Corrosion A journal of the Institute of Corrosion · Key to Reducing Corrosion under Insulation 22 Technical Article Failure Investigation of Internal Anodic Protection of Sulphuric

CorrosionManagement

A journal of the Institute of Corrosion

Issue 152 November/December 2019

Corrosion under

Insulation

www.icorr.org

Industrial Coating Applicator Training Scheme NewsPage 5

Keep up to date with the very latest Industry News Page 11

Corrosion Management

2 November/December 2019 www.icorr.org

FOR ALL THE LATEST CORROSION INDUSTRY JOBS VISIT THE ICORR JOB BOARD

For job seekers• Over 60 jobs currently being advertised • Set up job alerts for immediate notifications • Upload your CV so employers can find you • Free to use

For employers• Place your job in front of our highly qualified members • Over 10,000 visitors every month • Fill your jobs quickly with great talent

All sustaining members receive a 15% discount

For more information contact Jonathan Phillips on 0114 273 0132

or email [email protected]

ContentsIssue 152 November/December 2019

4The President Writes

4Institute News

11Industry News

14Innovative Products

16Technical Article Field testing for Soluble salts – A problem to be aware of

19Technical Article Correct Cladding Systems are the Key to Reducing Corrosion under Insulation

22Technical Article Failure Investigation of Internal Anodic Protection of Sulphuric Acid Tank

26

Sustaining Members

32Diary Dates

Published on behalf of the Institute of CorrosionSquare One Advertising and Design LimitedNeepsend Triangle Business Centre, Unit 8, 1 Burton Street, Sheffield, S3 8BW.Publisher and Managing EditorDebbie HardwickTel: 0114 273 0132Email: [email protected] EditorBrian GoldieEmail: [email protected] One Advertising & Designwww.squareone.co.ukAdvertising ManagerJonathan PhillipsTel: 0114 273 0132 Fax: 0114 272 1713Email: [email protected]

Editorial copy date for January/February 2020 issue is: 10th January 2020 SubscriptionsUK £70.00Europe £80.00Outside Europe £90.00 airmail £80.00 surface mailEnquiries and subscriptions to the Institute of Corrosion at the address below:The Institute of CorrosionPresidentGareth HindsPast PresidentSarah VaseyHon. SecretaryDr. Jane Lomas

Institute of Corrosion, Corrosion House, 5 St Peters Gardens, Marefair, Northampton, NN1 1SX

Tel: 01604 438222 Email: [email protected] Website: www.icorr.orgAll rights reserved Reproduction without written permission from the Institute of Corrosion is prohibited. Views expressed in editorial text or advertising copy are the opinions of the contributors/advertisers and are not those of the Institute or the Publisher. ISSN: 13 55 52 43

This publication is Recyclable.

Institute News


Welcome to the last issue of the magazine for 2019. Again there are three technical articles covering different aspects of our industry. Firstly, Simon Hope describes a problem to be aware of when carrying out field testing for soluble salts on steel surfaces prior

to painting. Next, James Meier discusses Corrosion Under Insulation and how the correct choice of protective cladding can help to prevent this problem, and finally, Ahmed Mahgoub explains how anodic can be used to protect sulphuric acid tanks, and highlights how getting it wrong can lead to failure.Next year, as well as the re-branding of the Institute, as described in Gareth’s presentation to Aberdeen branch, there will be some exciting changes to the magazine, starting with a new Q&A column.Finally, I would just like to add my good wishes for the festive season to those of the President.Brian Goldie, Consulting Editor

I am now officially halfway through my term as President and I have to say the time has really flown by! I have nothing but good things to say about the role – I get to see and do some very interesting things and meet some amazing people along the way. Above all, I have been continually impressed by the dedication, pride and professionalism of our members. ICorr is a very special institution and I feel a strong sense of responsibility to maintain and enhance this wherever possible.It was a pleasure to attend the AGM at the end of October in the rather grand surroundings of the

Birmingham Council Chamber, to which we have become accustomed in recent years. The meeting was hosted by the Midlands Branch and was preceded by an impressive talks on cathodic protection from Markus Büchler, Trevor Osborne, Brian Wyatt and Chris Wozencroft. This very distinguished list of speakers was undoubtedly a major factor in the large turnout of over 80 people, which was great to see. Many thanks are due to Bill Whittaker and the Midlands Branch committee for their organisation of the event.A number of important changes to our categories of membership were ratified at the AGM. The first was to introduce a new category of Honorary Life Membership. From July next year, all members over the age of 70 with at least 35 years of membership will be automatically entitled to free subscription for life through elevation to the category of Honorary Life Member. Those who do not meet the minimum years of membership requirement will still be able to attain Honorary Life Member status via a one-off payment of twice the annual subscription fee (for members over the age of 70)

or three times the annual subscription fee (for members over the age of 65).All of these new options will be laid out in detail in your subscription renewal letter next year and will apply to all categories of membership. We hope that this will make it much easier for members to retain links with the Institute after retirement, when membership subscription fees may understandably drop down the list of priorities. Honorary Life Membership is also a fitting recognition of the contribution to the Institute made by our members over their entire career.The second change was to rename Individual Members (formerly Ordinary Members) as Affiliates, which was deemed necessary in order to resolve the perennial confusion with Professional Membership. Affiliate is an important entry-level category of membership for the Institute, comprising almost one third of all members, and it is vital that we continue to highlight the opportunities for career development and progression that the Institute offers. Networking, training and accreditation rank highly among these, and we are working hard to enhance these benefits. We are particularly keen to increase the number of Affiliates progressing to Professional Membership, which can be achieved after 15 years of field experience, together with additional training and accreditation. If you know someone in this position, please do not hesitate to give them a nudge in this direction; more details can be found on the Membership section of the ICorr website.The AGM also saw the election of our Officers and Council members for 2019-20 and I would like to congratulate all concerned and thank them again for their valuable contribution to the Institute. In particular, we are pleased to welcome Caroline Allanach as a newly co-opted member of Council. Caroline has been doing a great job in supporting the activities of our Young ICorr Chair, Simon Bowcock, and we are looking forward to the fresh perspective she will bring to Council. I also had the pleasure to present David Harvey with Honorary Life Fellowship in recognition of all the hard work he has done for the Institute.May I take this opportunity to wish you and your loved ones a very happy Christmas and a prosperous New Year.

Icorr President, Gareth Hinds

The President Writes

From the Editor

ICorr President, Gareth Hinds.

The AGM was held in the Birmingham Council Chamber at the end of October, and at which David Harvey was presented with Honorary Life Fellowship by the President in recognition of all the work all the work he has undertaken for the Institute as chair of PAC, managing the ISO 9001 process and supporting CP training, for many years.

Institute AGM

Institute News

www.icorr.org November/December 2019 5

Industrial Coating Applicator Training Scheme (ICATS)ICATS NEWSICATS is moving rapidly towards its 15th anniversary in March next year and continues to grow exponentially with such prestigious organisation supporting the programme as; Highways England, Network Rail, Transport for London, London Boroughs, Sellafield, Workplace Solutions and Devonport Dockyard to name a fewThe business is packed with great stories where companies have been able to demonstrate improved workmanship and cost saving through the ICATS training programme;K&M Group (London) have used the ICATS training programme as the basis to build the skills necessary to develop their industrial coatings division. They have been incredibly successful in winning work in this sector around London including; Battersea Power Station and Southwark Council. They will be holding seminars in the New Year at Arsenal football club and inviting potential customers from the London area. Customers will be able to see the benefits of the ICATS programme and have the opportunity to talk to people who have benefited from the scheme.Survivex (Aberdeen) have installed some of the best training equipment in the country and have started the task of training applicators in the north-east of Scotland. They have won support from the Altrad Group and Bilfinger who they bring into the ICATS family. They will also be holding seminars in the New Year at their facilities in Aberdeen, and inviting customers from both the offshore and onshore industries.Paintel (Plymouth) continue to drive the excellent training programme, Work Place Solutions, at Babcock, and to the applicator community across the South West. Rob Hurley has become a Senior Specialist Trainer allowing Kevin Harold more time to develop the ICATS programme even further; new modules will be introduced in the New Year which will assist specialist activity in our industry.Livingstone Surface Treatments (Cumbria) continues to offer the ICATS programme with the Managers Course held at Sellafield in October being a great success and ICorr are planning a joint evening with the Materials Society of Cumbria in March next year. There will be further ICATS training delivered by Livingston Surface Treatments, for the engineering community in Cumbria throughout 2020.The Managers Course programme gives the specification writer and planning engineer a knowledge of protective coatings, standards, specifications and the complexity of their application. In addition to Sellafield the course has also be given at Babcocks There are two new Approved Training Centres in Aberdeen and London and additional companies to join the growing group in Birmingham and Southampton are being sought. SMART Card - the work is virtually complete on the new SMART card which will be launched in the New Year. This complies with the CSCS requirement for the Partner Card scheme of which ICATS is proud to be a member.The first apprenticeship programme, run by DN Colleges and driven by Jack Tighe Ltd, will be coming to a conclusion in mid2020 and the second apprenticeship cohort has recently started. It’s a great credit to JTL who have driven the whole programme and somewhat surprising other major applicators in the UK haven’t taken

Rustrol® Cathodic Isolator® effectively blocks the DC current needed for cathodic protection, while providing grounding path for:

• AC Fault Currents

• Lightning Protection

• Mitigation of Induced AC Voltages

• Power Switching Surge Currents

Cathodic Isolator® features electronic/electrical construction that responds instantly, protecting personnel and equipment against electrical shock hazards.

E-mail: [email protected] Central Fax: 905-333-4313

www.Rustrol.com

INTERNATIONAL CORROSION CONTROL INC.

INTERPROVINCIAL CORROSION CONTROL COMPANY LTD.Industry Leaders … since 1957

ATEX

up the programme. Martin Hillyard at JTL said that it offers young people a new opportunity, improves skills and capabilities, and starts to redress the industry issue of an aging workforce who are retiring with those skills. Kevin Harold and John Whittaker have worked tirelessly to develop these ICATS apprenticeship modules.We are pleased to announce that Skills Training UK will be adding the Industrial Coating Applicator training programme to its already successful NDT apprenticeship which is a perfect fit with the BINDT and IMechE in Sheffield.

ICATS training powers McLoughlin’s work at iconic London landmarkK&M McLoughlin has credited the ICATS training programme - which has trained 66% of its workforce - for not only the successful application of the high solids surface tolerant epoxy to girders in the turbine hall at the old Battersea Power Station, but also the smooth running of the project and the quality of the service. A few of the employees were doing the course whilst working on the application at Battersea, which allowed them to learn practical skills on site to back up the theory being taught.The London-based company has spent six months working in collaboration with tradesmen and scaffolders on Phase 2 of the £9bn project at the instantly recognisable landmark that will be transformed into housing, shops, offices, and over 19 acres of public space. The scale of this phase of the project at the Grade-II listed building, was something that had to be closely managed by K&M McLoughlin on site with a vast network of birdcage scaffolding needed to accommodate the variety of trades.

Continues on page 6

Institute News


Institute Awards – call for nominations Each year the Institute of Corrosion bestows a range of internationally-renowned awards in recognition of excellence in corrosion science and engineering and to reward outstanding service to the Institute and the wider corrosion community. Many of these awards are open to nomination by members of the Institute. Below is a brief description of each award together with details of how to nominate potential candidates.

U.R. Evans AwardThe U.R. Evans Award is the premier scientific award of the Institute of Corrosion and is presented annually for outstanding international achievements in pure or applied corrosion science. The recipient is selected by a Corrosion Science Division panel and presented with a sword at the annual Corrosion Science Symposium. The symposium is one which seeks to encourage the participation of the junior members of the corrosion community who would appreciate the visit of, and address by, a corrosion scientist of international repute. The form of the award symbolizes the fight in which we are all engaged. The recipient is also granted Honorary Life Fellowship of the Institute. Nominations may be submitted at any time via email to the CSD Chair, Julian Wharton ([email protected]).

Paul McIntyre AwardThe Paul McIntyre Award is presented to a senior corrosion engineer, who, as well as being a leading practitioner in his field, has advanced European collaboration and international standards development. The award consists of an engraved trophy, which is presented at the annual CED Working Day meeting. The recipient is requested to present a brief overview of their activities and encouraged to prepare an article for publication in Corrosion Management. Nominations should be submitted to the CED Chair, Nick Smart ([email protected]), by 28 February 2020.

H.G. Cole AwardThe H.G. Cole award is in the form of a poignard and is made in recognition of exceptional services to the development of the Institute. It is only awarded on an occasional basis, typically every 5 to 10 years, reflecting the highest possible level of commitment of the recipient to the activities of the Institute. Nomination and selection for this award is

administered by the ICorr Awards Committee. Nominations may be made at any time to the Awards Committee Chair, Gareth Hinds ([email protected]).

Honorary FellowshipHonorary Fellowship is awarded in recognition of outstanding service to the Institute over many years. The recipient is bestowed the suffix FICorr (Hon) and all future membership fees are waived. Nominations for Honorary Fellowship must be submitted via Council.

T.P. Hoar Award The T.P. Hoar Award is presented to the authors of the best paper published in the scientific journal Corrosion Science during the previous calendar year. The winning paper is selected by a sub-committee of the Corrosion Science Division and the authors receive a certificate and a cash sum of £400. The recipient of the award in 2019 will be announced by the end of the year

Galloway Award The Galloway Award is presented to a student author for the best publication describing original research in corrosion science and engineering as judged by a sub-committee of the Corrosion Science Division. A summary of the winning paper is published in Corrosion Management and the prize consists of a certificate and a cash sum of £300. The Institute does not retain copyright of the material, so this does not prevent separate publication of the work in a scientific journal. Submissions (in the form of papers published within the past 12 months or draft publications) may be sent via email at any time to the CSD Chair, Julian Wharton ([email protected]). The decision on this year’s award will be made shortly.

Lionel Shreir AwardThe Lionel Shreir Award is made to the best student presenter at the annual Corrosion Science Symposium. Selection of the recipient is carried out by a sub-committee of the Corrosion Science Division. The award consists of a certificate and a cash prize of £125.For further details on the Institute awards, including lists of past recipients, please visit https://www.icorr.org/icorr-awards/

Many of the team that worked on the Battersea project had been working on rail projects for London Underground, but now they have an industrial coatings qualification

thanks to the in-house training programme, which is great for everyone. According to Ross McLoughlan, head of the Industrial & Rail specialist coating division, “We invest in them. We pay the course for them, we pay them their wages while they’re here and it’s a mutually beneficial initiative for both the team and the company.” The benefits aren’t limited to the emerging pool of talented applicators though, as the training programme has also opened doors for K&M McLoughlin, which will be using ICATS trained staff in the application of a sophisticated two-pack epoxy fire protection system at the new Google building.“It increases our diversity as a company,” continued Ross. “Whereas some clients might outsource the job and not be able to complete the work themselves, we can offer it. We’re a £10 million company and one million of that is focused on protective coatings, which has helped reinforce the reputation of K&M McLoughlin, and we’ll be looking to grow that department by bringing as many people as we can through the ICATS training programme.”

Continued from page 5

The complex steelwork to be protected.

Institute News


Young ICorr

Young ICorr held a joint meeting with the Greater London region IMechE Young members network on the 21st of November. The talk was held in the Council room of the IMechE on Birdcage walk followed by networking in a nearby hostelry. The evening brought together young engineers, professionals and students from across the country who are interested in corrosion, materials, metallurgy and welding. It was a great opportunity to meet like-minded peers from other industries and also provided many of the attendees enrolled on the 2020 Young Engineering Programme (YEP) to meet prior to the programme starting in January.Guest speaker Roger Francis (RF Materials) gave a fascinating talk on “Corrosion Engineers (& Metallurgists) can save you money”. This covered a whirlwind tour of case studies from fertiliser production to deep sea diving, highlighting poor materials selection and the importance of working together

to understand the operating environment for the mechanical equipment. Often mistakes are repeated without learning, emphasising the need to engage a corrosion engineer. Roger’s extensive knowledge on duplex and superduplex stainless steels, in conjunction with correct heat treatments, demonstrated how the corrosion problems could be solved, often with cost savings. He then emphasised the importance of corrosion engineers’ involvements in QA/QC activities to ensure the correct testing and support regimes were put in place at the procurement stage. The talk was very well received and definatly got people thinking about the importance of materials selection.Sponsorship was kindly provided by the Institute of Corrosion and IMechE. To stay informed about future Young ICorr events please join the LinkedIn group by searching for ‘Young ICorr’ or alternatively email [email protected]

New Sustaining Member

Paintel Ltd has been specialising in industrial painting and maintenance of structures since 1999. They are privileged to have partnered with clients, and cared for some of the most iconic bridges and structures in the South West UK. Paintel applicators are fully ICATS trained, including Specialist and Supervisor modules. Their team have numerous years of experience between them and hold a raft of industry qualifications including; Rope Access (IRATA), MEWP (IPAF), Towers (PASMA) & Confined Spaces.The trainers, both ICA & specialist, operate from the Paintel office & ICATS Approved Training Centre in Lee Mill, Devon.They are proud to support Correx and be part of the ICorr/ICATS development team for creating courses. Kevin Harold is the lead ICATS trainer, delivering the ICATS Company Trainer, Supervisor and Technical Manger courses. Kevin is also involved with writing courses for ICorr, ICATS, and the ICATS Apprenticeship scheme.There is an experienced team of ICorr Painting Inspectors covering all three levels. Paint investigation work is carried out for various clients, including Highways, where the investigation is used to determine the existing paint system(s) and how best to prepare and re-paint with a new system. Paintel are accredited to ISO 9000 and NHSS 19A, ISO 14001 and ISO 45001, which demonstrates to customers that they are willing and able to take the extra steps to prove that they will be held accountable for what advice they give and work they do.

Paintel Ltd

www.icorr.org

Visit the ICorr website for all the latest news

Institute News


The annual ICorr corrosion induction presentation was given on September 26 at Aberdeen University by Zahra Lotfi, the branch University Liaison and CPD Officer. This event was excellently organised with the support of Dr. M. Amir Siddiq of the School of Engineering, Aberdeen University, which resulted in a brilliant turn out of new MSc students, as well as many returning students (35 in total).The presentation included an introduction to corrosion, corrosion costs, the importance of corrosion control/ mitigation/ monitoring, and the consequences of corrosion with several real life examples of catastrophic failure due to corrosion in oil and gas and transportation sectors. Common corrosion degradation mechanisms in the oil and gas industry and how the co-operation of different engineering disciplines can help protect the integrity of an asset, were also covered.

The students were also introduced to the Institute of Corrosion, its objectives, technical divisions, regional branches, training and qualifications provided, the many benefits of membership (e.g. ICorr mentoring programme to assist its members to achieve their Chartered Status) and how to apply for this. In addition, the students were familiarised with the work of the branch, its activities calendar and website, and how the Institute can assist students greatly in their continuous Professional Development (CPD).As a finale, questions on ICorr membership, chartered engineering requirements and local events were discussed in detail and Yunnan Gao (Immediate Past Chair) told the students how they can involve themselves in ICorr activities e.g. by way of a poster presentation, or presenting their research project in greater detail, at upcoming branch events. The branch held its first technical meeting of the 2019-2020 session at its usual venue, Robert Gordons University, on 24 September. This was the annual joint event with TWI (The Welding Institute – Northern Scottish Branch) at which a

Local Branch NewsAberdeen Branch

Student membership presentation by Zahra Lotfi.

topic relevant to both welding and corrosion communities is presented. This year it was “Environmentally Assisted Cracking in Offshore Assets – A Review of Mechanisms & Mitigations” presented by Dr Daniel Sandana of Rosen.Dr Sandana explained what environmentally assisted cracking is, its causes, and the conditions under which it occurs and to which materials. He discussed the well known ‘bathtub’ model for crack initiation, propagation and final fracture, and highlighted a number of key facts for stress corrosion cracking initiation, propagation and mechanisms, including the Staehle Diagram and the Parkins Spectrum.The effect of hydrogen embrittlement on steel and how hydrogen is absorbed into steel during corrosion was discussed and he touched on the various theories of how hydrogen may act to embrittle steel and showed the observable effects of embrittlement.Daniel also discussed sulphide stress corrosion (SSC) cracking which occurs in the presence of hydrogen sulphide, and showed the associated mechanisms of hydrogen induced cracking and stepwise cracking, and recalled failure examples of duplex stainless steels (DSS) by hydrogen induced stress cracking (HISC) in subsea pipelines in the late nineties and more recently in 2003. He detailed the requirement for HISC to occur in DSS and how this was countered by the requirements of DNV-RP-F112.Lastly, he talked about external chloride stress corrosion cracking which is a relatively common failure mechanism of stainless steels in an offshore environment.Daniel fielded many questions from the large audience and was assisted in responding by Craig Cooper (TWI, North Scottish Branch chair).At the end of the meeting, the branch chairman, presented the speaker with a Certificate of Appreciation from the branch.

The second of the branch’s regular technical meetings was held on 29 October. This was a double header event with Dr Gareth Hinds, the current ICorr President speaking about “Growing the Institute membership, and the ICorr Awards”, and Matt Streets of Rawwater: presenting “An understanding of Reservoir Souring and Mitigation”.Gareth started his presentation by posing the question: How can the Institute of Corrosion adapt to thrive in a rapidly changing world? He reminisced that he had first attended an Aberdeen Branch meeting 13 years ago, and complimented the branch for being one of the strongest and most active of the regional branches. He went on to say that since then he has learned a lot about what its members can give to the Institute and what they can expect to get from it in return.He described the history of the Institute and the benefits of membership, and stated his belief that the more one puts in, the more one will get out of being a member.Gareth reminded the audience of the history from when ICorr started as the British Association of Corrosion Engineers in 1959 and the name changes and location changes that it went through up until the present day when the Institute recently purchased its own headquarters building in Northampton.

The attendees at Robert Gordons University for the joint TWI/ICorr event.

Dr Daniel Sandana (of Rosen) was presented with a Certificate of Appreciation by the Aberdeen Branch Chairman Stephen Tate.

Institute News


He went through the different types of ICorr membership touching on the plans to change individual membership to “Affiliate” and other planned changes. He also touched on the challenge to get student members to stay, and by empowering younger members, for example to take part in the young engineers programme which has as a prize a free trip to the NACE conference in the USA, and free ICorr and NACE memberships. Gareth continued by highlighting membership benefits which he stated were networking, career development, visibility and financial rewards. He also gave the audience an update on the situation with the Engineering Council caused by the sudden failure of the Society of Environmental Engineers (SEE) in that the Institute hopes to combine with the Society of Operational Engineers (SOE) to continue to award Chartership status through the Engineering Council. It is expected that an agreement will be signed in January next year and ICorr head office will be in touch with all those chartered engineers affected to confirm this.He described the brand refresh which will be taking place at the start of next year when the ICorr website and all paperwork etc. will be revised to make the image of the Institute more modern. Pictures of rust and corrosion will be replaced by pictures of gleaming new infrastructure and similar modern hardware. He told how the Institute had undergone digital modernisation and members can now pay their subscription online on the website. He said that the Institute of Corrosion was once again looking to influence governing bodies as they had in the 70s when they had been influential in getting Capcis in Manchester and the National physical laboratory setup.Gareth’s comprehensive presentation was enlightening and uplifting showing his clear vision for the future of the Institute of Corrosion under his leadership.In the second presentation of the evening Matt Streets of Rawwater discussed how, as all oilfield reservoirs have different souring propensities, operators must view all injector/producer (I/P) pairs as unique in regard to H2S gas production, as well as control and mitigation strategies. Matt’s presentation described how a predictive oilfield souring model can be used to help forecast if, when, and to what extent, an oilfield will sour. He explained how the model describes the cooling of an oilfield due to water-flooding and the subsequent growth of sulphate-reducing microorganisms, resulting in sulphide production at the topsides facilities. Outputs from the model can be used to inform and influence key operational

decisions and have provided huge cost savings for operators through cost-effective material selection and chemical dosing. Matt’s presentation included a detailed review of the science that was used to produce the model and how the output from it can be used by Oil and Gas operators to plan to minimising costly problems caused by reservoir souring and thereby maximise their operating profits.At the end of his presentation Matt answered questions on where the model input data came from, how critical seawater breakthrough was to the modelling, how many core samples were required to confirm that they had not been contaminated, the viability of injecting alternative food stock to the reservoir and about re-educating operational personnel. At the close of the meeting, the branch chairman, presented both of the speakers with a Certificate of Appreciation.

Full details of future branch events can be found on the diary page of this magazine and on the website, or by contacting: [email protected]. Copies of the majority of past branch presentations can be found at: https://sites.google.com/site/icorrabz/resource-center, and a photo gallery for these events is at: https://sites.google.com/site/icorrabz/event-gallery

Matt Streets receives his Certificate of Appreciation.

Midland branchThe branch held a half-day networking event for sustaining members at the Severn Valley preserved steam railway on 26 September.It was a well-attended event by members from all ICorr disciplines, with all members expressing thanks to ICorr for sponsoring the event in return for being a sustaining member. All members thought the day severed them well in terms of networking with other corrosion professionals.

Following a 30min train ride on a steam train, lunch was severed within the Severn Valley museum, ICorr members then enjoyed the offerings at the museum followed by a train ride back to Kidderminster. The feeling of the day was that ICorr should be organising more events like this up and down the UK as it is a real member benefit.

Institute News


A joint meeting with the Society of Chemical Industry (SCI) was held at their newly refurbished auditorium in their Belgravia HQ, on 26 September. The audience of over 70, included Professor Ken Grattan, OBE, FREng, who is the Dean of the graduate school at City University, London, and who agreed to give the vote of thanks.

The evening Chairman, John T O’Shea, introduced Dr Fred Parrett, Hon Treasurer of the SCI London Group, who gave the first presentation on the laying of the first Transatlantic Telegraph Cables.The electric telegraph was first developed by Samuel F. B. Morse in 1832 who also developed Morse Code. Land based cables to use the telegraph soon followed, and within a decade, more than 20,000 miles of telegraph cable criss-crossed the USA, the UK and Europe. Trials of underwater cable were undertaken by Samuel Morse across New York Harbour in 1842 and Charles Wheatstone across Swansea Bay in 1844. In 1851 a cable crossed the English Channel.

The problems of laying a cable across the Atlantic were a greater challenge, not just the technical and logistical problems, but financing such a great undertaking. The first attempt in 1857 failed when the cable broke, and could not be recovered. New finance was arranged and in August 1858 they succeeded, when the first transatlantic telegraph message was transmitted. Unfortunately the cable failed after only three weeks, which was thought to be due to breakdown of the cable insulation when voltages of a few thousand volts were used to try and speed up transmission speed. It took another 7 years before new finance was arranged and improved cable designs were developed for the next attempt. For this Brunel’s ship the Great Eastern was acquired, the largest ship in the world at that time. In 1865 it almost succeeded, starting in Valentia Bay, Ireland it reached 600 miles from Newfoundland when the cable again broke. The final success came one year later in August 1866 when the cable finally crossed the Atlantic and permanent telegraph communication established. The 1866 transatlantic cable could transfer 8 words a minute, and initially it cost $100 to send 10 words, which translates

to about $1,340 today, and was mainly used by the British and American governments and large corporations. The second presentation was given by Trevor Osborne, a Past President of ICorr and a Past Chairman of London Branch, on 50 Years of Oil and Gas Offshore Corrosion Control Experience and Transfer of Technology to Offshore Renewables.Development of offshore structure corrosion control methodology in the North Sea, and all around the world, has been on-going for decades, in fact close to 50 years and possibly longer in some parts. Given this long experience, corrosion engineers rightly considered that all aspects of barrier coatings and cathodic protection were honed to a fine art and as a result one system followed another with great

success, in fact Trevor had been involved in many offshore structure designs with responsibility for painting, coating, CP, biocides, inhibitors and other aspects of corrosion control. However the fabrication and installation of new offshore structures for the oil and gas market has declined greatly and that work load has in part been replaced by the upsurge in renewable energy requirements. Specifically offshore wind generation in the form of monopiles, transition pieces and substation fixed jackets. All exposed parts of each structure need to be addressed from a corrosion perspective if the asset is to be protected and the lifetime met.The presentation walked the audience through the period of time from early offshore structure design and construction for the oil and gas markets, to the painful transition to wind energy, including the attendant problems that have occurred along the way and what should have been an easy transformation but often times was not.The first meeting at the branch’s new venue, the Lancaster Hall hotel in Bayswater, was held on 10 October. Kevin Harold of Paintel Ltd gave a fascinating insight into the world of an Industrial Coating Applicator, taking a look at past, present and future practices in the industry. Kevin explained how the Industrial Coating Applicator Scheme (ICATS) has changed the view of Health and Safety and the concept of “slap it on and get out of here”, to ensure the work is compliant to the specification. He began his presentation by describing his

journey as a painter from the era when PPE was non-existent, how he moved into industrial painting, became a painting inspector, and after joined the Tamar Bridge strengthening and widening project, found the painters could not apply coatings properly, so he began teaching them.Even as late as the early 21st Century clients were not getting what they wanted in terms of standards or quality, and in 2006 after becoming aware of ICATS, registered his company, got his workforce trained and subsequently became a trainer himself. Kevin could see the enormous benefits of ICATS, notably the evidence that the training results in major savings from less repeat work and the advantages gained by the asset owners and operators, so he became an ICATS senior specialist trainer, and the current ICATS course material, launched in 2018, was written by him and his wife Jo. He has also written the ICATS Supervisor course and the new Managers Coating Awareness course which provides an insight into coatings for specifiers and engineers.Kevin finished his presentation by saying that a lot of asset owner operators are happier with the final product they get from ICATS accredited applications, and ICATS is now mandated by many companies. The enormous impact of ICATS on the whole industry has yet to be completely realised and it’s now going global.The January meeting will be held on Wednesday 8th at the Lancaster Hall hotel (note change from usual second Thursday for this month), when there will be a panel discussion on “Linings for Extreme Duty” with Dr N Miskin, DuraPol, and Michael Harrison, Sherwin Williams.

London Branch

Trevor Osborne.

John O’Shea and the first speaker, Fred Parrett

Kevin Harold.

Institute News


Industry News


Industry NewsNew Research and Development Director appointed for Elcometer LtdElcometer Ltd, has announced the appointment of Paul King as their new Research and Development Director.

Paul joins Elcometer with over 17 years of leadership experience at global companies, which included mechanical engineering and technology groups. He spent a large part of his career at Nokia, finally becoming the Director of Mechanics Technology, before he was transferred to Microsoft in the position of Concepting Director.

His key responsibilities at Elcometer will include managing the overall activities in the R&D department at Elcometer’s head office in Manchester, UK, and ensuring that Elcometer continues to deliver world leading technology to its customers across the globe.

A new system for predictive Corrosion under Insulation (CUI) managementCorrosionRADAR, a Cranfield University spin-out company, has developed a novel automated system for monitoring and predicting Corrosion under Insulation (CUI). This patented system supports a move away from reactive risk-based inspections to predictive corrosion management.The system uses a distributed sensor system, with long, thin sensors (<3mm diameter) permanently embedded in the insulation around the asset. The core technology is called Electromagnetic Guided Wave Radar (EMGR), in which an electromagnetic wave injected into the sensor can be used to detect both the location and extent of corrosion damage, at long distances.The company approached the Oil and Gas innovation Centre (OGIC), Aberdeen, for support with two different projects that would help it develop next-generation sensors for its system. The first project related to the analysis of corrosion rates and corrosion correlation of various metals, and was carried out by the Condition Monitoring Research Group at the School of Engineering at Robert Gordon University. The second research project focused on sensor manufacturing technologies, deployment of sensors, and corrosion testing under simulated CUI conditions, in order to determine which materials could be used for the outer shield of the sensor. This project was undertaken with Dr Todd Green and Professor Sudipta Roy in the Department of Chemical and Process Engineering at the University of Strathclyde. The study included a survey of manufacturers and manufacturing techniques to identify manufacturers who could make prototype sensor cables and looked at deployment options, including retrofitting sensors in existing pipework and insulated structures, and the possible use of robotic pipe crawlers, as well as addressing the relative corrosion behaviour of various metals under CUI conditions that could be employed to manufacture the cable sensors. While there was a degree of variability in the corrosion rates of all the metals tested, the research showed it was likely that copper or aluminium sensor materials could be used to assess corrosion in a carbon steel pipe. More details on both studies can be found at, www.corrosionradar.com

Visit the ICATS website www.icats-training.org

Oilfield Corrosion Science and Engineering Course, University of Leeds, 19 –20 May 2020A two-day theoretical and technical course involving demonstrations, theory and hands-on interactive sessions covered by experienced academics and renowned industry guest speakers.This course will provide delegates with an introduction into the numerous corrosion threats associated with internal pipeline degradation within the oil and gas industry. Academic speakers will cover the details relating to specific mechanisms. Industrial guest speakers will provide an insight into the two main corrosion control methods relating to internal corrosion; corrosion inhibitors and material selection/optimisation. Practical interactive sessions will be held to help understand how to set up electrochemical cells for corrosion measurement, whilst also covering how such systems work. Finally, demonstrations will show how various field scenarios/mechanisms can be modelled in a laboratory environment to understand corrosion threats, as well as evaluate materials and inhibitors in different processes.The guest speakers include Prof. Bijan Kermani (KeyTech and University of Leeds Visiting Professor), who on day one, will provide a talk on corrosion management and material selection in the oil and gas sector. On day two, the guest speaker, Mr Trevor Hughes (Schlumberger), will deliver a talk on chemical inhibition in oil and gas systems.Full details can be found in the leaflet in this magazine or at, https://eps.leeds.ac.uk/dir-record/short-courses/996/oilfield-corrosion-science-and-engineering

Industry News


NACE Corrosion Expo 2020, 15-19 March, Houston, TexasThis year’s conference brings even more opportunities to get the latest technical insights from some of the industry’s leading experts through numerous symposia sessions, including new topics for this year, Corrosion in Sweet and Slightly Sour Production Conditions, which will feature technical papers on laboratory and/or field experience of CO2/H2S corrosion and mitigation in a hydrocarbon containing environment, and Innovations in Chemical and Mechanical Cleaning and Fouling/Corrosion Mitigation, featuring papers that will provide a fundamental

insight into new and up-and-coming innovations in the field of chemical and mechanical cleaning, including new chemistries, methods, applications or techniques, emerging equipment, and innovative partnerships. The plenary lecture on Tuesday, March 17 will be given by William H. Hartt, Professor Emeritus, Florida Atlantic University-SeaTech, on “Corrosion, Fracture, and Failure Issues for Post-tensioned Concrete Bridge Structures”, and the full advance programme can be found at, nace.org/events/c2020

Corrosion and Scale Inhibition – theory, testing and application course, 18 – 20 February 2020, Iserlohn, GermanyThe addition of functional chemicals (inhibitors) to aggressive media is a good solution for preventing corrosion failures and/or formation of unwanted scales in industrial assets. Thus, in oil and gas production and transport, energy production and distribution, production of metallic materials (specifically steel), and in many other areas, the use of appropriate inhibitors today is indispensable for the integrity, safety, sustainability, and economy of plants and installations. Inhibitors are effective even in small concentrations in a wide range of environmental conditions such as temperature or aqueous and non-aqueous media. The selection of appropriate chemicals or mixtures of substances is no “black magic”, but has a sound scientific basis.The course, organised jointly by the WCO and EFC (EFC Event 456), will summarise the present day knowledge in theory, testing and application of corrosion inhibitors and scale

inhibitors. The emphasis is on application and environmental aspects, and is intended to provide enough information to enable course participants to tackle inhibitor problems efficiently.For more details concerning the course and to register go to, efcweb.org/Events/Courses.htmlFurther WCO events include a forum in conjunction with NACE Corrosion 2020 in March, entitled “Corrosion in low-carbon energies (renewables, nuclear and carbon capture): issues and solutions” and a workshop on renewable energies and corrosion as part of the 21st ICC to be held in Sao Paolo, Brazil in May 2020. There is also a workshop on the topic of “Corrosion in low-carbon energies” being planned at EUROCORR 2020, Brussels, Belgium. Updated information on these events can be found at, www.corrosion.org

EUROCORR 2020, Brussels, 6-10 September 2020 - CALL FOR PAPERSThis meeting organised by VOM, together with EFC, and DECHEMA, has the theme of “Closing the gap between industry and academia in corrosion science and prediction”. The scientific programme will give delegates the opportunity to catch up with the most recent and reliable scientific results and the latest industrial achievements, and to take part in the development of new standards and regulations on the subject of corrosion control. As always during EUROCORR, each day 12 to 14 parallel sessions will run, some dealing with the most important general corrosion problems and some focusing on those specific to each branch of industry.Deadline for abstract submission is 15th January 2020 and instructions and the online submission form are available on the congress website, from which further information about the event can also be found. https://eurocorr.org/2020.html

PaintExpo, 2020The Leading Trade Fair for Industrial Coating Technologies will be held in Karlsruhe (Germany) from 21 to 24 April 2020The theme of this PaintExpo is Adjusting Painting Processes to New Requirements, and exhibitors will be presenting future-oriented solutions for meeting the increasing demands now being placed on quality, flexibility and productivity, as well as material, energy and cost-efficiency. As of August 2019, more than 450 companies from 22 countries – including all of the market and technology leaders – had already confirmed their attendanceFurther information, the entire exhibition portfolio and a preliminary exhibitor list can be accessed at www.paintexpo.com.

For all the latest news, events and debates join us on

Industry News


INLET FLOW CONTROL VALVE AT LADYBOWER RESERVOIR GOOD FOR ANOTHER 60 YEARSLeeds based corrosion protection and engineering services specialist, Corroserve, was contracted to repair and protect a 36” inlet flow valve which had been in service at Ladybower Reservoir for over 60 years, against any further corrosion. The reservoir, situated in the Upper Derwent Valley in Derbyshire, holds some 28 million cubic metres of water when full and is the largest of three connecting reservoirs which supply the water needs of Sheffield and the East Midlands. The reservoir’s inlet flow control valves have to withstand the most demanding requirements of water system control – including erosion and corrosion, so a reliable protective coating system that would ensure the valve would require minimal maintenance over a long period of time was required. Corroserve proposed abrasive blast cleaning the valve body and internal parts to Sa 21/2 to remove existing corrosion products and provide a suitable profile for the application of high performance coating systems. Multiple coats of a glass flake vinyl ester copolymer were then applied to all internal surfaces to achieve a minimum of 1000 microns dry film thickness, and two coats of a 2-pack epoxy surface tolerant glass flake inhibitive primer with

a 2-pack solvent free polyurethane/acrylic topcoat were applied to the valve externals. After curing, thickness and spark testing was carried out to ensure the quality of the coating work. The vinyl ester coating is suitable for immersed environments and is resistant to chemicals across the pH range, and is WRAS approved for town water and potable water service.

The flow control valve (left) after abrasive blast cleaning which revealed significant erosion corrosion and (right) after being lined with multiple coats of glass flake vinyl ester.

Pennsylvania refinery fire caused by corroded pipeA degraded piece of metal pipe has been found to be the culprit behind the fire at a Philadelphia crude oil refinery that occurred in June, according to a report from U.S. Chemical Safety and Hazard Investigation Board.The report noted that a pipe elbow in the refinery’s alkylation unit had corroded to roughly half the “thickness of a credit card” and ruptured, resulting in the release of process fluid that included over just over 2 tons of hydrofluoric acid. The

report also detailed that the elbow was susceptible to corrosion due to the hydrofluoric acid in the process fluid, and though the pipe thickness was measured periodically, the elbow at issue had not been assessed for corrosion. That segment of piping also had high nickel and copper content, and as the Board commented, “Various industry publications have found that carbon steel with a higher percentage of nickel and copper corrodes at a faster rate than carbon steel with a lower percentage when used in a process with hydrofluoric acid.”

Milestone shows major rail project is on right trackA leading galvanizing business has reached a significant milestone as part of its work on one of the biggest rail projects in the UK. Worksop Galvanizing is playing a key role in a major programme to upgrade the Midland Main Line, which runs from London to Sheffield. Huge sections of infrastructure used to support new electric cables are first being sent to the plant for the application of a protective coating, and the amount of the steel galvanized so far has reached 3,000 tonnes.The state-of-the-art facilities at the plant include the largest acid bath in the UK, which enabled sections as long as 30 metres to be galvanized at once, which meant that projects like this could be turned round very quickly.Network Rail’s £500m-plus upgrade and electrification programme is designed to reduce journey times and increase passenger capacity on the entire length of the line which bypasses Luton, Leicester, Derby and Nottingham. It includes the erection of 6,000 main steel components to support the overhead line equipment and current focus is on the section running from Bedford to Corby. Supporting infrastructure is being supplied by Adey Steel.The Bedford to Corby project scope is scheduled to be completed in 2023.

Galvanized steel section at Worksop Galvanizing.

Innovative Products


598, EN 969, EN 12842, EN 14525, for: - conveying water (e.g. potable water) at operating temperature up to 50 °C excluding frost; or - conveying waste water at operating temperature up to 45 °C excluding frost; or - conveying gas at operating temperature up to 50 °C; - suitable for external environments, i.e. soils, waters and atmospheres of all common corrosion loads, characterized in EN 545:2010, D.2.3.EN ISO 17872:2019 Paints and varnishes - Guidelines for the introduction of scribe marks through coatings on metallic panels for corrosion testing This document describes methods of scribing coated steel or test-pieces for corrosion tests, where the coating system is applied at dry film thicknesses of less than 500 μm. It is intended as a guideline only, being based on the results of a collaborative trial with no subsequent corrosion testing having been carried out to determine the suitability of the introduced scribe marks for such tests. This document covers the scribing of metallic panels or test pieces (chemically treated or not) made from: — steel; — galvanized steel; — aluminium alloys; — magnesium alloys. It does not cover the scribing of electroplated metal or clad aluminium panels.

ASTMhelp protect iron water pipes against corrosion. ASTM’s corrosion of metals committee worked on the standard. The purpose of the new guide is to summarise publications, case histories, and studies available regarding cathodically protected installations of polyethylene encased ductile iron pipe to give users guidance on this unique method of protection, and would be of use to entities such as asset owners, corrosion consultants, water companies etc.

Innovative ProductsNEW PASSIVE FIRE PROTECTION COATING TO SAFEGUARD CIVIL STEEL STRUCTURES

STANDARDS UP-DATE

ISOThe 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 2409 Paints and varnishes — Cross-cut test (Revision of 2013 standard)ISO/DIS 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 extractionISO/DIS 11127-1,2,3,4 and 5 Preparation of steel substrates before application of paints and related products — Test methods for non-metallic blast-cleaning abrasives — Part 1: Sampling, Part 2: Determination of particle size distribution, Part 3: Determination of apparent density , Part 4: Assessment of hardness by a glass slide test, Part 5: Determination of moisture (Revisions of 2011 standards)ISO/DIS 22858 Corrosion of metals and alloys — Electrochemical measurements — Test method for monitoring atmospheric corrosionISO 26202 Magnesium and magnesium alloys — Magnesium alloys for cast anodes (Revision of 2007 standard)ISO/FDIS 11844-3 Corrosion of metals and alloys — Classification of low corrosivity of indoor atmospheres — Part 3: Measurement of environmental parameters affecting indoor corrosivity (Revision of 2006 standard)ISO/FDIS 18086 Corrosion of metals and alloys — Determination of AC corrosion — Protection criteria (Revision of 2015 standard)ISO/FDIS 21062 Corrosion of metals and alloys — Determination of the corrosion rates of embedded steel reinforcement in concrete exposed to simulated marine environmentsNew international standards published during the last two monthsISO 12944-5:2019 Paints and varnishes — Corrosion protection of steel structures by protective paint systems — Part 5: Protective paint systemsISO 21968:2019 Non-magnetic metallic coatings on metallic and non-metallic basis materials — Measurement of coating thickness — Phase-sensitive eddy-current method ISO 8504-1:2019 Preparation of steel substrates before application of paints and related products — Surface preparation methods — Part 1: General principlesISO 8504-2:2019 Preparation of steel substrates before application of paints and related products — Surface preparation methods — Part 2: Abrasive blast-cleaningISO 14713-2:2019 Zinc coatings — Guidelines and recommendations for the protection against corrosion of iron and steel in structures — Part 2: Hot dip galvanizing

CENStandards published within the last two months.

EN 14901-1:2014+A1:2019 Ductile iron pipes, fittings and accessories - Requirements and test methods for organic coatings of ductile iron fittings and accessories - Part 1: Epoxy coating (heavy duty)This European Standard defines the requirements and test methods for factory applied epoxy coatings (fusion bonded powder or liquid two-pack) used for the corrosion protection of ductile iron fittings and accessories conforming to EN 545, EN

Hempel has announced a new generation fire-protection coating – Hempafire Optima 500, which is specifically designed to improve the productivity of passive fire protection (PFP) coating applications. It achieves this by reducing the number of coats required and the process time required to apply them – saving time and costs.

Innovative Products


According to the company, the product helps to maintain the stability of steel structures in large infrastructure buildings such as airports, stadiums and commercial centres by delivering up to 180 minutes protection against cellulosic fires, and being optimised for 120 minutes in ISO 12944 C3 interior environments. It is a one component waterborne acrylic intumescent coating with zero volatile organic compounds (VOC) and can be used for both open or closed steel sections.It is fast drying and highly resistant to sagging, and dries to an excellent aesthetic finish meaning there is minimum surface reworks to achieve the required cosmetic finish when applying a topcoat. The ease of application allows customers to improve their painting process by reducing the number of coats needed, minimising drying times and maximising the speed of the application. Taken together, these properties save both time and money as projects can be completed faster and with lower total application costs.At 40 C it can easily be applied at 750 microns DFT per coat, and can be overcoated in just three hours. For applications where speed is the key, coats of 500 μm DFT can be applied every 75 minutes and recoated with a PU topcoat after 16 hours. This means that the whole system - primer, PFP, and topcoat - can be applied and dry to handle within a 48-hour period, concluded the company.Hempafire Optima 500 is now available in the Middle East and Europe.

NEW RANGE OF INTERPON COATINGS SIMPLIFIES CORROSION PROTECTIONAkzoNobel Powder Coatings has announced the launch of a range of high performance primers. The new Interpon Redox range consists of four innovative systems developed to cover a variety of substrates, surfaces, and environments – from swimming pools to chemical plants and high humidity to highly corrosive areas. The range consists of:• Interpon Redox Active, a robust primer system with a wide curing window and excellent edge protection.• Interpon Redox Plus which offers durable protection for a wide variety of substrates and pre-treatment methods.• Interpon Redox PZ, a high performing powder primer for corrosion protection over blasted steel.• Interpon Redox Triplex an extremely protective three-layer system for highly corrosive environments.Powder coatings offer inherent sustainability benefits, such as no VOCs, reduced energy use, and less waste, and the new Interpon Redox range is suitable for everything from bus shelters, elevators and security gates, to wind turbines, metal fences, and agricultural equipment, concluded the company.

NEW DURABLE COATING SYSTEM FOR OFFSHORE WIND TURBINE FOUNDATIONS Master Builders Solutions® has launched MasterProtect 9000, which according to the company is the first coating system which ensures 25 years of maintenance-free protection for offshore and marine structures. The coating system is based on a hard wearing high-build hydrophobic PU membrane which provides extremely effective protection for two main critical areas of the offshore structure, the splash zone and the submerged part of the foundations. Additional properties of the system are chemical and mechanical resistance and high flexibility. The hydrophobic properties protect the steel

structure from the aggressive impact of seawater. The chemical and mechanical resistance of the product are fit to withstand severe attack by waves, abrasion and impacts, especially affecting the splash zone and the high flexibility ensures that the barrier will not crack and will keep its integrity even after years of weathering, impact and vibrations. The combination of all these properties results in a consistent, reliable and highly durable protection against steel corrosion. In addition, the coating helps in significantly reducing the application time and cost compared with the most common epoxy paint systems used in the market, as the full system can be applied in only one day, concluded the company. The system has been tested by the independent Fraunhofer institute in accordance with the international standards NORSOK M-501 and ISO 20340.

A NEW STATE-OF-THE-ART PROTECTION FOR STEEL REINFORCEMENT Master Builders Solutions® has also launched MasterProtect 8500 CI, a new corrosion inhibitor developed by BASF to enhance and complement their broader refurbishment and repair portfolio for concrete. It is a dual-function, silane-based corrosion inhibitor that can be applied to the surface of all types of reinforced concrete structures – both new and existing – without changing the appearance of the concrete. In addition, it has a very low viscosity to improve penetration into the concrete over a wide temperature range, a lower VOC content and a higher flash point, which together makes the handling of the product and its application much easier and safer than many other inhibitors.

AKZONOBEL LAUNCHES RECYCLED PAINT TO HELP CLOSE LOOP ON WASTEAccording to AkzoNobel it has become the first major manufacturer to launch recycled paint due to a ground-breaking partnership in the UK with resource management experts Veolia. Developed by the company’s Dulux Trade brand, the revolutionary Evolve matt emulsion is made from the waste of other people’s paint tins in a bid to reduce the amount that goes to landfill. Once any leftover white paint has been reclaimed, it is sorted, filtered and refined by Veolia. It’s then re-engineered with new paint by AkzoNobel and tested extensively to ensure

that every tin meets the high standards expected from Dulux Trade. The final product contains 35% recycled paint, and is initially only available in white.

www.icorr.org


Institute News


Technical Article

It is well recognised by our industry that proper surface preparation prior to the application of a protective coating is paramount in ensuring good long term corrosion protection of steel substrates. The amount and type of this preparation depends on the state of the existing surface, the particular coating to be used, and its application method.However in all cases the object is to get the surface as clean as practicably possible, and in compliance with the specified standards. The contaminants on a surface which can affect the coating’s adhesion, and hence performance, can be split into those visible to the naked eye, for example, oil and grease, mill scale, old coatings, dust and detritus and rust, and those that are not, the so-called soluble salts and micro particulates. To further ensure good adhesion of a coating, the steel substrate is normally roughened to significantly increase its surface area and hence improve the surface for bonding of the coating. The most common method of carrying this out is by abrasive blasting.Painting specifications normally include a requirement for pre-cleaning of the surface to be carried out before any surface roughening, to ensure that any contamination present is not just spread across the surface, or driven into it, and hence not removed. Typically this cleaning involves solvent washing, fresh water washing with or without detergent, or a combination of these, and this step is covered in various standards.However, by far the most difficult contaminants to remove, and detect, are the soluble salts, and the presence of these is a major factor in premature breakdown of protective coatings, and resultant increased maintenance costs for the asset owner. In the context of surface contamination of steel surfaces before coating, these salts are typically chlorides, sulphides/sulphates and nitrates, of calcium, magnesium and sodium, which are commonly found in the atmosphere and environment, and although they are termed “soluble”, this is not true in all cases, as otherwise they could be simply washed away easily. The solubility of a salt depends on both the cation and anion present, as well as the concentration and the temperature, but put simply, nitrates are soluble, most chlorides are soluble, as are most sulphates, however carbonates, hydroxides, and sulphides tend to be mostly of low solubility.Of particular concern for maintenance painting are the salts which can be deposited on a steel surface by acid rain, or by exposure to a marine or chemical processes environment.

Why are these salts a problem in the corrosion protection industry?As corrosion is an electrochemical process, the rate of reaction is heavily influenced by the conductivity of the surrounding electrolyte. It is well known that these soluble salts, particularly chlorides and sulphates, can initiate and accelerate corrosion of steel due to the high conductivity of their aqueous solutions. Over time, soluble salts can be trapped, along with the products of corrosion, on the steel surface or more seriously, in pits. They are therefore the prime candidates responsible for causing coating breakdown due to osmotic blistering which subsequently leads to coating disbondment and ultimate failure. Osmotic blisters form due to the semi-permeable nature of the applied coating, when a strong solution is on one side and a weaker solution on the other, nature likes equilibrium, so solvent (in this case water) migrates through the membrane (coating) until equal concentrations are on each side. Osmosis can create huge pressures as is seen by the osmotic pump in trees that moves water from the roots to the leaves, which on a 100 foot pine equates to over 3 bar, they can also produce areas of different concentration and hence areas of different potential, which allows a corrosion current to flow, and in addition certain salts

can lower the pH at the coating/steel interface, resulting in acid attack. Where owners suspect that a surface may have been contaminated by salts, the painting specification will quote a level of salt, generally always specified as chloride ion, which is acceptable before the coating is applied. There are two commonly used sets of units used to describe soluble salt levels, namely milligrams per square metre (mg/m²) or micrograms per square centimetre (µg/cm²). It is important to note that these units are NOT equivalent. Any numerical value expressed as mg/m² is a factor of 10x the value expressed as µg/cm².These levels differ between existing standards and specifiers, as there is no consensus as to what level is safe. For example the maximum levels, quoted as sodium chloride, vary from <15 to <70 mg/m2, and a typical figure would be < 20 mg/m2, as given by the NORSOK M-501 and ISO standards (ISO 8502, parts 6 and 9).

If we cannot see these salts, then how do we measure them?One of the most common tests used to measure the presence of soluble salts is the Breslé test (ISO 8502-6). This involves injecting distilled water into a patch placed on the steel surface. This water dissolves any salt present to form an electrolyte, and the conductivity of this can be measured with a standard conductivity meter. It must be remembered that it is the total salts and materials present which are dissolved, and depending on their solubility in distilled water, and the nature of the salt, that will determine the conductivity. As it is generally not known which salts are present, then to arrive at a result to compare with a specification, a very naive and dangerous assumption has to be made. The conductivity is through this assumption interpreted as being due solely to sodium chloride, and a correction factor is applied to the conductivity measured to give a result equal to ‘x’ mg/m2 of sodium chloride. This value is then compared to the specification, and if found to be equal to or below this, then it can be said that the surface is acceptable for coating. But what if the value is higher than the specification, does this mean it has automatically failed? If a higher reading than the specification is recorded, then normal practise is to repeat the washing stage and re-blast to the specified standard. However if the re-test still gives a higher than acceptable result, competent inspection would deem that further investigation really should be carried out to determine the source of the raised conductivity. This situation is demonstrated in the case study described later.

Field testing for Soluble salts – A problem to be aware ofSimon Hope, Consultant, Auquharney Associates Ltd.

Breslé test kit.

Technical Article


Under laboratory conditions the Breslé method is an excellent test for the detection of water soluble ions on metal surfaces, but in the field there several ways in which the reading obtained by the this method can be influenced by other sources of electrolytes. The main examples being:n using contaminated distilled water,n contaminated calibration solutions,n inadequate flushing of the meter,n poor cleanliness (ie not wearing clean gloves throughout the entire process),n leaving test kits unsecured and unattended where third parties can interfere with it),n continually re-using syringes and hypodermics from previous tests,n the quality of the “patch” used for the extraction,n the temperature and relative humidity when the test was carried out,n or simply the conductivity of the water used to carry out the initial surface washing.From a general safety and quality perspective, this method of testing can be unreliable as it assumes that the operative is fully trained and competent to undertake the testing and then report/record the results accurately, also many sites do not like ‘sharps’ at the workplace, let alone hypodermic needles being carried around, often in someone’s pocket. There are several other conductivity-based methods available to the industry (often proprietary) for field measurement, for example, n Proprietary “soluble salt meters” are available, which also use the conductivity method to measure salt concentration, but these hand-held devices are different from the Breslé method in that they perform both the taking of the sample and its analyses automatically. Measurement is faster as the number of steps is fewer, thus reducing the possibility of error, and they are claimed to have more reliable and repeatable performance. n Paper extraction methods, which remove the need for patches, use filter papers onto which a measured amount of water is added, this in theory absorbs any soluble salts present, and the conductivity can then be measured by a modified meter.However, these methods still have most of the drawbacks of the Breslé method, and can also introduce other errors.There are alternatives to the use of conductivity to determine the presence of soluble salts, however these methods are generally more suitable for use in a laboratory. These include titrimetric determinations, a highly accurate method and ion specific, ie it can measure the chloride ion concentration alone. Other laboratory methods use ion selective electrodes and spectrophotometry to determine individual salt concentrations and these are also highly accurate and specific quantitative test methods. One method which does not rely on conductivity, and which is suitable for field use involves ion exchange technology, and is described in ISO 8502 Part 5. For example one proprietary system uses a calibrated titration tube containing a silver chromate solution which reacts with any sodium chloride present in an extract from the surface to form a white precipitate. 2NaCl (aq) + Ag2CrO4 (aq) › 2AgCl (s) +Na2CrO4 A major benefit of this method is that each test is stand-alone and cannot be contaminated by earlier tests. Simply, a known area is washed with a correspondingly known volume of a specific reagent, to create a solution that is drawn up into the titration tube which is calibrated in ug/cm2. The colour change on reaction with chloride is from pink to white, and the concentration of chloride can be read directly on the tube at the interface of the two colours. However it should also be noted that the presence of other halides (bromides, iodides and fluorides) and sulphide ions (which produce a brown stain) will give positive, bogus readings that should be taken as indicatives of other contaminants that may need investigation. Kits are also available for the specific determination of sulphates and nitrates.

Case StudyThe following case study demonstrates the possibility of other sources of electrolyte affecting the result from a Breslé test, and the resultant increase in (unnecessary) surface preparation costs.During maintenance painting of areas of an offshore structure, Breslé patch salt testing was carried out on two random areas after abrasive blasting. A very high reading for ‘sodium chloride’ was obtained and the surface was washed further. Subsequent testing also produced a high result. The surface was then re-blasted and rewashed, but the measured salt concentration was still too high. The coating that was being removed had been in situ for a period of around 25 years and had been exposed to a C5M environment, and was generally in fair condition with only breakdown where mechanical damaged had occurred. This was interesting as if, as had been thought originally, that the contamination was on the steel from the initial manufacture, why hadn’t the coating failed catastrophically within a short period of the original application? The readings indicated levels of contamination 9x higher than acceptable to NORSOK M-501 and over 3x the maximum acceptable to the manufacturer. So this should have precipitated a train of thought to wonder what was in reality going on?An independent inspection was then carried out for further testing, this time using a proprietary ion detection tube method, alongside a direct comparison Breslé patch test. The results of which showed that no chloride was present by the chloride specific test but the Breslé test still gave a very strong positive test.The problem, when analysed, was attributed to the dissolution into the distilled water of zinc salts (from the very finely

Non-conductivity test kit for chlorides.

Titration tube.

Institute News


Technical Articledispersed metallic zinc within the original primer used) being driven into the surface during blasting which created an electrolytic solution mimicking the conductive behavior of sodium chloride. If an ion selective test had been carried out initially, it would have shown that the surface had minimal chloride level and was perfectly satisfactory and compliant for coating. This would have saved the time and cost of the (ineffectual) re-washing and blasting.It should be noted that ion-specific test kits are also available for the determination of sulphate and nitrate soluble salts which can be just as damaging to coating adhesion. However in this case, as there had been little or no failure of the original coating, which was thought to have been caused by the presence of salts beneath the coating, then these other contaminants could not be present either. The biggest problem in the inspection of a surface prior to coating is in knowing what is being checked for. Soluble salts are not just sodium chloride as often defined in specifications, as noted above any salt or other contamination on the surface can contribute to the overall conductivity and hence the potential for osmotic blistering and coating failure. Test results between conductivity and ion specific methods can lead to large differences and any anomalies should be investigated further to find the root cause of the problem.Breslé patch and any other tests that rely purely on conductivity need to be treated with caution, negative readings are fine and can be used as a definitive guide but ‘positive’ readings need to be treated as ‘non-negative chloride’ until it is confirmed as being the source of the conductivity.One wonders how often major cleaning and surface rejections of a substrate have taken place that with a bit more investigation were perfectly fit for purpose, and what the cost and time implications of this have been.

Perhaps also the definitions of soluble salts in specifications need to be reviewed and tightened-up, but that is for another article.Surface cleanliness is defined under the ISO 8502 series of international standards, along with equivalent standards from organizations such as NACE and SSPC. ISO 8502 consists of the following parts, under the general title, “Preparation of steel substrates before application of paints and related products — Tests for the assessment of surface cleanliness”.n Part 2: Laboratory determination of chloride on cleaned surfacesn Part 3: Assessment of dust on steel surfaces prepared for painting (pressure-sensitive tape method)n Part 4: Guidance on the estimation of the probability of condensation prior to paint applicationn Part 5: Measurement of chloride on steel surfaces prepared for painting (ion detection tube method)n Part 6: Extraction of soluble contaminants for analysis — The Bresle methodn Part 9: Field method for the conductometric determination of water-soluble saltsn Part 11: Field method for the turbidimetric determination of water-soluble sulphaten Part 12: Field method for the titrimetric determination of water-soluble ferrous ionsIn addition, new ISO standards are under development to describe some of the other commonly used methods for determination of soluble salt levels.

Advertise in Corrosion Managementa leading industry organisation publication

Corrosion Management • Circulation of 1500 subscribers• Published bimonthly – 6 issues a year• 75% of subscribers UK Based• Majority of readers employed at senior level as decision makers and

specifiers in their field• The main focus of each issue is a themed

technical article • Editorial also includes: Institute News, Industry News, Innovative

Products, Diary of Events, Recruitment and currently the Sustaining Members Directory

Don’t delayWe have a range of advertising opportunities in Corrosion Management Magazine. However because this is a technical journal, space is limited and is booked on a first come first served basis.

Display AdvertisingFull page from £400.00Recruitment advertising full pages from £600.00

Key Facts

2

CorrosionManagement | September/October 2016

ContentsIssue 133 September/October 2016

4The President Writes

4Institute News

8Industry News

12Technical ArticleGrout and Concrete Electrical Resistivity Testing – External Cathodic Protection of Steel Pipelines within Grout Filled Cased Crossings

15Technical ArticleHazards in Closed Pipe Water Systems

17Innovative Products

18Project News

20 Sustaining Members

26ICATS Registered Companies

32Diary Dates and Branch Contacts

Published on behalf of the Institute of Corrosion

Square One Advertising and Design Limited

84 Queen Street, Sheffield S1 2DW, United Kingdom.

Publisher and Managing Editor

Debbie Hardwick

Tel: 0114 273 0132

Fax: 0114 270 0422

Email: [email protected]

Consulting Editor

Brian Goldie


Design

Square One Advertising & Design

www.squareone.co.uk

Advertising Manager

Jonathan Phillips

Tel: 0114 273 0132 Fax: 0114 272 1713


Editorial copy date for November/December 2016 issue is: 11th November 2016

Subscriptions

UK £70.00

Europe £80.00

Outside Europe £90.00 airmail £80.00 surface mail

Enquiries and subscriptions to the Institute of Corrosion at the address below:

The Institute of Corrosion

President

John Fletcher

Former President

Trevor Osborne

Vice President

Sarah Vasey

Hon. Secretary

Dr. Jane Lomas

Barratt House, Suite S3, Kingsthorpe Road,

Northampton, NN2 6EZ

Tel: 01604 438222


Website: www.icorr.org

All rights reserved Reproduction without written permission from the Institute of Corrosion is prohibited. Views expressed in editorial text or advertising copy are the opinions of the contributors/advertisers and are not those of the Institute or the Publisher.

ISSN: 13 55 52 43

Surface Profile MeasurementThe Surface Profile Probe, part of Fischer’s materials testing range, measures blasted surfaces, enabling the user to prepare the substrate, select the cleaning method and apply the right amount of coating.

The probe is interchangeable with Fischer’s coating thickness probes and used with the FMP series of measurement handhelds to provide quick and repeatable measurements.

For coating thickness and surface profile precision and accuracy on tough jobs, turn to a Fischer instrument.

For more information, call 01590 684100www.fischergb.co.uk

Applied Graphene Materials plc

The Wilton CentreRedcarCleveland TS10 4RFUnited Kingdom

+44 (0)1642 [email protected] www.appliedgraphenematerials.com

Create new barriers…• Significantly enhanced anti-corrosion and

barrier properties

• Very low loading additions

• Other multi-functional performance gains with graphene

• Dispersions developed and tailored to customers’ requirements

• Extensive in-house coatings and product integration expertise

• Commercialised graphene production

Tomorrow’s anti-corrosion material. Today.

03_A6 advert_for James.indd 1 03-Oct-16 2:00:34 PM

Developers and manufacturers of test equipment

TQC UK Po Box 977A Surbiton, KT1 9XL United Kingdom +44 208 255 0143 [email protected] www.tqc.eu

Order your FREE

catalogue now on

www.tqc.eu

155

tEchnical spEciFications hUll RoUGhnEss

GaUGE / GEnERal pURposE pRoFilomEtERAccuracy +/- 5 microns or <2%, whichever is greater

Memory Enough for 4 complete surveys done both

in- and out-docking, totally over 10.000

readings Location storage Simply point and click the hull location in the

displayed graphical representation of the

ship’s hullUnits MicronsSpeed 50 mm/s, with speed indication LED in the

Sensor unitInterface USB serial to PC connectionPower supply AA type Alkaline Cells, available

worldwide Material ABS, aluminiumDimensions Sensor: 205x80x50 mm / 8.07x3.15x1.97 inch

Control Unit: 200x115x40 mm / 7.87x4.53x1.47

Weight Sensor: 630 g / 22,22 oz Control unit: 350 g / 12,35 oz

oRDERinG inFoRmation hUll RoUGhnEss GaUGE / GEnERal pURposE pRoFilomEtER

Art. No

Dc9000 Hull Roughness gauge and general ProfilometerScope of supply: Hull Roughness control unit, sensor unit, calibration reference plate, USB flash drive with software, USB data cable, neck strap, batteries

and waterproof rugged casing & traceable calibration certificate.

accEssoRiEs / spaREsDc9015 Calibration plate for TQC Hull Roughness Gauge Dc9025 Protective pouch for Hull Roughness Gauge

stanDaRDs NACE TG461 Measuring Hull Roughness of Vessels While in Dry-dock (Draft standard)

SURFACE CLEANLINESS AND ROUGHNESS

ccicaliBRation cERtiFicationinclUDED

154

HULL ROUGHNESS GAUGE / GENERAL pURpOSE pROFILOmEtERTQC has made the next evolutionary step in hull roughness surveys. Surpassing the industrial standards with an easy to operate 4-way directional push button, graphical represen-tations, storage of data in multiple batches and survey reports in Microsoft Excel®. The whole system fits into a small sized waterproof rugged casing that is allowed as carry on travel luggage and benefits your overseas travel plans.

Controlling the roughness of a ship’s hull plays an important role in the operating costs of a vessel. The roughness of a ship’s hull increases mainly due to corrosion, pitting, plate undulation, mechanical damage, dry spray and above all bio fouling. Proper maintenance and the correct application of high-end anti-fouling coatings reduce the hydrodynamic effects and will lead to significant savings on fuel consumption and CO2 emissions.

The hull roughness is measured during in-docking and out-docking. The Hull Roughness Gauge measures the AHR value (Average Hull Roughness) of sea going vessels. AHR is the ‘mean’ of all the vessel’s hull roughness readings and is the measure against which ship’s performance is correlated.All profile measurements The new adjustable RT parameter suits all general purpose profile measurements like windmill blades, aircraft wings etc.

Significant savings The TQC Hull roughness Gauge consists of a Control unit and a Sensor unit. The Hull Roughness Control unit can be operated with just one hand, a 4-way directional push button operates an intuitive menu on a large illuminated display. The neck strap keeps the users’ hands free when required.

The Sensor unit is equipped with three non-slip wheels and a carbide tipped stylus and is moved over the ship’s hull in a horizontal way collecting series of measurements. A set of LED’s indicate the status of the instrument so operation is possible without observing the control unit.

Statistics, time/date and location of each series and the average hull roughness are automatically calculated and stored in the Control unit. Using the supplied USB-cable and software you instantly create inspection reports in Microsoft Excel. Your own company logo and or -details can be incorporated to restyle your reports.

SURF

ACE

CLEA

NLI

NES

S AN

D R

OU

GH

NES

S

FEATURES Easy to operate 4-way directional push button Storage of data in multiple batches Survey reports in Microsoft Excel® Rugged casing

Suits all general purpose profile measurements

inspection equipment for quality control and assurance during blasting and coating

Hardness

lCoating Thickness dry / wet lEnvironmental conditionslSurface CleanlinesslInspection toolslSoluble SaltslAdhesionlHardness lPorosity lProfilelEtc.

To help you target your advertising effectively we have developed a features list

2020 Features ListJanury/February – Pipelines n March/April – Testing/Corrosion Mechanisms

May/June – CP Planning and Monitoring n July/August Issue – Petrochem September/October Issue – Bridges n November/December Issue – Oil and Gas

Technical Article


Correct Cladding Systems are the Key to Reducing Corrosion under Insulation

Corrosion under insulation (CUI) refers to the external corrosion of piping and vessels that occurs underneath externally clad/jacketed insulation as a result of the penetration of water. By its very nature CUI tends to remain undetected until the insulation and cladding/jacketing is removed to allow inspection, or when leaks occur. CUI is a common problem shared by many industries, particularly the refining, petrochemical and power sectors. CUI typically occurs on insulated systems operating in a temperature range from -4 to 150 C. This is an ongoing and growing concern among facility owners and is estimated to cost a $300 Billion per year problem in the United States alone and over a trillion dollars on a global scaleThere are three key components to a good CUI risk minimisation programme. The first is to have the correct and suitable coating on the insulated surface. The second is to have an insulation system that minimises the intake of moisture, such as a closed cell foam or hydrophobic type material. The third component, which is the focus of this article, is to use a cladding system that minimises the ingress of moisture, and has high resistance to mechanical damage.

Current Issues with Metallic Cladding SystemsMetals such as aluminum, stainless steel, or aluminised steel have been used as the cladding of choice over industrial insulation systems for many years. They have

provided an adequate barrier to weather, have been key components in fire protection systems, and can offer some chemical resistance in certain atmospheres. There are, however, several growing concerns over the use of metal as a cladding over this type of insulation.

The biggest concern from a CUI point of view is the mechanical means by which the individual metal sheets must be joined. Typically, self-tapping screws or rivets are used to tie these together. At each of these points the vapour barrier can be compromised, and each penetration requires a sealant to be used. Although this is normally properly addressed in specifications, in practice it is very hard to accomplish, and inspect. Another issue with metal jacketing is that it often relies on the strength of the insulation underneath to give it rigidity. If the insulation is fibrous, or if the contour of the metal doesn’t exactly match the form of the insulation underneath, as is often the case at elbows or transitions, the metal cladding can be highly susceptible to mechanical abuse which can open the joints. Metal cladding systems are not ideal for pre-insulated systems or for modular designs. This is because of the tendency of the metal to dent easily or open at the joints when transported. Finally, the price volatility of the metals market can make it difficult for a maintenance manager to properly budget this item. Figures 1 shows a typical example of these faults.

James Meier, ProClad Systems, USA.

Typical clad insulated storage tank.

Technical Article


Institute News


Technical Article

Benefits of Pre-Cured GRP for Reducing CUIPre-cured GRPs have many benefits over a traditional metal cladded system. They are fabricated from UV-cured GRP, and are a composite laminate based upon high grade isophthalic polyester resins and chopped glass fibres. This cladding arrives at the site pre-formed and pliable for easy installation. When installed with the manufacturers’ adhesive it can provide an instantly hard and durable cladding system. The benefits of this type of cladding are, n No mechanical attachments such as screws or rivets are required to hold it in place. n It is easily modified on site and can be cut using standard metal cutting tools, which allows correct fitment at terminations.n High risk water ingress points can be sealed using an un-cured GRP roll, which once cured in situ, has high adhesion strength to coated metal substrates. This can provide a long lasting watertight seal.n Overlapping joints are fully waterproof and will pass-wash down tests from high pressure washing and deluge system testing. n It has excellent resistance to chemical attack when compared to some metallic cladding systems.Figure 2 shows how un-cured GRP can be used on-site to easily cover non-standard insulation, and then cured by natural sunlight or a UV light source, and figure 3 shows how pre-cured GRP cladding can be easily modified using standard metal-working tools.

Fire PerformancePre-cured GRPs can be ideal in fire rated areas. These systems do not drip like aluminum and are self-extinguishing with low smoke production. Pre-cured GRP’s have been tested against, and have passed a variety of industry standard fire tests and requirements (see below), however it is essential that each individual product is specifically tested for the particular environment that it is going to be used in.n ASTM E-84 (15/50) n ASTM E1317n IMO FTP Code 2010 Part 2n IMO FTP Code 2010 Part 5 n BS 476 part 7n NFPA 274

Figure 1 - Example of dented metallic cladding.

Figure 2 - Example of the use of un-cured, UV-cure GRP applied at site.

X Figure 3 - Easy modification of Pre-Cured GRP

Figure 4- Pre-cured GRP installed on tank side walls.

Figure 5 - Pre-insulation of vessels with pre-cured GRP.

Technical Article


Pre-Insulation with Pre-Cured GRP (figures 4 and 5)

Pre-cured GRP cladding is also suitable for use in the construction of pre-insulated systems. Due to its high strength and the fact that it can be chemically bonded at the joints, a vessel or pipeline pre-insulated and jacketed with it should have a lower risk of damage due to mechanical stresses and/or water ingress. This is a key concern with the growing trend for today’s mega projects to build pre-fabricated modules in overseas construction yards and then ship them, often thousands of miles, to the jobsite. This trend will most likely continue as energy companies are working on new projects in increasingly remote destinations. The strength and flexibility of the pre-cured GRP is ideal for withstanding the mechanical abuse that inevitably occurs during handling, shipping and installation of these modules. Full sealing and joint integrity are also critical as often imported modules will be quarantined and subjected to wash down procedures, which is the norm for modules imported into environmentally sensitive regions. These two key points are integral for a pre-fabricated system which reduces CUI risk, and has the added benefits of providing better schedule control and lower scaffolding costs.Figure 6 shows a typical LPG module pre-insulated at an off-site location prior to shipping and installation, and figure 7 shows piping for pipe-racks pre-insulated in an off-site workshop.

ConclusionsCUI is a major maintenance issue that must be addressed by owners. A key component to reducing CUI is having a cladding system that is strong enough to handle the

mechanical abuse that inevitably occurs in an industrial environment. A good cladding system also maintains tight seals at overlaps and terminations and fully protects the integrity of the vapour barrier and insulation system underneath. Though metallic cladding has been the choice of many specifiers and owners, there are some fundamental problems with these systems that have contributed to the CUI problem industry now faces on a global scale. A good alternative in the CUI process range is to use UV-cured GRP and pre-cured GRP systems. These exhibit superior resistance to mechanical damage, compared to metal cladding, and offer greater potential to seal the overlap and termination joints. Both systems can also offer better fire resistance and chemical resistance compared to typical metal cladding.

Figure 6 - LPG modules pre-insulated with GRP.

Figure 7 - Pre-insulation of pipe racks with pre-cured GRP.

Technical Article


Institute News


Technical Article

Failure Investigation of Internal Anodic Protection of Sulphuric Acid Tank

It is well known that corrosion can sometimes be controlled by cathodic currents and, even with an elementary knowledge of electrochemistry; it is easy to appreciate why this should be so. Corrosion involves the oxidation of the metal and it is reasonable to expect that cathodic polarization, which discourages oxidation and favours reduction at the metal surface, should give protection. In fact, the position is somewhat more complicated and, in many cases, other factors override this apparently simple one.What is not so well known is that corrosion can also be prevented in suitable cases by anodic polarization, and it is certainly very much more difficult to understand why this should be so from the somewhat oversimplified theory of corrosion which the non-specialist is bound to have. It is probably because of this that this method, which is extremely powerful, and is often applicable just when cathodic protection is not possible, has not been easily accepted as a practical proposition and is still regarded as only a laboratory curiosity. There is, it seems, perhaps unconsciously, the thought that method is basically unsound.The purpose of the this article is to explain, in as simple a way as possible, why anodic protection is possible, its benefits

and limitations as an anodic protection system and describe a failure of a sulphuric acid tank protected by anodic protection due to the lack of experience in this not so well known type of protection.

Overview of Anodic ProtectionAnodic protection is one of a number of electrochemical techniques used to prevent corrosion of immersed metals. These techniques employ a controlled DC current to influence the rate of the corrosion reaction. Figure1 illustrates the applicability of anodic protection with respect to pH of the electrolyte.Although the selected technique is dependent on the metal/process stream combination, all techniques share a common electrochemical theory and all systems share common components.This section discusses both the theory and the function of the system components required for the anodic protection of carbon steel in sulphuric acid.Sulphuric acid is normally stored in large vertical cylindrical tanks fabricated from carbon steel. Tank design can vary

Ahmed Wahba Mahgoub, Cathodic Protection Specialist.

Typical sulphuric acid plant.

Electrochemical corrosion protection

or minimisation

Parental controlled protection

Anodic protection

Cathodicprotection

Vessels or structures subject to crevice

and/or pitting

Storage vessels electrolyte

pH <3, >9

Underground structures process

vessels electrolyte pH >3Figure 1 - Protection methodology with respect to electrolyte pH.

Technical Article

Technical Article


from region to region but is usually based on available ‘local’ standards such as American Petroleum Industry [API] 650 welded steel tanks for oil storage, or an equivalent specification. While these specifications are a sound basis for storage of oil and other fluids, they fail to take full recognition of the unique physical properties of sulphuric acid, in particular its density and the corrosive nature of the liquid.Commercially sulphuric acid is normally produced in grades ranging from 93 to 95% H2SO4, due to their low freezing points. Sulphuric acid is highly corrosive, and the corrosion occurring within a given storage tank is dependent on a number of issues, e.g. temperature, concentration and activity of tank and purity of acid.Anodic protection uses an external source of controlled direct current as shown in figure 2 to keep the solution potential of the immersed tank wall in the passive, low corrosion rate zone. Direct current is discharged from the tank walls to the cathodes suspended from the tank roof. DC power cabling is routed from the positive output terminal of the source to the tank, and from the source negative terminal to the cathode. The resulting change in solution potential is measured with respect to a reference electrode immersed in the acid and used to control the current magnitude to maintain the potential in the passive range.

Figure 3 shows an idealised potentio-dynamic curve for carbon steel in sulphuric acid. When solution potentials are in zones ‘A’ (fig 3), active corrosion occurs. Small changes in solution potential result in large differences in corrosion rate due to the logarithmic nature of the solution potential/current density curve. Solution potentials in zone ‘B’ represent passivity and a correspondingly low corrosion rate.The presence of a passive zone of solution potentials is common for carbon steel in both strong caustics and acids. Ensuring that solution potentials are always in the passive zone would also ensure a correspondingly low corrosion rate, where corrosion rates are an order of magnitude lower.

Benefits and Dangers of Anodic Protection Anodic protection is particularly suitable for application in the heavy chemical industry, but the solutions handled in chemical plants differ so greatly, that each case has to be studied. The following section illustrates the benefits and dangers of using of anodic protection.The most important benefit however, is in tanks with varying liquid levels. Once passivated and maintaining the passivation criteria, the corrosion rate in the continuously immersed zone

can be reduced by up to a factor of ten. The operating costs also need to be considered, as after initial passivation, power requirement is nominally several Kw.An anodic protection system is cost effective when compared to cathodic protection combined with coatings or linings for the same application. It should be noted that it is potentially dangerous to coat the anodic member of the couple. This reduces its area, and severely accelerated attack can occur at the holidays, or imperfections in the protective coating. When using barrier coatings to control galvanic corrosion, it is always the cathode which should be coated. Hence a tank which is internally coated cannot be protected by an anodic system.The greatest danger comes, however, when the potentials are just below or above those at which protection is established, as the rate of corrosion is very high (this can be seen from the shape of the curve sketched in figure 3). In. some cases this rate can be many orders of magnitude greater than that of the passivated metal.If a tank were to be actively corroding, then in order to re-establish passivity, a current equivalent to the highest possible rate of corrosion would need to be applied. This means that the potential control must be able to provide a current many orders of magnitude above that necessary for protection, and if it cannot, then corrosion will occur.Another limiting factor of the anodic protection application is that when the acid level falls to a low level, and before acid/cathode contact is lost, an instantaneous change in system resistance will be created and with explosive gas mixtures, the possibility of sparking (arcing) may exist in this type of storage tank.Additional precautions are therefore required to overcome this risk through the use of spark preventers and an auto-shutdown system which uses the process level sensor for feedback.

Case StudyA 7m diameter and 6m high storage tank, commissioned in 2012, containing 98% sulphuric acid at ambient temperature was protected against internal corrosion with an anodic protection system. It had an air-cooled transformer/rectifier with potential and current control modes, and an auto shut down option in case of low tank acid level, but which was not activated in this tank.Three cathode rods, made of hastelloy composite with a copper core were installed through hardware in the roof of the vessel. The arrangement of the cathodes was designed to provide a uniform current density on the wall of the tank. The designed low acid level of the tank was 10 % of the maximum level of the tank (0.54m), with maximum tank level at 5.4m.

AC Power Input

0 V DC

+ –

Cathode

Reference Electrode

DC PowerPotential Control

Controlled Current Source

Figure 2 -Anodic Protection System.

+

–1 10 100

Carbon steel

solution potential

A

B

A

Log of corrosion rate (Log current density mA/cm^2)

Active Corrosion

Passivation

Figure 3 - Anodic Polarisation Curve.

Institute News


Technical ArticleOne end of the cathode inserted through the roof was insulated by Teflon. The other end of the cathode was submerged in the acid. The submerged end of the cathode has a niobium end cap to protect the copper core.The system included two platinum (Pt) reference electrodes for measurement of the solution potential. One is the primary reference electrode and used for control in concert with the transformer/rectifier, and the other is secondary, used to validate the controlling reference electrode. The normal SET potential for acid tank anodic protection systems to assure passivation is +400mV with respect to platinum.The reference electrode solution potentials measured at the reference electrodes (mV) should be within 20 mV of the set potential and each other, thus ensuring that the tank is in the passive, low corrosion rate zone.A leakage incident occurred in 2018, and an investigation was carried out, and the findings are given below.On commissioning, the sulphuric acid level inside the tank was 50% of the electrolyte height and the transformer/rectifier was being operated in current control mode NOT potential control mode. The recorded potential measured with respect to the primary and secondary platinum reference electrodes was +400mV and + 350mV respectively, and no comment was made regarding the 50mV difference between both reference electrode measurements in the commissioning report.The anodic protection system had been commissioned on the basis of the measurement of the primary reference electrode, which matched the required potential criteria (+400mV with respect to platinum).The sulphuric acid level trend for 12 months ( July-2017 to July-2018), showed that the maximum operating electrolyte level was only 37% (i.e. 1.99m) while the minimum operating level was approximately 17% (i.e. 0.91m). The fixed distance between the end of the cathode and the tank bottom is 1.1m, 20% of the maximum electrolyte level. Consequently, the current required to maintain passivation was not achieved all the time, as the actual level of sulphuric acid for a period of time was less than the distance between the end of cathode and the tank bottom and therefore there would be no DC output from the transformer /rectifier.Table.1 shows the maintenance records for the latest three annual surveys, and from this it can be seen that there is shift in potential between the two reference electrodes (REs) A calibration check carried out for both electrodes with respect to the master RE to check the accuracy, showed that the primary RE was not accurate with a +60mV shift in potential. The accurate potential reading is the secondary RE measurements.

Table.2 illustrates both maximum and minimum potentials for the last three years and the variation between the maximum and minimum potentials is due to changes in the electrolyte level inside the tank and the anodic protection system operating under current control mode, which cause changes in protection level of the protected zone inside the tank.Maximum potentials recorded (+309 and +347) in 2015 and 2016 respectively, and the minimum potential +455 in 2017 w.r.t secondary RE shows that the tank is outside the passivation / low corrosion rate boundary (as can be seen in figure3), meaning the tank has been under corrosive attack for the last three years!

The noticeable change in polarisation level is due to the dramatically fluctuating sulphuric acid level during the time of tank operation.

ConclusionsIn this Case Study, as the transformer/rectifier unit was operated in current control mode, the changing sulphuric acid level would affect the degree of protection/passivation, as the current output of the DC supply is always constant. It is necessary to set the anodic protection system for internal tanks in potential control mode to assure it sustains the passivation potential required regardless the level of the electrolyte.It can be easily seen that reference electrodes should be calibrated with respect to a master reference electrode to ensure the desired accuracy, as reference electrodes are critical to system operation and effective control of corrosion rate. Because anodic protection must be a potential controlled system, the reference electrode solution potentials measured at the reference electrodes (mV) must be within 20 mV of the passivation criteria, thus ensuring that the tank is in the passive zone.For this application, it is essential to maintain the level of sulfuric acid inside the tank higher than the distance between the end cap of electrode and the tank bottom (20% of the maximum electrolyte level) to assure maintains the required current for passivation. If the actual level of sulphuric acid is less than the distance between the end cap of cathode and the tank bottom, there would be no DC output from the transformer/rectifier.In addition, use of spark preventers and an optional auto-shutdown system that uses the process level sensor for feedback in order to avoid the possibility of sparking (arcing) is recommended.Braided nylon rope can be also used in case that the level sensors are inaccurate and the level falls below the cathode, to allow the acid to ‘wick’ up to the cathode tip thereby preventing an instantaneous change in system resistance, which could create a spark.Updating the plant preventive maintenance strategy is recommended to minimise the inspection interval of the anodic protection system. The operating parameters should be recorded and reviewed weekly to ensure the required passivation level for the tank is being maintained.Periodic ultrasonic thickness measurements should be carried out on piping exiting or entering the tank, below the maximum fill level, between the tank wall and the first downstream or upstream valve to identify any possible interference, resulting in the steel piping connected to the tank experiencing an increased corrosion rate due to the operation of the anodic protection system.Maintenance personnel should be familiar with the operation procedures of these units and anodic protection techniques. Only qualified personnel should be allowed to work with this equipment, under competent supervision.

Survey- 2015 (mV)

Survey- 2016 (mV)

Survey- 2017 (mV)

Primary RE +320 +386 +559

Secondary RE +255 +311 +503

Table 1 - RE potentials in last three annual surveys.

Survey- 2015 (mV)

Survey- 2016 (mV)

Survey- 2017 (mV)

Primary RE +357 +405 +623

Primary RE +278 +326 +508



Table 2 -Max &Min potentials in last three annual surveys for both RE’s.

Technical Article


www.icorr.org


References[1] Andersen, T.N., N. Vanorden and W.J. Schlitt, Metallurgical Transaction A, “Effects of Nitrogen Oxides, Sulfur Dioxides, and Ferric Ions on the Corrosion of Mild Steel in Concentrated Acid”, Volume 11A, August, 1980.[2] Riggs, O.L. and C.E. Locke, “Anodic Protection”, Plenum Press, New York, 1981.[3] Shim, W. W. and J.I. Munro, “Anodic Protection in the Sulfuric Acid Industry, Materials Performance”, Dec, 2000[4] Munro, I. And W. Shim, “Anodic Protection-Its Operation and Applications”, Materials Performance, May, 2001.[5] Riggs, Olen, Jr. And Carl Locke, Anodic Protection, Theory and Practice in the Prevention of Corrosion, Plenum Press, New York, 1981.

[6] Fontana, M. and N. Greene, Corrosion Engineering, 2nd edition, McGraw-Hill, 1978.[7] Kain, R.M. and P. E. Morris. Corrosion/76, Paper No. 149, March, 1976.

[8] Munro, J. I., Anodic Protection of White and Green Liquor Tankage With and Without the use of Protective Organic Linings, Pulp and Paper Symposium, NACE, 1992.[9] Sastry, T.P. and V.V. Rao, Corrosion, 39, 1983 (p.55).[10] Breault, R. and A. Simard, Light Metals, Ed. By E.R. Cutshell, The Minerals, Metals & Materials Society, p.101, 1991.


Sustaining Members


CATHELCO Marine House, Dunston Road, Chesterfield S41 8NYTel: +44 (0) 1246 457900 Fax: +44 (0) 1246 457901Email: [email protected] www.cathelco.com

CATHODIC PROTECTION ENGINEERING LTD Chapel Green Farm, Chapel Lane, Wythall, Birmingham B47 6JXTel: 07399607344 Email: [email protected]

CORROCONSULT UK LIMITED The Kiosk, Overley, Telford, TF6 5HD Tel: 01952 740234

3C CORROSION CONTROL COMPANY AB (GOLD MEMBER) Box 324, 261 23 Landskrona, Sweden Tel: +46 418 411 900 Fax: +46 418 411 935 Email: [email protected] Website: www.3ccc.se

CORROSION CONTROL INCORPORATED (GOLD MEMBER) 494 Fairplay Street, Rutledge, Georgia 30663, USA Tel: +706 557 9624 Email: [email protected]

CORROSION TECHNOLOGY SERVICES EUROPE LTD (GOLD MEMBER) 11 & 12 Merlin Park, Mildenhall, Suffolk IP28 7RD Tel: 01638 711955 Fax: 01638 711953 Email: [email protected] www.ctsonline.com

CORRPRO COMPANIES EUROPE LTD (GOLD MEMBER) Adam Street, Bowesfield Lane, Stockton On Tees, ClevelandTel: 44(0) 1642 614 106 Fax: +44(0) 1642 614 100Email: [email protected] www.corrpro.co.uk

ICR INTEGRITY LTDClaymore Avenue, Aberdeen Energy park, Bridge of Don, Aberdeen AB23 8GWTel: 01224 822822 www.icr.world.com

IMPALLOY LTD Bloxwich, Walsall, West Midlands, WS3 2XNTel: 01922 714400 Fax: 01922 714411 Email: [email protected] www.impalloy.com

BEASY Ashurst Lodge, Ashurst, Southampton, Hants, SO40 7AATel: 02380 293223 Fax: 02380 292853 Email: [email protected] www.beasy.com

CESCOR UK LTD Gable House, 18-24 Turnham Green Terrace Chiswick, London, W4 1QPTel: 0208 996 5111 Email: [email protected]

CORROSION CONTROL 3 Ivy Court, Acton Trussell, Staffordshire, ST17 0SN 01785 711560 Fax: 01785 711561 Email: [email protected] www.controlcorrosion.co.uk

ECHEM CONSULTANTS LIMITED Suite 108, 3 Edgar Buildings, George Street, Bath, BA1 2FJTel: 01225 650103 Email: [email protected] www.e2chem.co.uk

CORROSION ENGINEERING SOLUTIONS LTD Unit S1, 64-66 Akeman Street, Tring, Herts, HP23 6AFTel: 01442 767 899 Email: [email protected] www.corrosionengineering.co.uk

PRO-TECH CP LTD Chase End, The Oxhey, Tewkesbury, Gloucestershire GL20 6HRTel: 01684 298679 Mobile: 07717 487632Email: [email protected] www.protechcp.com

SEGCORR LTD 11a Springfield Avenue, Newport, Shropshire TF10 7HPTel: 07484838232 Email: [email protected]

SGK (GOLD MEMBER) Technoparkstr 1, Zurich 8005, SwitzerlandTel: +41 44 2131590 Email: [email protected]

AQUATEC GROUP LIMITED Aquatec House, Stroudley Road, Basingstoke, RG24 8FWTel: 01256 416010 Email: [email protected]

[email protected] +44 (0) 1476 590 666

UK based specialists in cathodic protection since 1950:• Buried and immersed, marine and steel in concrete• BS EN ISO 15257 qualified staff• Design and consultancy• Full range of material supply• Maintenance services• Surveys (CIPS, DCVG, DOC, ECDA)

TRUst® Transformer RectifiersThyristor / Switch Mode Power SuppliesRemote Monitoring and Control Systems

Refine™ Reference ElectrodesELGARD™ MMO Mesh AnodesCuprion® Marine Anti Fouling

Cathodic ProtectionCo Limited

CATHODIC PROTECTION CONSULTANCY SERVICES

CATHODIC PROTECTION AND MONITORING

CATHODIC PROTECTION INTERNAL CORROSION MONITORING PIN BRAZING POWER SUPPLIES

T: +44 (0) 1952 290321 E: [email protected] W: www.bacgroup.com W: www.rcslgroup.com

Specialists in Cathodic ProtectionInspection - Design - Installation

Commission - Monitoring - TestingTel: 01952 230900 Email: [email protected]

CANADA USA

TEL: 905-634-7751 FAX: 905-333-4313

www.Rustrol.com

SOLID-STATE CATHODIC ISOLATOR®

Mitigation Of AC Induced Voltages • Lightning • AC Fault Current

Leaders in the Cathodic Protection Industry…Since 1957INTERPROVINCIAL CORROSION CONTROL CO. LTD.

ALWAYS RUGGED. ALWAYS RELIABLE.

THERE’S A REASONWE MAKETHEM RUGGED.World-Wide Leaders in Decoupling Technology • Optimize CP Systems • Solid-State Construction • Fail-Safe Performance • Maintenance-Free • Rated for AC Faults, Lightning • Rated for Induced AC Current • Third Party Certification

www.dairyland.com • [email protected]

Sustaining Members


MAPEI UK LTD (GOLD MEMBER) Mapei House, Steel Park Road, Halesowen B62 8HDTel: 0121 5086970 Email: [email protected] www.mapei.co.uk

METEC CATHODIC PROTECTION LIMITED Visage House, 2 Shaftesbury Avenue, South Shields NE34 9PHTel: 0191 7316010 714411 Email: [email protected]

MGDUFF INTERNATIONAL LIMITED (GOLD MEMBER)1 Timberline Estate, Gravel Lane, Quarry Lane, Chichester,West Sussex, PO19 2FJTel: +44 (0) 1243 533336 Fax: +44 (0) 1234 533422 Email: [email protected] www.mgduff.co.uk

MME GROUPMateriaal Metingen Europe B.V, Rietdekkerstraat 16,PO Box 4222, 2980 GE Ridderkerk, The NetherlandsTel: +31 (0) 180 482 828 Fax: +31 (0) 180 462 240 Email: [email protected] www.mme-group.com

OMNIFLEX UK LTD67 Europa Business Park, Bird hall Lane, Cheadle, Stockport Cheshire SK3 0XATel: 0161 491 4144 Email [email protected] www.omniflex.com

PENSPEN (GOLD MEMBER)Corrosion Engineering and Cathodic Protection Field ServicesTel: 0800 0328210 / 0191 2606200 Email: [email protected] / [email protected] www.penspen.com

PHOENIX CPC LTD26 Markwick close, Newark, Nottinghamshire, NG24 2LGTel: 07486076800 Email: [email protected] www.phoenixcpc.com

SAITH LTDICM House, Yeoman Road, Ringwood, Hampshire BH24 3FATel: 01425 207555 Email: [email protected] www.saithlimited.com

SILVION LIMITEDThe Brambles, Grantham Road, Old Somerby, Grantham, Lincs, NG33 4AB, UKTel: 01476 590932 Fax: 07872 857310 Email: [email protected] [email protected] www.silvion.co.uk

SPECIALIST CASTING LTDTatham Street, Sunderland SR1 2AGTel: 0191 5108843 Email: [email protected] www.specialistcastings.com

VECTOR CORROSION TECHNOLOGIES27a Upper High Street, Cradley Heath, Birmingham, B64 5HXTel: 01384 671400 Email: [email protected]

VOLKERLASERThe Lodge, Blackpole Road, Worcester, WR4 9FHTel: 0800 022 3292 Email: [email protected] www.volkerlaser.co.uk

ALFRED BAGNALL & SONS LTD6 Manor Lane, Shipley, W.Yorks BD18 3RDTel: 01274 714800 Fax: 01274 530171 Email: [email protected] www.bagnalls.co.uk

APB CONSTRUCTION (UK) LTD (GOLD MEMBER)First Floor Offices, Grange Business Centre, River Works, Grange Lane, Sheffield, S5 0DPTel: 01709 541000 Fax: 01709 541411 Email: [email protected]

APB GROUP LIMITEDRyandra House, Ryandra Business Park, Brookhouse Way, Cheadle, Stoke on Trent ST10 1SRTel: 01538 755377 Fax: 01538 755010

BRIDGECOAT LTD3 Shawcross Industrial Estate, Ackworth Road, Hilsea, Portsmouth, PO3 5JPTel: 02392 666161 Email: [email protected]

DENHOLM INDUSTRIAL SERVICES200 Carmichael Street, Glasgow, G51 2QUTel: +44 (0)141 445 3939 Email: Damian.O’[email protected]

D.F. COATINGS LTDUnit 17 Willments Industrial Estate, Hazel Road, Woolston, Southampton, SO19 7HSTel: 02380 445634 Email: [email protected]

DYER & BUTLER LTDMead House, Station Road, Nursling, Southampton, Hampshire, SO16 0AHTel: 02380 742222 Fax: 02380 742200 Email: [email protected] www.dyerandbutler.co.uk

F A CLOVER & SON LTDBardolph Road, Richmond, TW9 2LHTel: 020 89486321 Fax: 020 89487307 Email: [email protected]

FIRESAFE SERVICES (NE) LIMITEDUnit 28A Spencer Road, Blyth Riverside Business Park, Blyth, Northumberland, NE24 5TGTel: 01670 351666 Fax: 01670 352666 Email: [email protected]

FOUNTAINS (PART OF THE OCS GROUP)Blenheim Court, George Street, Banbury, OX16 5BHTel: 07876 556197 Email: [email protected]

R & R Corrosion Ltd. 5 Broomiesburn Road,

Broomiesburn Industrial Estate, Ellon, Aberdeenshire AB41 9RD

Tel: 01358 729644 Fax: 01358 729655 Email: [email protected]

www.rrcorrosion.com

COATING APPLICATORS

T: +44 (0) 113 2760 760 E: [email protected] www.corroserve.com

• Specialist in corrosion protection and engineering services, both on and off-site• We combine engineering expertise and coatings application technology to ensure the best long-term protection of all types of equipment and structures• A proven track record within many sectors including petrochemical, oil & gas, power generation, mining, marine, water and waste and structural steel• Fully equipped engineering facility and coating application shop in Leeds and specialist on-site teams• Repair and refurbishment of components including pumps, pipes, valves, tanks and vessels

Corroserve ad 75x90.qxp_Layout 1 23/1/19 4:12 pm Page 1

stoprust.com

OFFSHORE CORROSION CONTROL

Deepwater EU Ltd. 4.8 Frimley Business Park | Frimley Camberley | Surrey | GU16 7SG

Tel: +44 (0) 1483 600482

UK based specialists in DC Power solutions with over 35 years experience. Designer and manufacturer of Impressed Current Cathodic Protection Power solutions.

Pipelines, Storage tanks, Piers, Platforms, Well castings, Wind farms and Concrete Structures.

• Switch Mode Power supplies • Enhanced Surge Protection • External Interrupter - 50V 50A • Remote Monitoring and control • Portable ICCP solution • Custom Cabinets and Frames

Duvine Ltd Unit a8, Sturmer Road

Haverhill, Suffolk CB9 7UU

www.duvine.co.uk

Tel: +44 (0)1440 706777 Email: [email protected]


Sustaining Members


R & W RAIL LTDLocks Farm, Main Road, Dibden, Southampton SO45 5TDTel: 02380 845379 Website: www.rwcivilengineering.co.uk

RailX UK LTDUnit 1, Innovation Centre, Segro Park, Consul Avenue, Rainham, Essex RM13 8HZTel: 07961764943 Email: [email protected] Website: www.railxuk.com

SCA GROUP LIMITED7 Crane Way, Woolsbridge Industrial Park, Three Legged Cross, Dorset, BH21 6FATel: 01202 820820 Email: [email protected] Website: www.sca-group.com

SPECIALIST PAINTING GROUP LTDUnit 3 Prosper House, Astore Park, Padholme Road East, Fengate, Peterborough, PE1 5XLTel: 01733 309500 Email: [email protected] www.specialistpaintinggroup.co.uk

SHUTDOWN MAINTENANCE SERVICES LIMITEDTel: 01634 256969 Fax: 01634 256616 Email: enquiries@shutdownmaintenance.comwww.shutdownmaintenanceservices.co.uk

SPECIALIST BLASTING SERVICE LTDTrevol Business Park, Torpoint, Plymouth, PL11 2TBTel: 023 8044 4455

STANDISH METAL TREATMENT LTDPotter Place, West Pimbo, Skelmersdale, Lancs, WN8 9PWTel: 01695 455977 Fax: 01695 728835 Email: [email protected]

SURFACE TECHNIK (OLD HILL) LIMITEDSovereign Works, Deepdale Lane, Lower Gornal, Dudley, DY3 2AFTel: 1384 457610 Fax: 01384 238563 Email: [email protected] www.surfacetechnik.co.uk

WEDGE GROUP GALVANIZING LTDStafford Street, Willenhall, West Midlands WV13 1RZTel: 0845 271 6082 Email: [email protected] www.wedge-galv.co.uk

WESCOTT INDUSTRIAL SERVICES LTDWestcott House, Unit 9 B/C &10 Tyne Point Industrial Estate, Jarrow, Tyne & Wear, NE32 3UPTel: 0191 497 5550 www.wescottis.com

W G BEAUMONT & SON LTDBeaumont House, 8 Bernard Road, Romford, RM7 0HXTel: 01708 749202 Fax: 020 85909885 Email: [email protected]

WILLIAM HARE LTDBrandlesholme House, Brandlesholme Road, Bury BL8 1JJTel: 0161 609 0000 Fax: 0161 609 0468 Email: [email protected] www.williamhare.co.uk

AW CORROSION SOLUTIONS LTD5 Brookfield, Four Elms, Edenbridge, Kent, TN8 6NJTel: 01732 700924 Email: [email protected]

GABE (IS) LTD 12 Church Street, Omagh, Co Tyrone, BT78 3BXTel: 028 82240391 Email: [email protected]

HANKINSON PAINTING GROUPCotton Place, 2 Ivy Street, Birkenhead, Wirral CH41 5EFTel: 0870 7892020 Email: [email protected]

HDM TUBES LTDI Shed, Longships Road, ABP Ports, Cardiff Docks, CF10 4RPTel: 07710080845 Email: [email protected] www.hdmtubes.co.uk

HERRINGTON INDUSTRIAL SERVICES LTD Crown Works, Crown Road, Low Southwick, Sunderland, Tyne & Wear, SR5 2BS Tel: 0191 516 0634 Fax: 0191 548 1553 Email: [email protected] www.herringtonltd.co.uk

HRS RAIL LTD Unit 1A Dengemarsh Road, Lydd, Romney marsh, TN29 9JH Tel: 01797 329421 Email: [email protected] www.hrsrail.co.uk

INDUSTRIAL COATING SERVICEIndustrial Coating Services Ltd., A1 House, Rolling Mill Road, Norton Canes, Cannock, Staffordshire, WS11 9UH Tel: 01543 450167 Email: [email protected] www.industrialcoatingservices.co.uk

JACK TIGHE LTDRedbourne Mere, Kirton Lindsey, Gainsborough, Lincolnshire, DN21 4NWTel: 01652 640003 Email: [email protected]

JPV (PAINTERS) LTDUnit 8, Prospect Way, Hutton Industrial Estate, Brentwood, Essex, CM13 1XATel:01277 201515 Fax: 01277 201616 Email: enquiries @jpvpainters.co.uk

KAEFER LIMITEDEthan House, Royce Avenue, Cowpen Lane Industrial Estate, Billingham, TS23 4BXTel: 01642 371850 Fax: 01642 562971 www.kaeferltd.co.uk

KUE GROUP LIMITEDBirksland Street, Bradford, BD3 9SUTel: +44 (0)1274 721188 Fax: +44 (0)1274 720088 www.kuegroup.com

MCL COATINGS LTDPickerings Road, Halebank Industrial Estate, Widnes, Cheshire, WA8 8XWTel: 0151 423 6166 Fax: 0151 495 1437 Email: [email protected] www.mcl.eu.com

MCL SITE PROJECTS LTDPickerings Road, Halebank Industrial Estate, Widnes, Cheshire WA8 8XW Tel: 0151 423 6166 Email: [email protected]

MIDIS ENERGY SERVICES LIMITED (GOLD MEMBER)29 Alhaji Bashorun Street, South-West Ikoyi, Lagos, NigeriaTel: +234027218985 Email: [email protected] www.midisenergyservices.com

NUSTEEL STRUCTURESLymane, Hythe, Kent CT21 4LREmail: [email protected] www.nusteelstructures.com

ORRMAC COATINGS LTDNewton Chambers Road, Thorncliffe Park Estate, Chapeltown, Sheffield S35 2PHTel: 0114 2461237 Fax: 0114 2570151 Email: [email protected] www.orrmac.co.uk

PAINTEL LIMITED4 Bowker House, Lee Mill Bridge, Ivybridge, Devon, PL21 9EFTel: 01752 719701 Email: [email protected] www.paintel.co.uk

PIPELINE TECHNIQUE (GOLD MEMBER)Deveronside Works, Steven Road, Huntly, Aberdeenshire, AB54 4PSTel: 01466 795888 Email: [email protected]

PIPERCREST LTD T/A HALLS SPECIALISED SERVICESBrooklyn Farm, North Hill, Norden on the Hill, Essex SS17 8QATel: 01375 361408 Fax: 01375 361448

OWENS CORNING FOAMGLAS® INDUSTRY (GOLD MEMBER)31-35 Kirby Street, Hatton Garden, London, EC1N 8TETel: 07789 507094 Email: [email protected]

CONSULTING TESTING AND INSPECTION

Sustaining Members


STEEL PROTECTION CONSULTANCY LTDPO Box 6386, Leighton Buzzard, Beds. LU7 6BXTel: 01525 852500 Fax: 01525 852502 Email: [email protected] www.steel-protection.co.uk

TOPLINE LIMITED40 Birabi Street, GRA Phase 1, Port Harcourt, Rivers State, NigeriaTel: 084 46238 Email: [email protected] www.toplinelimited.net

SSE LTDGrampian House, 200 Dunkeld Road, Perth, PH1 3GHTel: 01738 456000 Fax: 01738 456647

CANHareness Road, Altens, Aberdeen, AB12 3LETel: 01224 870100 Fax: 01224 870101 Email: [email protected] www.cangroup.net

CLIENT INSPECTION SERVICES LTDSuite 004 Swan Hunters Centre for Innovation, Station Road, Wallsend, Tye & Wear, NE28 6HJTel: 0191 4477730 Email: [email protected] www.clientinspectionservices.co.uk

CORROSION MANAGEMENT LTDEngineering Consultants, Rugby, CV22 6HL, United KingdomEmail: [email protected]

EQUILIBRANT LTDUnit 45, North City Business Centre, 2 Duncairn Gardens, Belfast, BT15 2GGTel: 02890 767227 Email: [email protected] www.equilibrant.co.uk

ERIMUS INSULATION52 Newham Avenue, Tollesby, Middlesbrough, Teesside, TS5 7PNTel: 07968828825 Email: [email protected] www.erimusi.com

EXOVARosewell house, 2A(1F) Harvest Drive, Newbridge, Midlothian, EH28 8QJTel: 03302220321 Email: [email protected] www.exova.com

HELVETICA TECHNICAL CONSULTING SAGL (GOLD MEMBER)Piazza Indipendenza 3, 6830 Chiasso, SwitzerlandTel: +41 768307656 www.htc-sagl.ch

HYDROCOMM LTD1 Kent Place, Oughtonhead Way, Hitchin, Hertfordshire, SG5 2LETel: 07779333781 Email: [email protected]

HYDROSAVE UK LTDSwallow Court, Kettering Pkwy, Kettering, Northamptonshire NN15 6XXTel: +44 (0) 1536 515110 Fax: + 44 (0) 1536 515119 www.hydrosave.co.uk

INTECSEALansbury Estate, 102 Lower Guildford Road, Knaphill Woking, GU21 2EPTel: 01483 795300 Email: [email protected]

OCEANEERING INTERNATIONAL SERVICES LTDOceaneering House,Pitmedden Road, Dyce, Aberdeen, AB21 0DPTel: 01224 758500

PAINT INSPECTION LIMITED61 High Street, Fareham, PO16 7BGTel: 0845 4638680 Email: [email protected] www.paint-inspection.co.uk

PIPELINE TECHNIQUE (GOLD MEMBER)Deveronside Works, Steven Road, Huntly, Aberdeenshire, AB54 4PSTel: 01466 795888 Email: [email protected]

PLANT INTEGRITY MANAGEMENT LTD1st Floor Office, Woodburn House, Woodburn Road, Blackburn AB21 0RXTel: 01224 798870 Email: [email protected] www.pim-ltd.com

RAWWATER ENGINEERING COMPANY LIMITEDCulcheth Enterprise Park, Withington Avenue, Culcheth, Warrington WA3 4JETel: 01925 767990 Website: www.rawwater.com

SAFINAH LTD5 Keel Row, The Watermark, Gateshead, Tyne & Wear, NE11 9SZTel: 01670 519900 Email: [email protected]

SCALED SOLUTIONS LTD6 Nettlehill Road, Houston Industrial Estate, Livingston, EH54 5DL Email: [email protected] www.scaledsolutions.co.uk

SGK (GOLD MEMBER) Technoparkstr 1, Zurich 8005, SwitzerlandTel: +41 44 2131590 Email: [email protected]

SONOMATIC LTDDornoch House, The Links, Kelvin Close, Birchwood, Warrington WA3 7PBTel: 01925 414000 Email: [email protected] Web: www.sonomatic.com

SPECIFIERS

SUPPLIERS COATINGS

Winn & Coales (Denso) LtdDenso House, Chapel Road, London SE27 OTR Tel: 0208 670 7511

Fax: 0208 761 2456 Email: [email protected] Web: www.denso.net

LONG-TERM SOLUTIONS FORCORROSION CONTROL

LEADERS IN CORROSION PREVENTION &SEALING TECHNOLOGY

A MEMBER OF WINN & COALES INTERNATIONAL

• Developer and manufacturer of an extensive range of high technology coating systems and composites• Fully committed to research and development and providing high levels of technical support• Many coatings have an extremely low VOC content with little or no solvent content for reduced atmospheric pollution• Effective single coat solutions available

T: +44 (0) 113 2760 760 E: [email protected] www.corrocoat.com

Corrocoat ad 75x90.qxp_Layout 1 23/1/19 4:07 pm Page 1


Sustaining Members



PRESSERV LTDUnit 7 Ocean Trade Centre, Altens, Aberdeen, AB21 0GUTel: 01224 772694 Email: [email protected]

RENTAJET GROUP LIMITEDPaultons Park, Ower, Romsey, Hampshire SO51 6ALTel: 02380 817160, Fax 02380 814016 Email: [email protected]

SCANGRITEastfield Road, South Killingholme, Immingholme, Immingham, North Lincs, DN40 3NFTel: 01469 574715 Fax: 01469 571644 Email: [email protected] www.scangrit.co.uk

ELSEVIER SCIENCE LTDThe Boulevard, Langford Lane, Kidlington, Oxford, OX5 1GDTel: 01865 843000 Fax: 01865 843010

INSTITUTE OF METAL FINISHINGExeter House, 48 Holloway Head, Birmingham, B1 1NQTel: 0121 6227387 Fax: 0121 6666316 Email: [email protected] www.uk-finishing.org.uk

DEV4 ONLINE LTD Innovation Centre, Exploration Drive, Bridge of Don, Aberdeen AB23 8GXTel: 0795 2203531 Email: [email protected] https://condi.online

IMECHE ARGYLL RUANE 4 Europa View, Sheffield Business Park, Sheffield, S9 1XHTel: +44 (0)114 3995720 Fax: +44 (0)114 2430035

QUALITY CONTROL

+44 (0)161 371 [email protected] www.elcometer.com

- Surface Profile - Surface Cleanliness- Climatic Testing - Dry Film Thickness- Material Thickness - Adhesion- Appearance - Pinhole & Porosity- Concrete Inspection - Data Management

from start...

...to finish

Corrosion Management Jan 2016 65x75mm.indd 1 1/21/2016 2:11:54 PM

CHEMCO INTERNATIONAL LTDInnovative rust & wet-tolerant, Solvent-free Coatings East Shawhead Industrial Estate, Coatbridge, Scotland, UKTel: 01236 606060 Fax: 01236 606070 Email: [email protected] www.chemcoint.com

HEMPEL UK LTD (GOLD MEMBER)Berwyn House, The Pavillions, Cwmbran, Torfaen, South Wales, NP44 3FD, United KingdomTel: 01633 874024 Fax: 01633 489012 Email: [email protected] www.hempel.com

HEXIGONE INHIBITORS LTDBaglan Bay Innovation Centre, Central Avenue, Baglan, Port Talbot, SA12 7AXTel: 01792 606494 Fax: 01633 489012 Email: [email protected] www.hexigone.com

INDESTRUCTIBLE PAINT LTD25 Pentos Drive, Sparkhill, Birmingham, B11 3TATel: 0121 7022485 Email: [email protected] www.indestructible.co.uk

INTERNATIONAL PAINT LIMITED (GOLD MEMBER)Stoneygate Lane, Felling, Gateshead, Tyne & Wear, NE10 0JYTel: 0191 469 6111 Fax: 0191 496 0676 Email: [email protected] www.international-pc.com

JOTUN PAINTS (EUROPE) LTD (GOLD MEMBER)Stather Road, Flixborough, Scunthorpe, North Lincolnshire DN15 8RRTel: 01724 400 125 Fax: 01724 400 100 Email: [email protected] Web: www.jotun.co.uk

SHERWIN-WILLIAMS PROTECTIVE & MARINE COATINGS (GOLD MEMBER)Tower Works, Kestor Street, Bolton, BL2 2AL, UKTel: +44 (0)1204 521771 Email: [email protected] sherwin-williams.com/protectiveEMEA


PPG PROTECTIVE & MARINE COATINGS (GOLD MEMBER)Huddersfield Road, Birstall, Batley, West Yorkshire, WF17 9XATel: 01924 354700 Email: [email protected] www.ppgpmc.com

SPECIALTY POLYMER COATINGS INC (GOLD MEMBER) LTDContact our UK based stockist & certified distribution centreTel: +44 (0) 7748 993326 Email: [email protected] www.spc-net.com

FISCHER INSTRUMENTATION (GB) LTDGordleton Industrial Park, Pennington, Lymington, Hampshire, SO41 8JDTel: 01590 684100 Email: [email protected]

FUTURE PIPE LIMITED11 Hobart Place, London SW1W 0HHTel: 0207 8388660 Email: [email protected] www.futurepipe.com

GMA GARNET (EUROPE) GMBHPO Box 9, Middlewich, Cheshire, CW10 9FDTel: 01606 836233 Email: [email protected] www.gmagarnet.co.uk

HODGE CLEMCO LTD36 Orgreave Drive, Handsworth, Sheffield S13 9NRTel: 0114 2540600 Email: [email protected] www.hodgeclemco.co.uk

LAKE CHEMICALS & MATERIALS LTD3 Paper Mill Drive, Redditch, Worcestershire, B98 8QLTel: 01527 594630 Email: [email protected]

LLEWELLYN RYLAND LTDHaden Street, Birmingham, B12 9DBTel: 0121 4402284 Email: [email protected]

MILLER FABRICATIONS LTD (GOLD MEMBER)Overtown Road, Waterloo, Wishaw, Scotland, ML2 8EWTel: 01698 373 770 www.millerfabrications.com

MPI GROUPPeel House, Upper South View, Farnham, Surrey, GU9 7JNTel: 01252 732220 Fax: 01252 732221 www.protectivecoatingseurope.com

SUPPLIERS GENERAL

RECIPROCAL ORGANISATIONS

TRAINING AND COATING INSPECTORS

TO ADVERTISE IN CORROSION MANAGEMENT

Please contact Jonathan Phillips or Debbie Hardwick at:Square One +44 (0) 114 273 0132 [email protected]

Absolutely reliable.Even under harsh conditions.

Corrosion protection starts well before the fi rst coat of paint. The corrosion kit MMS® Inspection comprises three devices that are needed before, during and after surface coating. With the SPG, you can reliably measure the surface profi le. The DPM provides all the necessary data for determining the dew point. The powerful DFT is your mobile companion for all coating thickness tasks (ferrous and non-ferrous substrates).

www.fi schergb.co.uk

THE NEW MMS® INSPECTION SERIES

BRANCH DATES8th January 2020 London Branch Venue: Lancaster Hall Hotel, 35 Craven Terrace, London W2 3EL Panel discussion on “Linings for Extreme Duty” with Dr N Miskin, DuraPol, and Michael Harrison, Sherwin Williams.

28th January 2020 Aberdeen Branch Venue: Robert Gordon University Structural Integrity Issues: Under-deck, air-gap, splash zone deterioration (of conductors, caissons and risers).

23rd February 2020 London Branch Venue: Lancaster Hall Hotel, 35 Craven Terrace, London W2 3EL Topic to be confirmed.

25th February 2020 Aberdeen Branch Venue: Robert Gordon University Two key areas of risk based inspection, pressure safety valves and FPSO cargo tanks. John Morgan, Chris Bell, and David Baxter, DNV GL.

ADDITIONAL DIARY DATES16th December 2019 Insulation and Fireproofing Inspector IMechE Argyll Ruane, Sheffield

6th January 2020 Painting Inspector – Level 1 IMechE Argyll Ruane, Sheffield

8th January 2020 ICorr Coating Inspector Levels 1 &2, Workshop & Assessment Corrodere, Surrey

Institute EventsDIARY DATES 2019

www.icorr.org

Visit the ICorr website for all the

latest news

www.icorr.org

BRANCH CONTACT DIRECTORYABERDEEN:Stephen Tate (Chairman)Email; [email protected]

LONDON: Paul Brooks (Chairman)Mobile: 07880 791087Steve Barke (Secretary)George Winning (Speakers)[email protected]

MIDLANDS BRANCH: Bill Whittaker (Chairman)Email: [email protected]

NORTH EAST:Neil Wilds (Chair)Marie Halliday (Vice Chair)Alex Sandilands (Secretary)Email: [email protected]

NORTH WEST: Andy Bradley (Chairman)Tel: 01706 871700Email: [email protected]

YORKSHIRE: Nigel Peterson-WhiteTel: 07793 710559Email: [email protected]

CSD DIVISION: Julian [email protected]

CED DIVISION: Nick SmartTel: 0118 913 7752


13th January 2020 Cathodic Protection Buried (ISO 5257) – Level 2, IMechE Argyll Ruane, Sheffield

20th January 2020 Insulation and Fireproofing Inspector IMechE Argyll Ruane, Sheffield

20th January 2020 (to be confirmed) Cathodic Protection Buried (ISO 5257) – Level 1, IMechE Argyll Ruane, Sheffield

27th January 2020 Painting Inspector – Level 2. IMechE Argyll Ruane, Sheffield

3rd February 2020 Painting Inspector – Level 1, IMechE Argyll Ruane, Sheffield

10th February 2020 Pipeline Inspector, IMechE Argyll Ruane, Sheffield

12th February 2020 ICorr Coating Inspector Levels 1 &2, Workshop & Assessment, Corrodere, Newcastle

17th February 2020 Painting Inspector – Level 2, IMechE Argyll Ruane, Sheffield

17th February 2020 Fundamentals of Corrosion for Engineers course, ICorr offices, Northampton

18th February 2020 Corrosion and Scale Inhibition – theory, testing and application course, Iserlohn, Germany

11th March 2020 ICorr Coating Inspector Levels 1 &2, Workshop & Assessment, Corrodere, Aberdeen

15th March 2020 NACE Corrosion Expo, Houston, Texas

18th March 2020 ICorr Coating Inspector Level 3, Workshop & Assessment, Corrodere, Newcastle

To advertise contact Jonathan or Debbie at Square One

O +44 (0) 114 273 0132m [email protected]

Visit the ICATS websitewww.icats-training.org

Documents

Corrosion A journal of the Institute of Corrosion · Key to Reducing Corrosion under Insulation 22 Technical Article Failure Investigation of Internal Anodic Protection of Sulphuric