

• Determining suitability of a coating for use as a stripe coat (cumulative DFT, compatibility)

• Preparing outside corners and edges for application of a stripe coat

• Treatment of flame-cut edges prior to application of stripe coat.
Additional changes Include, examples of specification language in a non-mandatory appendix, and illustrations of areas that may be considered for stripe coating.

This guide discusses the technique called “stripe coating” or “striping” as a way of providing extra corrosion protection measures on edges, outside corners, crevices, bolt heads, welds, and other irregular

steel geometries, including optional techniques that can be used to improve coating performance. It is not intended to provide all-encompassing guidance but rather offer options when preparing a project specification. The engineer should evaluate and address details on a project-specific basis.

SSPC-CPC 1/NACE SP21412 Corrosion Prevention and Control Planning

This standard defines the key elements/composition of what corrosion prevention and control planning encompasses for design, manufacturing, construction, operation and sustainability of products and facilities. Although intended for use by US Federal agencies, it may be applied to other industries where appropriate. It provides a standardised framework for a supplier’s plan to control corrosion on products and facilities.

The 2020 revision includes:

• Adding two new key elements in the body of the standard that provide critical and desired characteristics for each element in the appendix.

• The addition of an evaluation methodology on how to assess corrosion prevention and control (CPC) planning of a programme/project as a second appendices.

• Now provides the key elements for performing CPC planning, desirable characteristics of each element, and a method for determining the overall adequacy of CPC planning for a given program or projects.

Eurocorr 2020

Eurocorr 2020

Due to the COVID-19 pandemic, the EUROCORR 2020 organisers have decided to hold this year’s conference as a virtual event, which will take place from 7th-11th September 2020.

So far, more than 380 oral presentations and around 100 posters have been registered for the event. These submissions encompass all of the Working Parties and Task Forces devoted to the various aspects of corrosion and its prevention.  Together with this extensive scientific programme, the following renowned colleagues will give plenary lectures.

Prof. Stuart Lyon (The University of Manchester, Corrosion and Protection Centre, Manchester, UK): European Corrosion Medal lecture.

Prof. Maria Forsyth (Deakin University, Institute for Frontier Materials, Burwood, Australia): “Environmentally friendly multifunctional corrosion inhibitor systems”.

Prof. Fabrizio Zucchi (University of Ferrara, Centro di Studi sulla Corrosione e Metallurgia « A. Daccò », Ferrara, Italy): Cavallaro Medal lecture.

Dr. Carol Frances Glover (University of Virginia, Centre for Electrochemical Science and Engineering, Charlottesville, VA, USA) Young EFC proposal: “The many colours of metal-based primers: corrosion protection mechanisms and latest developments”.

Dr Oumaïma Gharbi (Sorbonne Université, Campus Pierre et Marie Curie, Paris, France) Young EFC proposal: “The additive manufacturing of high strength Al alloys: a new challenge in corrosion science”.

Registration for the virtual EUROCORR 2020 is now open. Further details can be found at: www.eurocorr.org.