The branch was very fortunate to have some excellent speakers for its winter meetings at Robert Gordon University (RGU) which attracted good audiences.
Dr Ed Whyte, principal corrosion engineer, and Paul McCarthy, of Plant Integrity Management (PIM) commenced the Q1 2019 programme with some great insights into the concepts of Maximising Economic Recovery (MER). Ed’s role has encompassed the provision of corrosion and integrity engineering services to PIM’s clients, while Paul is currently involved in various maintenance and inspection optimisation projects for a range of North Sea Operators.
They discussed the historic barriers to MER and how a step change from 60-74% production efficiency has recently been achieved, highlighting that only a 1% increase in efficiency, can dramatically produce an extra 12 million barrels per year in the North Sea, as 2016 figures have demonstrated.
Dr Ed Whyte of Plant Integrity Management (PIM) discusses managing integrity issues v. MER.
The initial UKCS Review (2013), the final Wood Report (2014) and new OGA (2015) UK MER Legislation (2018), have all recognised the importance of reducing UK plant
downtime / lost production. The most high profile MER document being the Wood Review (https://www.ogauthority.co.uk/about-us/what-we-do/the-wood-review/)
Although there has been a continuing downward trend in the number of plant losses, there remains an ever growing demand to limit UK Oil / Gas production outages, so as to maximise what income is available.
Most importantly, the presenters explained how gains to production efficiency can be achieved by approaching integrity management in a very different manner than has been the case before, through taking a long-term (but modular) view, with improved collaboration and engagement, assisted in all this by modern IT tools and devices that control data and costs more effectively.
The McKinsey Global Institute (2017) has studied in detail the longer term economic impact of “short termism”, and industry’s reluctance to invest in larger / longer maintenance projects. McKinsey claim that this figure is as high as 87% of executives and directors that feel pressured to demonstrate strong financial performance within 2 years or less, thus limiting available anti-corrosion / preventative maintenance expenditure.
In line with the McKinsey findings, PIM proposed that large maintenance projects be broken into more manageable / more achievable smaller repair / intervention scopes that target just one specific area or system, under a single project manager. This approach was then explained in greater detail by looking at the specific needs of upcoming CUI / PFP / FM preventative maintenance programmes and how they could be accommodated within this new modular approach to minimise external corrosion risks.
The full text of this most interesting and informative presentation can be seen at: https://www.youtube.com/watch?v=6Y36lf6ApIE
The February meeting was billed as a special Coating / Linings event, with two very knowledgeable presenters, Ajith A Varghese from International Paint Ltd and Gary Carswell of AEGION Group of Companies, who gave most interesting talks on Corrosion under Insulation (CUI) preventative coatings and Anti-Microbial Pipeline Linings, respectively.
The well attended Special Coatings Event at RGU in February.
Firstly CUI, which is a major issue that causes great cost to industry, and is currently the subject of a major project by the Oil & Gas Technology Centre, Aberdeen (OGTC). CUI poses a significant operational, safety and economic challenge. This is magnified in the North Sea, where many of the assets and infrastructure are operating well beyond their expected design life, and the OGTC vision is to eliminate all corrosion failures due to CUI by 2026.
Ajith A Varghese from International Paint presents on alkylated amine epoxies.
Ajith explained in great detail, the mechanisms of CUI, the integrity risks created, and the extensive research and development programmes undertaken in their Newcastle Laboratories. All prevailing ISO and NACE Standards, and their recent amendments, were discussed in the context of developing a new preventative product, and the lengthy but very necessary processes by which this is then taken to market, incorporating lessons learnt from field trials and customer feedback. In particular alkylated amine epoxies were discussed, which have been proven to have superior DFT cracking tolerance to over-application and increased productivity even at low temperatures, compared to standard epoxy phenolic systems.
Gary Carswell then explained in the context of internal corrosion prevention, how the use of protective pipeline liners has been very widely adopted by both the Energy and Non-Energy Sectors.
MIC related pipeline leaks typically account for 40% of all corrosion related failures, thus these compressive and rotational liner insertion processes can bring great advantages and enormous savings by extending the lives of water injection lines offshore and in many water distribution systems onshore. The 47km long Tweedsmuir offshore water injection lining was a prime example of this technology being put into practice for North Sea operations with sections pre-lined before laying.
This technology incorporates anti-microbial mitigation chemicals into the lining system that can then successfully prevent the growth and spread of MIC organisms. Typically a design life of 25yrs is specified for such lining systems but further R&D programmes are working towards a 50 year design life. In service failure of linings is extremely rare, provided adequate care is taken in respect of preparation and across pipeline joints.
Gary explained the many different lining types that protect against internal corrosion, their application systems and different geographical needs, in a very informative manner that was appreciated by all.
Both January and February talks generated many questions from the audience, which were well responded to by the speakers. The talks will be the subject of follow-up technical papers later in Corrosion Management.
Dr Yunnan Gao, the ICorr Aberdeen Chair, congratulated all speakers and presented them with Certificates of Appreciation.
Branch Chair Dr. Yunnan Gao presents a Certificate of Appreciation to Gary Carswell of Aegion.
The next technical evening, which will be run jointly with the Marine Corrosion Forum, will be held on Tuesday 30 April, when Dr. Ian Carpenter of Scaled Solutions, will present a talk on ‘Corrosion Inhibitor Screening: Impact of Test Approaches’ For the convenience of MCF conference attendees, this event will be held at ICorr’s old home, the Palm Court Hotel, starting at 5.30 pm.
Prior to this, a large range of papers will be presented by MCF commencing at 10.30 a.m, including:
• Oilfield reservoir souring; Forecasting of Microbiological sour gas production using the DYNAMICTVS© model, by Matt Streets of Rawwater Engineering.
• A comprehensive approach to Integrity assessment of Critical structural components operating in Marine environments with ASPIRE™ by Sebastian Hartmann, Payam Jamshidi, Innospection and TWI.
• CP inspection and monitoring of Subsea pipelines by Ross Fielding of Impalloy Ltd.
A full list of upcoming presentations can be found at https://www.marinecorrosionforum.org
Looking further ahead, the branch will be hosting its annual full-day Corrosion Awareness course on 27 August 2019, comprising of a number of lectures / presentations focusing on microbiologically influenced corrosion (MIC) in pipeline systems. This year’s CAD programme will include talks by ROSEN specialists and other visiting speakers, on their MIC experiences from global operations covering – Sampling, Analysis, Monitoring of Pipelines for MIC damage, Chemical Mitigation / Cleaning Strategies and finally Inspection, Modelling and Monitoring approaches.
Most certainly this event will provide a very comprehensive introduction, to this very significant and often troublesome area of Corrosion Control / Prevention.
As usual, all branch presentations can be found on: https://sites.google.com/site/icorrabz/resource-center, and full details of future events can be found on the diary page of the magazine and on the website, or by contacting, ICorrABZ@gmail.com
As noted in the President’s column, the official handover of Corrosion House in Northampton from the architect, was performed at the beginning of March.
Apart from the outer shell and the roof, the building has been gutted and rebuilt, with unbelievably fantastic results. It’s a 3-story building, the ground floor being dedicated for the Admin team, the middle floor for training, and the top floor as a conference room. Each floor has its own kitchen, and the training centre has a breakout facility for delegates.
Trevor Osborne commented that this is a world class facility fitting for the Institute of Corrosion and based in a location in easy reach for both national and global customers, and that we look forward to welcoming our customers and members to our new facility.
It’s state of the art, extremely well converted, and a credit to all those involved.
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, email@example.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 last presentation of the 17/18 season was a joint meeting with NACE UK, and Francois Lirola of Saipem, gave a very interesting talk entitled, “Fusion Bonded Joint: an innovative technology for cost effective plastic pipe installed in J&S lay”.
In deepwater, corrosion protection of flowlines is becoming a major issue. Conventional corrosion allowance of carbon steel flowlines, or cladding, leads to excessive procurement costs, installation weight, welding and NDT challenges. Francois introduced an interesting alternative to achieve an acceptable corrosion protection – is the use of plastic liners. However, plastic lining has been mostly limited up to now to reel lay. SAIPEM has developed and patented an innovative and cost effective field-joint system, the Fusion Bonded Joint (FBJ), which can maintain the corrosion barrier across girth weld locations along the flowline. It has minimal impact on the offshore laying rate and it is based on field proven technologies and methods that are commonly employed in gas transportation networks. The design and fabrication of the FBJ system were explained, and the results of the extensive qualification that has been carried out, were shown.
This excellent presentation led to a high level of discussion by the audience, and the chairman thanked Francois for the time taken in preparing this talk and for coming to London to deliver it.
The third branch 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 a technical presentation of “Sour Service Testing of Carbon Steel Girth Welds” by Phil Dent, Element’s Global Corrosion Specialist, followed by a visit to the new H2S / Sour Service Laboratories.
Phil Dent, Element’s Global Corrosion Specialist explains SSC Phenomenon.
Ian Farquharson, General Manager of Element Aberdeen and Edinburgh branches, introduced Element, and noted that is ranked as the 5th biggest materials testing and certification firm 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.
Phil Dent started his technical presentation by defining sour service conditions, followed by a description of the 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 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 the 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 also explained.
The corrosion testing laboratory visit was supervised by Paul Roberts, Corrosion and Chemistry Manager, who explained that 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 also 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 international testing standards and protocols such as those from ASTM, IP MIL and NACE. Paul summarised the procedures for the H2S sour service axial tensile test, high temperature / high pressure, electrochemical tests and strain gauging.
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 visit one of the major testing and materials qualifications bodies here in United Kingdom. Overall, it proved to be an excellent event in every respect.
The April evening meeting had 78 attendees, and followed on from a very successful visit to Aberdeen by the Marine Corrosion Forum.
George Gair – Global Inspection Manager for Subsea 7 presenting to ICorr ABZ.
George Gair of Subsea 7, started 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.
Very clearly the drive is to produce new and robust methods of harvesting sensor data, and subsea hardware suppliers are looking at increased in-situ 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.
Monzar Najami – Principal Inspection Engineer of Oceaneering International.
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.
The presenters informed the audience that the greatest challenge to developing and implementing an asset integrity programme 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 delay in the implementation of these activities impedes the Integrity Management Programme (IMP) and increases the level of risk to the facilities in the operating stage.
Key stages in an IMP project were highlighted as:
Identify stakeholders early in the project (project team, operations, planners, site personnel)
Define strategies and processes and add activities to the construction plan (integrated project activity approach)
Analyse historical data (collect the available list of failures, anomalies and review root cause analysis)
Material fitness for new process (review threats assessment and existing material suitability)
Baseline inspections: Get in early (define scope and input your inspection requirements in the manufacturer’s ITP)
Brownfield revamp activities: Scrutinize output (repair recommendations were challenged and resulted in major cost saving, and change in material selection)
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)
Deployment of new and advanced inspection technologies (to achieve major cost savings)
A wide range of questions followed the very comprehensive presentation and all the 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. To sign up to the branch mailing list, go to, https://sites.google.com/site/icorrabz/home
ICorr Aberdeen will host its Annual Corrosion Awareness Event on Tuesday 14th August 2018. For further details please contact: Corrosion Awareness Chair, Steve Tate on, firstname.lastname@example.org
Dave Griffiths being awarded a plaque and certificate by ICorr President, Sarah Vasey in recognition of his contributions to training.
The Institute of Mechanical Engineers training centre in Sheffield (Engineering Training Solutions) has confirmed that Dave Griffiths has retired from his consulting role in support of the ICorr courses provided by IMechE.
Dave’s role with IMechE, and previously ARL, was multi-faceted and has been a key part of the ICorr training provided first in Rotherham, and latterly in the brand new training centre in Sheffield. Dave delivered training to many of the Painting Inspector groups but also acted as Scheme Manager and provided invaluable support to ICorr’s Professional Development Training and Certification (PDTC) Committee over a considerable number of years.
Dave was recently awarded a plaque and certificate by ICorr President, Sarah Vasey, in recognition of his contribution to training, and all at ICorr take this opportunity wish him well.