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CorrosionManagement
A journal of the Institute of Corrosion
www.icorr.org
Media PackPack 2017
Corrosion Managementwww.icorr.org
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 (see the features list on the back page).• Editorial also includes: Institute News, Industry
News, Innovative Products, Diary of Events, Recruitment and currently the Sustaining Members Directory.
www.icorr.org • All the latest industry news is updated on a
regular basis.• Conferences and events can be booked online.• Visitors can ‘find an expert’ using our full
searchable business directory.• Visitors can also access information about the
Institute and its activities as well as applying for membership online.
Key Facts
The leading Journal and Website for corrosion control and prevention, Corrosion Management is published bi-monthly and is sent to subscribers throughout the world. www.icorr.org complements Corrosion Management as the Institute’s official website. Both the journal and the website are read by a large international audience of academics and professionals in the field of corrosion science, technology and engineering management.
How find out how ICATS can benefit new membersPage 5
A guide to the latest Innovative Products on the market Page 23
Corrosion Protection in Maritime Environments Assessing Systems for Offshore StructuresPage 17
www.icorr.org© HEMPEL A/S
CorrosionManagement
A journal of the Institute of Corrosion
Issue 132 May/June 2016
Coatings technology conference
Dycomet opens new cold spray laboratory facility
By Günter Binder, Federal Waterways Engineering and Research Institute (BAW).
16 May/June 2016 www.icorr.org
Technical Article
There are currently more than 800 wind generating structures in the Northern Sea and 80 in the Baltic Sea, and more than 20 wind farms, each with a large number of structures and/or towers, will open in the next few years in these areas. In planning for these wind farms, the corrosion protection of the structures to be installed has become a focus of public interest, especially their effect on the environment which is often criticized or feared. There is also a large and immediate task for corrosion specialists to formulate standards in order to protect these steel structures effectively for a period of 25 years under very corrosive conditions.The German Federal Maritime and Hydrography Agency (BSH) has formulated “minimum requirements” (Mindestanforderungen1) which describe the measures to be taken for German offshore wind energy structures concerning their integrity, i.e. ensuring their function and stability, for a lifetime of 25 years. This includes planning, certification, three-step releases and suitability of corrosion protection systems. The BSH will therefore will introduce guidelines for corrosion protection for wind farm
structures (VGB-BAW-Standard2) in 2016. It is important in Germany that corrosion protection measures for wind farms have no adverse impact on the marine environment. This means that while there is a high risk of pollutants entering the maritime environment, virtually no pollution is permitted. Problems can arise because of the release of iron due to corrosion, and aluminum as well other metals from sacrificial anodes, and last but not least, because of solvents and other components typically used as coating materials, for example, isocyanate and bisphenol-A.Previous tests of binders carried out by Federal Waterways Engineering and Research Institute (BAW) have shown that there are well-formulated materials such as epoxy and polyurethane which show no relevant emission of environmentally hazardous molecules3. The calculated large mass of aluminium used for galvanic anodes for cathodic protection4 can easily be reduced when these anodes are used in combination with coatings or replaced by impressed current systems.The problem of corrosion of maritime structures should be resolved in the context of all questions concerning the
Corrosion Protection in Maritime Environments Assessing Systems for Offshore Structures
SSPC-PA 1, “Shop, Field and Maintenance Coating of Metals,” provides basic requirements for best practices for application of industrial/marine protective coatings to coated or uncoated metallic substrates. This guide is intended as a reference for specifiers and contractors in regard to the coating application and process control procedures. The scope of this standard includes specific as well as general requirements for the application of liquid coatings applied by brush, spray or roller. The main revisions include, an expanded scope that includes coated or uncoated metallic substrates in addition to steel, and a brief discussion of the importance of a contractor’s work plan as a method of project oversight and quality assurance, with supplementary resource information;Additionally, a section has been added to address pre-application requirements clarifying that the contractor is responsible for documenting resolution of ambiguous or conflicting requirements prior to beginning the application process, verifying that the prepared
surface meets project requirements for cleanliness and surface profile prior to coating application, and ensuring that ambient conditions comply with project requirements prior to coating application.SSPC ACS-1 Standard Practice/NACE No. 13, “Industrial Coating and Lining Application Specialist Qualification and Certification,” can be used to validate or assess a candidate’s or employee’s knowledge and skills level based on qualification in a certification program. It was designed for use by personnel involved in developing such education and certification programs.Important revisions include, adjustments to Level I, II and III qualifications requirements, including demonstration of abilities, work experience and training options, and exam completion, and requirements to maintain qualification status.SSPC-CS-23.00, “Specification for the Application of Thermal Spray Coatings (Metallizing) of Aluminum, Zinc, and Their Alloys and Composites for the
Corrosion Protection of Steel”, is a joint standard, issued by SSPC, AWS (the American Welding Society) and NACE International. It is designed for use by facility owners and specifiers, inspectors and contractors in applications of thermal spray coatings.Also classed as AWS C2.23 and NACE No. 12, the standard establishes minimum requirements for surface preparation before thermal spray application; application of thermal spray coatings; and applications of sealers or topcoats over thermal spray coatings.The 2016 revision of this standard includes a reorganization of the previous 2003 version, as well as the revision of requirements that have been revised since 2003. New appendices also describe optional procedures for verifying adhesion and thermal spray coating thickness, referring to SSPC-PA-2. Appendices that described or applied to procurement and contract requirements were removed in the new version of the standard.
Three standards have recently been updated by sspc: the society for protective coatings
Creating new barriers with graphene According to Applied Graphene Materials (AGM), independent testing has shown that the addition of their graphene nanoplatelets (A-GNPs) to epoxy coatings, has demonstrated performance enhancements in standard anti-corrosion and barrier tests. Very small additions of A-GNPs decreased water vapour transmission rates by up to 95% and extended time to initial corrosion by more than 500%. AGM reports that it has already entered several product development programmes and these latest results highlight the technical and commercial viability of this technology.
Elcometer sa moves to new purpose built officeElcometer is moving its Belgian sales, service and repair centre to purpose built offices in Awans, where they will also offer technical advice and product certification.The new address is:107 Rue Jean Lambert Defrene, 4340 Awans, Belgium.
4 May/June 2016 www.icorr.org
Industry News
Arc energy resources acquires clg engineering
Gloucestershire-based Arc Energy Resources, the weld overlay cladding and fabrication specialist, has acquired precision machining company CLG Engineering, based in Stonehouse, Gloucestershire.CLG Engineering provides CNC milling, CNC turning and assembly services to, amongst others, the oil and gas, automotive and rail industries. It is certified to ISO 9001and has over 40 years’ engineering experience.The acquisition means that Arc Energy Resources’ 80 employees are supplemented by CLG Engineering’s 14, to create a stronger team with a wider mix of skills. Both companies are supported by teams of experienced project managers, inspectors and welding engineers, with access to a wide range of auxiliary processes in-house, including heat treatment, NDT and CMM inspection.
Arc Energy Resources managing director Andrew Robinson
Advertising OpportunitiesWe 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 AdvertisingWe have a number of display advertising slots available throughout the magazine which can be booked at the following rates:Full page £800.00Half Page £495.00Quarter page £395.00
Prime PositionsThe inside front cover and inside back cover are our prime advertising positions. These prime positions are offered to Sustaining member companies free of charge and attract a 25% loading charge for all other advertisers.
Series DiscountWe are pleased to offer a range of series discounts to advertisers. Series bookings are billed in full after the first insertion.
2 insertions 5% discount3 insertions 10% discount4 insertions 15% discount5 insertions 20% discount6 insertions 35% discount
Recruitment AdvertisingAdvertising your vacancy in Corrosion Management is an extremely effective way of reaching corrosion related professionals and academics. Backed by our online Job Board it offers the perfect platform for corrosion related professionals.
Full Page £1200.00Half Page £700.00Quarter page £450.00
Online Job Board£195.00 + VAT if placed in conjunction with an advertisement in the magazine£295.00 + VAT Web posting only, for 30 days
Leaflet InsertsWe can design, print and insert your leaflets into Corrosion Management, or if you prefer to supply your own leaflets, we will insert them in the magazine.
Design, print and insert an A5 double sided leaflet £595.00Design, print and insert an A5 four page or A4 two page leaflet £845.00Insertion of you own leaflets (Maximum A4 sheet) £295.00
Sustaining Members DiscountAll our sustaining member companies enjoy a 15% discount in addition to our standard discount structure.
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: debbie@squareone.co.uk
Consulting Editor
Brian Goldie
Email: brianpce@aol.com
Design
Square One Advertising & Design
www.squareone.co.uk
Advertising Manager
Jonathan Phillips
Tel: 0114 273 0132 Fax: 0114 272 1713
Email: jonathan@squareone.co.uk
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
Email: admin@icorr.org
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 438214info@appliedgraphenematerials.com 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 janet@tqc.eu www.tqc.eu
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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 connection
Power 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 GaugeDc9025 Protective pouch for Hull Roughness Gauge
stanDaRDs NACE TG461 Measuring Hull Roughness of Vessels While in Dry-dock (Draft standard)
SURFACE CLEA
NLIN
ESS AN
D RO
UG
HN
ESS
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 A
ND
RO
UG
HN
ESS
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.
2017 Features ListTo help you target your advertising effectively we have developed a features list for 2017.
January/February issue - Testing March/April Issue - Corrosion of Rebars May/June Issue -- Cp Planning and Monitoring July/August Issue - Protecting Petrochem Facilities September/October Issue - Pipeline Field Joints November/December Issue - Corrosion Science
To advertise in Corrosion Management Magazine please contact the Advertising Manager Jonathan Phillips on 0114 273 0132 or email jonathan@squareone.co.uk
CorrosionManagement
A journal of the Institute of Corrosion
Find out about the latest Industry News Page 9
Issue 133 September/October 2016
Maintaining CP in Pipeline Cased Crossings
www.icorr.org
Hazards in Closed Pipe Water SystemsPage 15
TECHNICALARTICLETECHNICALARTICLE TECHNICALARTICLETECHNICALARTICLECorrosionManagement | September/October 2016
14 15
of the samples began to increase when compared to that of the reference samples (lid kept on) and again this is presumed primarily to be due to water loss by evaporation.
Re-wetting the samples had an immediate effect. This is taken as being indicative that the resistivity of the grout is controlled to a large extent by its water content.
Placing the grout samples on wet sand led to a marked increase in resistivity. This is presumed primarily to be due to water loss by evaporation through the upper and side surfaces and that the rate of water absorption through the base of the sample was not sufficient to offset the overall water loss. The concrete samples were not much affected by being placed on wet sand. Presumably, they have a much better rate of water absorption.
The results of the present testing were similar to those published elsewhere (6,7,8 and 9). The resistivity of the grout samples, particularly those that were kept moist, was relatively low and all would be considered acceptable from a pipeline CP perspective.
Conclusions1. The resistivity of two types of grout, and the effect of moisture availability, have been assessed by testing over a 730 day (two year) period.
2. The drying out of samples led to an increase in resistivity. The addition of water to dried-out samples immediately acted to decrease the sample resistivity by significant amounts. The rate of water absorption by the grout samples placed on wet sand was not sufficiently high to maintain a low resistivity.
3. From an electrical resistivity viewpoint, the tested ‘standard’ and ‘gel modified’ grout materials would be considered acceptable for use as an annular fill on cathodically protected cross-country pipelines provided they were kept moist.
TECHNICALARTICLETECHNICALARTICLE
AcknowledgementsTarmac ‘CMS Pozament’, Swadlincote, for supplying the two grout materials.
References1. ISO 15589-1, Petroleum and Natural Gas Industries, Cathodic Protection of Pipeline Transportation Systems, Part 1: Onshore Pipelines
2. BSI BS 7361 Part 1: 1991, ‘Cathodic Protection Code of Practice for Land and Marine Applications’.
3. NACE SP1069, Control of External Corrosion on Underground or Submerged Metallic Piping Systems
4. IGEM/TD/1, Edition 5, Steel Pipelines and Associated Installations for High Pressure Gas Transmission, Edition 5
5. API 1102, Seventh Edition, Steel Pipelines Crossing Railroads and Highways
6. ISO/FDIS 16440 Petroleum And Natural Gas Industries -- Pipeline Transportation Systems Design, Construction And Maintenance Of Steel Cased Pipelines (presently under development)
7. ASTM G57, Test Method for Field Measurement of Soil Resistivity using the Wenner Four Electrode Method
8. “Mechanism of Corrosion of Steel Strands in Post Tensioned Grouted Assemblies”, Alberto Sagüés, Rodney G. Powers and Hongbin Wang, Paper 03312, NACE International, Houston, 2003
9. Nufins “Nugrout Flowable Concrete”, Data Sheet
10. Weber “weber.cem mortar CP”, Data Sheet
Table 1: Summary of Grout and Concrete Resistivity Testing, ohm.m
Sample Condition Initial Value 7 Day Value 28 Day Value 84 Day Value435 Day Value(Re-wetted)
730 Day Value[Wet Sand]
G-A2 Lid on 2 3 6 21 388 588
G-A3 Lid off – 7 days 2 3 15 148 (55) (43)
G-A1 Lid off – 28 days 2 3 6 88 (72) [196]
GM-B1 Lid on 2 5 14 52 255 343
GM-B3 Lid off – 7 days 2 5 22 104 (41) [171]
GM-B2 Lid off – 28 days 2 5 14 83 (46) (44)
C-C Lid off – 7 days 17 38 471 1,548 (64) [64]
C-D Lid off – 7 days 10 22 190 367 (9) [16]
For all the latest news, events and
debates join us on
Pre-commission cleaning of closed circuit pipework systems and the subsequent monitoring of water quality are essential in any building. The implications of getting these wrong can be severe. The resulting problems include disruption to occupants whilst systems are re-cleaned or, in the worst cases, complete closure of buildings whilst entire systems are replaced due to early failure. Although the risks associated with open systems (where the circulating water might come into contact with humans) are generally appreciated, there is less awareness of the problems that can affect closed systems.
A closed re-circulating water pipework system is one in which the water typically spends all of its time being heated, cooled and re-circulated and is not exposed to the atmosphere nor significantly depleted due to evaporation or draw-off.
All systems serving terminal devices from radiators to fan coil units or chilled beams are examples of closed systems.
Potential problems which can occur with these systems start during construction. In large buildings, heating and cooling circuits can include pipes that are over a metre in diameter. In an ideal world, these pipes would be installed in a clean, debris free condition but in practice, hard hats, beverage can, plastic bags etc, have all been found inside these systems. If left undetected, when the pumps are switched on, these items can cause major damage to expensive boilers, chillers and pumps. Smaller particles can be just as bad, as some modern control valves have clearances
of less than half a millimetre. This means that sand, grit, jointing material or welding slag can cause blockages and consequent heating or cooling dead spots. All of this debris should therefore be removed by dynamic flushing of the system during pre-commission cleaning. But even successful removal of these items does not end the danger.
Most closed re-circulating systems are constructed from carbon steel pipe, which although having the significant advantage of being both strong and cheap, in the presence of oxygen and water it will corrode rapidly. Thick walled steel pipe has some tolerance built into it and can retain its integrity for some time, but thin walled steel has less tolerance.
Dynamic flushing of pipework involves circulating highly oxygenated water through the pipes at high velocity. Hence, as we’re removing the problem of system debris we are potentially encouraging corrosion. As a result, following the dynamic flush, some form of chemical clean is usually essential to remove
any corrosion products from the surfaces of steel pipes.
Corrosion process potentially controllableIn theory, once the system is put into operation, the corrosion process should be controllable. If there is no replacement of the water in the system, the oxygen in the water should gradually become depleted thereby stifling the corrosion. Furthermore, corrosion inhibitor chemicals can be added to further reduce the rate of corrosion. However, corrosion protection regimes can go wrong and water quality monitoring is therefore essential.
Whenever water is lost from a system, whether due to system modification or to replace a component, fresh oxygenated water is drawn in whilst water containing valuable corrosion inhibitor is lost. This combination can be sufficient to initiate corrosion. Inhibitor levels can drop even without water being taken out of the system. The active ingredients of
HAZARDS IN CLOSED PIPE WATER SYSTEMSChris Parsloe & Dr Pamela Simpson
Tubercle formation within a closed hot and cold water system.
Pseudomonas spp biofilm development on surfaces of pipework.
Figure 3: Grout Resistivity Test Results - 28 Days
Figure 4: Grout Resistivity Test Results - 730 Days
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