Young Engineer Programme

Young Engineer Programme

The October meeting, held as usual at the offices of McDermott’s in Paddington, was the penultimate meeting of the Young engineer Programme (YEP). The subjects for this meeting were “Presentation Skills” given by David Mobbs and “Inspection methods” given by Ian Daniel from Sonomatic.

The culmination of this programme is the presentation by the delegates of their Case Study solutions, and as this meeting was fast approaching, the presentation skills section was a timely reminder on how to prepare for a presentation that is concise, and the do’s and don’ts in developing an effective presentation. This is a skill that we are all required to use in our everyday working life, but few are ever trained in. The team mentors (John Boran, Rob Doggett and Chris Googan) were also present which gave the opportunity for some last minutes discussion on the results of their investigation into the Case Study and possible solutions, with one team having a draft presentation already prepared.

After the presentation on training, Ian Daniel described the various methods of inspection and the benefits of each, and how it’s possible to combine the various techniques to broaden the amount of useful information obtained.

Non-intrusive inspection, NII, was a key aspect of the discussion, as many operators are looking to “zero man entry” over the life of the asset. The presentation covered developments in storage tank bottom inspection, and remote monitoring via robotics.

The evening closed with a dinner and the opportunity to network.

A report on the Case Study presentation evening can be found on page 8 of this issue.

ICATS News

This is a very exciting time for ICATS as we launch the new ICATS course material and prepare for the introduction of the updated website and online registration/renewals.

The new ICATS course addresses every aspect of Protective Coating application including:
Health and Safety
Surface preparation
Metal spray
Paint application
Fire protection
Access options and specific industry requirements
Trouble Shooting

During November we introduced this new course to our Trainers at seminars in Bristol, Manchester, Edinburgh and Northampton. These were a great success, and also included an overview of the ICATS development plans and a detailed look at the new programme.

We are also about to introduce our new website which will work much better with smart phones and tablets than the old site, and is part of a wider ICATS update.
As previously announced, the Protective Coating Apprenticeship Programme is progressing and a pilot programme begins in January 2019.

For further information on any of the above please contact the office, at correx@icorr.org, or phone 01604 438222.

From the Editor

From the Editor

Another year is almost over, and if you’re like me, you’ll have wondered where the time has gone, with all those things you planned to do, but haven’t managed. I had hoped to get more cutting-edge technical articles in each issue, but didn’t quite manage this. However this issue has a bumper four technical articles, two relating to testing and two about above ground storage tanks.

There is a short piece on measuring dry film thickness of thermal sprayed aluminium coatings and the importance of the measuring method, and a thought-provoking look at specifications and protective coating testing, by experts from AkzoNobel.

The articles on storage tanks cover the use of Finite Element Modelling to more accurately design the cathodic protection system, and how looking at an alternative industry helped solve a corrosion protection problem.

Looking forward to next year, there are exciting developments in our training programmes and our move to new offices, and I look forward to bringing you news of these. I would welcome technical article submissions from members (and their colleagues) on their developments in corrosion protection and control. These can be sent to the editor, brianpce@aol.com. A list of the editorial themes planned for next year can be found in the media pack at, www.icorr.org/publications.

All that remains is for me to wish all readers the compliments of the season.
Brian Goldie, Consulting Editor

The President Writes

The President Writes

I am writing this to you from Tel Aviv where I have the pleasure of attending the 13th Biannual Conference of the Israeli Corrosion Forum. This is the last opportunity that I will have to write to you as President, as at the AGM on the 29th November in Birmingham, Gareth Hinds will be elected as the new President. It has been a real honour for me to serve in this position. I have a new found respect for the Presidents that have gone before me, and for Gareth taking on the role. On that note I would like to thank John Fletcher who steps down as a Trustee after 6 years of service to the Institute.
Our new President Dr Gareth Hinds is based at the National Physical Laboratory (NPL) in Teddington, Middlesex, where he leads a group with research interests in corrosion and electrochemistry. Gareth has participated in the activities of the Corrosion Science Division since 2003, and is a long-standing member of Council. He is also a Trustee and a member of the Correx board so he has a good understanding of the way the Institute works.

The Presidency is certainly a position that keeps you busy, and often in ways you would not expect! We have record membership numbers, a new initiative to benefit members and a new home in 5 Saxon Court, Northampton. The 8th of November was the presentation of another round of Young Engineers Case Studies. All of these activities are possible due to the dedication of our volunteers, and I hope that you will continue to support both Gareth and the Institute as a whole.
Over the past 2 years I have thoroughly enjoyed meeting many of the members and attending branch meetings, we really do have a great membership and a strong community. All that is left to me is to say thank to you all for this experience and to wish Gareth all the success, I know he will do a fantastic job, and I am excited to see where he take us.

The Young Engineer Programme (YEP) – Final Evening Presentation

The 2018 YEP culminated in the teams presenting their findings on the Case Study at Imperial College on Thursday 8th November.

This was 12 months of work for the delegates who have worked through modules that span the breadth and depth of our industry.

It was a truly fantastic evening with 3 excellent presentations from the teams

Team Boran

Agniezka Knyter

Rachel Colpitts

Liam Fox

Konstantinos Katsounis

Team Doggett   

Daniel Burkle

Oliver Smith

Caroline Earl

Jessica Easton

Team Googan

Mark Fearns

Stephen Shapcott

Liya Guo

There were a good deal of questions from the audience after each presentation following which the Judges went away to deliberate.

Bill Hedges of BP, when making his award speech, said “its been very hard to select a winner as they were all so good. However there has to be a winning team and that is Team Doggett.”

The winning team will be travelling to the USA in April 2019 to attend the NACE Conference in Nashville where a whole programme will be arranged. They will post a blog of their activity and learnings on a daily basis which will be attached to the Institute of Corrosion website. We are grateful to the President and staff of NACE for pledging their support to the winners whilst they are in Nashville by providing conference registrations and access to the student award ceremony.

The teams will also present their conference learning in the 2019 winter lecture series at ICorr London Branch.

The response from the delegates has been incredibly encouraging;

This programme has altered the way I think about my work and how I carry it out”

“I have found a new job and moved to London living in Kew Gardens and cycling to work each day  I love it”

“I hadn’t realised the value of ICorr and I will go back to work on Monday and encourage them to engage

A comment from one of the senior Engineers in our fraternity gave the programme even more credibility, “This is probably the most important function in the UK Corrosion calendar, it’s truly fantastic

It’s also interesting to note that Agne Knyter of Team Boran travelled to the U.K. from Poland in 2015 under her own steam to take part in the YEP Case Study presentation and decided then she wanted to be involved in the next YEP programme.

The week before the YEP presentation, Chris Bridge and Simon Bowcock, representing Young ICorr, presented at Oxford University and 32 people signed up as student members of ICorr. We are finally pulling young Engineers into our Institute and showing them the value of being a member.

Thanks go to all those involved in the YEP process; the organising committee, the lecturers, the hosts, the mentors, the Judges, the delegates and of course a big thank you to the sponsors of the event BP.

 

The Mary-Rose and the Dynamic Duo – Joint Meeting of the Institute of Corrosion, London Branch with the SCI London Group

The second annual Joint Meeting of the Institute of Corrosion, London Branch with the SCI London Group was recently held at their prestigious headquarters in Belgravia Square. This ultra-modern auditorium made for a most comfortable setting and was enjoyed by an attendance of over 60. In the previous two days, eight health-related apologies had been received with many more from younger members on holidays with their children, as this was half-term week.

The Evening Chairman, John T O’Shea, a Past President of ICorr, began the evening procedures by thanking Dr Fred Parrett, currently Hon. Treasurer of the SCI London Section, for all his work in helping to organise this event. This was an excellent venue and was just around the corner from the Star Pub.

John T O’Shea, a Past President of ICorr, open the meeting

There were two separate presentations – “A Fighting Ship” and “Fighting Corrosion”.

The first presentation “A Fighting Ship” was based around the Mary-Rose project at Portsmouth. This was given by Professor Eleanor Schofield, Head of Conservation and Collections Care at the Mary Rose Trust. Eleanor graduated from Imperial College, where she also received her PhD in Material Science. She has recently received an Honorary Chair at the University of Kent, at Canterbury.

Whilst we are all familiar with the story of the recovery of the Mary Rose in 1982, Professor Schofield began her talk by correcting the too often quoted story that she sank in 1545 on her maiden voyage. In fact she was built in 1510 and served for 34 years as the flagship of Henry VIII’s navy in many battles particularly in wars against France.

Professor Eleanor Schofield giving presentation on “Fighting Ship”

Following the lifting of the ship out of the seabed mud, to prevent further deterioration once exposed to air, the timber hull was treated over many years by spraying with water and polyethylene glycol. Perhaps less well known is the work in restoring and maintaining over 19,000 artefacts that had also been recovered. A significant part of the collection were the 1200 plus iron cannonballs. These have been exposed to sea-water since the ship sank, and the chlorine in sea-water which is very damaging to iron when later exposed to air. This corrosion can eat away at the metal and weakening its structure. It was vital that ways were found of preserving the cannonballs. It was recognised that while the cannons were made to last and be used many times, the cannonballs were only needed for a one-off use. Thus they were greatly inferior in their quality and standards of manufacture.

Initially researchers attempted to remove chlorine from the cannonballs, by soaking in water with and without chemical treatment. Chlorine reduction by heating in an atmosphere of hydrogen was also attempted. Unfortunately, this did not successfully prevent disintegration when they were later put on display. To better understand this, Professor Schofield, established a research project with UCL Archaeology and the UK Diamond Light Source, to understand what was going on inside the cannonballs.

Diamond Light Source in Didcot is the UK’s national synchrotron. It works like a giant microscope, harnessing the power of electrons to produce penetrating bright light that scientists can use to study anything from fossils, to jet engines, to viruses and vaccines.

Diamond’s bright light X-rays combined with absorption spectroscopy, and fluorescence mapping made it possible to visualise the differences in the corrosion profiles. These could be traced to the treatments applied in the 35 years since the cannon balls were recovered with the Mary Rose. The results of the bright X-rays have revealed detailed maps of the elements involved in the corrosive process, an unprecedented insight into conservation on a molecular scale. This crucial information will help protect this and other cultural heritage artefacts for many decades to come.

The second presentation, “Fighting Corrosion” was given by Jim Glynn, a previous Chairman of London Branch and currently the Hon Treasurer. He also runs his own business, Beanny, which is a Coating Distribution Company.

Jim Glynn delivering a presentation on Fighting Corrosion

In his introduction to this presentation, John reminded the audience that the Annual Award of the U R Evans Prize included the presentation of a full-size Sheffield Steel sword, while the H G Cole Award was a mounted poniard (a large dagger). These weapons represent the continued fight against corrosion.

Jim concentrated on the Dynamic Duo, starting with a suitable protective coating as the primary source of defence against corrosion. This should then be supported, where appropriate by a cathodic protection system to prevent any corrosion occurring at holidays or in areas of coating damage. This applies to in-ground and sub-sea structures.

It is often commonly conceived that rusting is a simple, chemical oxidation reaction – but it is not. Aqueous corrosion is however, a complex, multi-stage step process which includes electron transfer at the molecular level. Thus these Electro-Chemical operations during corrosion can be influenced by the external application of electrical potentials. Under the right circumstances, corrosion can be stopped by applying the appropriate level of negative potential using a DC current supply.

Jim presented many examples where the correct conditions of a good coating and a suitable working cathodic potential were present. However, he also described many examples where this was unsuccessful. These included a pipeline coating that had totally disbonded and broken away from the pipeline. This was due to a higher potential than required, which generated hydrogen gas on the surface of the pipeline, causing the damage.

He also described Thermally Sprayed Aluminium (TSA) applications, which are excellent protective coatings when properly applied. The aluminium content can also act as its own in-built cathodic protection anode. However, in the wrong environment, the aluminium can be quickly used up.

Jim expanded his presentation to compare the recent Case Studies of retro-fitting remote anode beds to two similar North Sea rigs. These rigs had exceeded their design life, but it was decided that the sub-sea structure could be further protected using cathodic protection. One had been fully coated with coal tar epoxy, while the legs on the other had been left bare, but with a built-in corrosion factor that should exceed its expected life. The survey confirmed that both could be successfully protected using the methods adopted in the much deeper waters of the Gulf of Mexico.

The coated structure required 1,000 Amps, while the bare steel legs needed around 7,500 Amps to produce the correct comprehensive negative potentials. The location of the anode sea-beds were also calculated. These high DC currents were produced by banks of adjustable transformer rectifiers (TRs) connected to an AC mains electrical source.

Jim also interspersed a number of quiz questions, asking the audience to identify some notable Dynamic Duos in life, film and comic books with several bottles of wine as prizes! This was well received and considered a fun way to conclude the presentations.

The Vote of Thanks was given by Dr Parrett and he presented the speakers with ICorr Engraved Cross pens, as a memento of the evening.

 John T O’Shea, Jim Glynn, Professor Eleanor Schofield and Dr Parrett