Industry News
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 both members and non-members of the Institute. Below is a brief description of each award together with details of how to nominate potential candidates.
U.R. Evans Award
The 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 an engraved sword at the annual Corrosion Science Symposium (CSS). 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 symbolises 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 (j.a.wharton@soton.ac.uk).
Paul McIntyre Award
The 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, Danny Burkle (D.Burkle@lbbcbaskerville.co.uk) by 28th February 2023.
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.
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. The student should be the primary author of the work and preferably first author. 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 a paper published within the past 12 months or a draft publication) may be sent via email at any time to the CSD Chair, Julian Wharton (j.a.wharton@soton.ac.uk). Supervisors may nominate students.
Lionel Shreir Award
The Lionel Shreir Award is given 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/
Institute News
The 63rd Corrosion Science Symposium (CSS) again joined the Electrochem meeting, which was hosted by the University of Edinburgh between the 4th and 6th September. Electrochem is an annual meeting organised jointly by the RSC Electrochemistry Group and the SCI Electrochemical Technology Group. There were 21 oral talks and the UR Evans award plenary talk, plus a dozen posters over the two days.
The U.R. Evans award for 2022 was presented to Prof Alison Davenport (University of Birmingham, UK) by Stephen Tate (ICorr Vice President) at the 63rd CSS. In her plenary talk entitled ‘Passivation vs. Active Dissolution’, Alison explored how the shape and stability of localised corrosion sites are determined by the delicate balance between passive film growth and metal dissolution. The plenary focused on the nature of passive films and localised corrosion sites, and how they can be successfully explored in situ using a variety of synchrotron-based characterisation methods.
The Lionel Shreir Award is given to the best student presenter at the annual Corrosion Science Symposium, and this year was presented to Alyshia Keogh (University of Manchester). Alyshia gave a fascinating and insightful talk entitled ‘effect of microstructure on localised corrosion and atmospheric stress corrosion cracking of 15-5 precipitation hardened stainless steels, linked to understanding of pitting and atmospheric chloride-induced degradation associated with microstructural features effected by the ageing temperature (see summary of Alyshia’s presentation below). Alyshia commented that she enjoyed the interaction between academics, industry specialists and students at the CSS, and thought the symposium was especially stimulating with an excellent range of presentations and posters from many Universities, and she hoped to attend next year!
Effect of Microstructure on Localised Corrosion and Atmospheric Stress Corrosion Cracking of 15-5 PH Stainless Steels
Alyshia Keogh, Anthony Cook, Emily Aradi, Alex Wilson, Fabio Scenini, Phil Prangnell, University of Manchester, and Zacharie Obadia, Airbus, Toulouse, France.
This work aimed to enhance mechanistic understanding of pitting and atmospheric Cl-Induced Stress Corrosion Cracking (AISCC) in 15-5 Precipitation Hardened (PH) Stainless Steels (SS) by establishing links between microstructural features affected by varying ageing temperature (here, 450 C, 540 C and 650 C) and susceptibility to such phenomena. This microstructural evolution, as a function of ageing temperature, was investigated via scanning TEM energy dispersive X-ray spectroscopy (STEM EDS), and differences in environmental behaviours assessed using both electrochemical and environmental testing under controlled conditions of temperature and Relative Humidity (RH). Statistical scatter in pitting potential determined via potentiodynamic polarisation was too high to determine any trend in localised corrosion resistance with confidence. However, useful information was obtained via Double Loop Electrochemical Potentiokinetic Reactivation (DL-EPR) and Electrochemical Noise (EN) measurements. DL-EPR revealed a linear trend between the degree of sensitisation and ageing temperature which correlated with an increase in number density of Cr carbides. EN measured by galvanically coupling dissimilar microstructures suggests that the highest temperature ageing treatment (650 C) was most susceptible to metastable pitting events and, hence, has a higher probability of transitioning to stable pitting.
AISCC tests (four-point bend specimens with Cl-salt deposits exposed to controlled temperature and RH) revealed that over-aged specimens (ageing temperature 650 C) were most resistant to cracking, whilst EN indicated they had greatest susceptibility to pitting. The opposite was found for under-aged specimens (ageing temperature 450 C). The mode of AISCC transitioned from an intergranular (IG) pathway in under-aged specimens (450 C) to mixed IG and transgranular (TG) for those peak-aged (540 C), no cracks were observed under the same testing conditions in over-aged specimens. Overall, these results are consistent with the theory that AISCC, like conventional SCC, only occurs under conditions of slow and stable localised corrosion.
Institute News
Over the last quarter, the branch has held three technical meetings. On Thursday 22nd September, there was the annual joint meeting with TWI, and Neil Gallon, Principal Engineer of Rosen, gave a talk on ‘Repurposing of Pipelines in the Energy Transition’.
There are many integrity challenges and differences between hydrogen, CO2 and hydrocarbon pipelines, and a pragmatic phased approach is required to enable safe and economic conversion of existing infrastructure.
Hydrogen is the lightest and most abundant element, and has the highest energy content of any common fuel by weight. It is found in water or hydrocarbons and can be produced without carbon footprint through electrolysis, steam methane reforming (SMR) and Carbon Capture (CC). It can be transported over long distances, stored like traditional fuels, but produces clean power and heat so it has advantages over fossil fuels in the drive towards net zero emissions.
The European hydrogen backbone will continue to grow with more connections across member states to about 26,000km by 2035 with a plan to double again by 2040, this will be approximately 69% of retrofitted infrastructure and 31% of new hydrogen pipelines. This emphasis on the re-use of existing infrastructure, while obviously attractive, places heavy demands on inspection and integrity engineering in order to ensure that assets remain fit for purpose.
In the transportation of hydrogen and “rich” CO2 by pipelines, there are key integrity challenges to be addressed for long-term safe operations. However, the major points of interest are the same as any pipeline integrity management system:
• Pipeline condition – What are the time-dependent threats? Which type of defects should I tackle? Where are they located? How severe are they?
• Integrity Remaining Life – How safe is my pipeline operations? How long can l operate it?
• Consequences – What are the consequences of loss of containment?
• Management – Can I safely manage pipeline operations going forwards?
Nonetheless, there are differences between the different modes of transportation which derive from the specific physicochemical behaviour of the fluid, and its interaction with the pipeline materials. For instance, internal corrosion is not a major concern for hydrogen service, while it is a key consideration for CO2 (and hydrocarbon) infrastructures. On the other end of the spectrum, ‘crack management’, broadly speaking, is a more critical topic for hydrogen pipelines than for other services.
While CO2 and hydrogen pipelines could be purpose-built to address the range of applicable integrity concerns, it is very likely that a major proportion of the future transmission network will revolve around the integration of existing Natural Gas (NG) or other hydrocarbon infrastructures. Hydrogen and CO2 pipeline design codes tend to be more constraining or restrictive than that for hydrocarbons. For example, typical hydrogen standards will limit the use of steels up to API 5L X52 (L360) to tackle hydrogen embrittlement issues, while over 45% of the European NG system is designed with higher steel grades.
The fundamental feature, which drives much of the integrity concerns and challenges in gaseous hydrogen pipelines, is the absorption of atomic hydrogen within the steel microstructure. The interactions of hydrogen lead to major degradation of mechanical properties, such as strength, ductility, fracture toughness and fatigue crack growth rate, and have been studied by various researchers of material types used in repurposed pipelines such as, API Series 5L X42, X52, X65, X80 and X100.The data are not yet fully comprehensive but all show that all properties are reduced by increasing levels of hydrogen.
A key reason for this is that the magnitude of interaction of hydrogen and steel is determined by the specific nature of the steel microstructures and chemistries not just the grade. This important facet puts a greater emphasis on the understanding of materials ‘DNA’ and on testing. These aspects are at the core of conversion and integrity management strategies. Crack detection technologies such as Electro-Magnetic Acoustic Transducer (EMAT) and materials properties in-line inspection (ILI), such as ROSEN’s RoMat PGS and DMG services, are likely to be integral to the inspection and conversion of hydrogen pipelines.
In many respects, the management of time-dependent threats in CO2 pipelines is an extension of the knowledge and the experience gained through the traditional oil and gas industry. The main key difference is that in “traditional” gas production, CO2 is mainly an unwanted by-product or impurity, while for CCUS, CO2 will be the primary fluid being transported, and hence will likely be at a higher partial pressure (i.e. presents a greater corrosion risk) and may have its own inherent impurities. Nonetheless, internal time-dependent threats will remain negligible, so as long as no free (separated) liquid water is present in the pipeline. This means that inspection of a CO2 line with ultrasonic technologies, which generally rely on a water couple, can be challenging and other methods must be considered.
Neil summarised by saying, the conversion of existing infrastructure to hydrogen or CO2 service brings unique integrity management challenges. It is unreasonable to expect that facilities designed specifically for hydrocarbon service can be directly converted to hydrogen or CO2 service without due diligence being applied. Management strategies will revolve around understanding material “DNA” and testing, and the deployment of in-line inspections to address pipeline and pipework fitness-for-service.
For hydrogen lines some of the major time dependent integrity threats are associated with potential hydrogen embrittlement of the pipeline steel, and the consequent threat of cracking. ILI of hydrogen pipelines can also be challenging due to the different physical and flow characteristics of hydrogen compared to natural gas, despite this it can be achieved.
For CO2 lines, ILI is necessary to understand the materials and presence of any time dependent threats such as metal loss corrosion or cracking. ILI of dense phase CO2 pipelines is challenging due to the nature of the fluid being transported.
On Tuesday 25th October, the branch welcomed Vinay Tripurana, Applications Engineering, Manager, Flexitallic UK Ltd., to talk on “Flange Face Corrosion in seawater and hydrocarbon environments, related to gasket material selection”.
Vinay oversees the company’s UK Applications Engineering Team. He is a Chartered Mechanical Engineer with Masters’ degree in Manufacturing Systems and has several years’ experience in providing engineered solutions to a wide range of industries including automotive, fabrication and sealing technology.
Bolted flange joints in seawater and hydrocarbon services can be vulnerable to gasket degradation and flange face corrosion. In its guidance document on corrosion management, the UK’s Energy Institute ranks corrosion as the second most frequent cause in initiating loss of hydrocarbon containment in offshore platforms, and highlights corrosion as a major threat to asset integrity and plant efficiency. Flange face corrosion can be extremely difficult to detect prior to leakage leading to considerable loss of valuable resources. The impact on the environment can also be a major concern, as can the immediate safety of plant personnel. Replacement or remedial works often means unscheduled downtime, additional costs, and reduced asset efficiency.
A holistic approach must be taken to a flanged assembly as there are several aspects which are critical to good integrity, and the gasket alone cannot solve all issues. Junctions differ in that there are process parameters of pressure, temperature and carried media, and the hardware differs in design of bolting, support, insulation, and types of flanges. Finally, the installation must be well supervised by competent personnel and correct lubricants and tools used in a controlled and safe manner to give good integrity of a pipe junction.
Unfortunately, gaskets that brought us through the ‘oil boom’ years were traditionally made of asbestos which was a fire-proof material, could deal with most chemicals, and had excellent sealing and corrosion prevention properties, but the material fell from use due to health and safety issues. Traditional alternative materials such as Graphite, Mica and PTFE have characteristics that can be, or appear to be, very useful to flange applications, but they do not have the qualities to offer optimum performance in the area of corrosion prevention. Graphite is naturally an electrical conductor and its ‘noble’ nature promotes corrosion, Mica exhibits very poor sealing characteristics and PTFE is not fire safe and exhibits poor sealing characteristics. This has led to further research into alternative materials to mitigate this issue. For example, Flexitallic went in search of a new material that would:
– Mitigate flange face corrosion – electrically neutral and clean
– Significantly improve connection tightness (Net Zero)
– Be fully compliant with current gasket standards – ASME B16.20
– Meet industry service envelope requirements (-196 to 260oC & B16.5 #150 thru #2500)
– Meet fire safe requirements
– Be easy to use and require no change to established installation procedures
– Economically viable compared with graphite
The solution was a new composite material now known as Corriculite – a spiral wound gasket material based on vermiculite with filler materials and enhancements. It is electrically inert, high purity spiral wound with good tightness properties, that is both fire safe and compliant with the requirements of ASME B16.20. It offers a direct and cost-effective, replacement for conventional, graphite filled gaskets. (Editor: more information can be found in the May/June issue of the magazine).
Once the fundamental gasket property criteria had been fulfilled, the material was tested to validate it for flange face corrosion and in order to prove this, corrosion testing was conducted to ISO 9227, which is simple 600 hour salt spray test (90 mins spray, then 90 mins dry with 170 cycles in total) for M20 Stainless steel bolts, with material to be tested sandwiched between SS washers with PTFE isolator. Multiple rings were placed in series and bolts torqued to 20 MPa.
Other required testing involved flange face corrosion sensitivity testing. Potentiostatic polarisation techniques were used with an impressed current to accelerate the likely corrosion reactions, comparing older graphite performance with the new material. The voltage required to initiate corrosion in graphite was found to be nearly half as much as for the new Corriculite material. Seal tightness was also assessed using a cyclic pressure test to EN13555, whereby 4” diameter sample gaskets were loaded and unloaded to increasing levels of pressure up to 40 bar of helium, and the leakage measured. Quick comparison showed that there is superior performance at the 3 main stress ranges tested when compared with graphite.
A validation test for thermal cycling was also conducted to demonstrate the gasket’s ability to seal when exposed to thermal fluctuations. For the ‘ambient’ test, the gasket was pressurised to 51 bar for 1 hour, a ‘fail’ being drop > 1 bar. A further high temperature test was conducted at 42.5bar pressure at 260°C for 1 hour then cooled for, for 10 cycles in total. These independent results showed max 4 bar loss over the thermal cycling.
Cryogenic testing was also conducted, which is a’ Blowdown’ qualification for between -110C and -196C. Again, this was a pressurised, hold 1 hour, depressurise, but for 3 cycles on ASME Class 150 & 900 grp2.2 flanges. The leakage test showed tight seal and high performance. Fire safety tests were also passed for the new material at 650C 30min cyclic test with forced cool and pressurised cycles.
Vinay then concluded his talk by stating, the Corriculite gasket development is proving to be an innovative spiral wound filler material that mitigates flange face corrosion in up-stream environments. It is fully compliant with current gasket standards and meets industry service envelope requirements fire safe complaint. It can be used as a direct replacement for graphite using existing assembly procedures and is seen as a viable economic alternative to conventional graphite sealing technology.
For its final technical meeting, the branch held a joint event with The Mining Institute of Scotland (an Affiliated Local Society of IOM3) on Wednesday 16th November, with Dr Prafull Sharma as the speaker. Prafull currently serves as the Chief Technology Officer of UK based CorrosionRADAR Ltd which is bringing innovative corrosion monitoring technologies to the Energy Sector using Industrial Internet of Things (IIoT). As a Technologist, he has brought vast industrial experience to Corrosion Management, especially in the area of digitalisation of on which there are several inventions to his credit.
Predictive maintenance and Industry seems to have been talked about for at least a decade now, but in his talk, Prafull considered what this means on a ‘day-to-day’ basis to asset integrity professionals. New advancements in technologies including sensors, battery powered devices, wireless connectivity, remote data analytics are enabling creation of Industrial Internet of Things (IIoT).
Corrosion Management is now emerging as a big user for applications of digitalisation tools. CorrosionRADAR invented a predictive CUI monitoring system that combines corrosion and moisture sensors, which is gaining increasing global traction, addressing a major issue for the industry.
CorrosionRADAR currently have a number of site trials ongoing with both UK and overseas Energy Operators. They continue to have many have many high-profile Investors including – Net Zero Technology Centre (NZTC), and Saudi Aramco Energy Ventures (SAEV).
Certificates of Appreciation were issued to all our branch presenters. The branch also held its AGM at the October meeting, during which a new committee was elected.
Abstracts of potential papers for the Aberdeen Technical Programme are always welcome, and anyone wishing to join committee should correspond with the Aberdeen Chair: Dr Muhammad Ejaz itsejaz@yahoo.com
Further Information about the Aberdeen Branch, and past presentations, may be found on their website page: Aberdeen Branch – Institute of Corrosion (icorr.org), and to join the Aberdeen Branch mailing list, please contact: icorrabz@gmail.com
TABLE:
Dr Muhammad Ejaz Chair Hooman Takhtechian YEP 2022 Coordinator and Past Chair
Adesiji Anjorin Vice-Chair Leela Ramachandran University Liaison & CPD Officer
Dr Nigel Owen Secretary External Steve Paterson YEP Mentors and Case Study Co-ordinator
Lian Ling Beh Secretary Internal Dr Olubayo Latinwo Branch Sponsorship Officer
Bryn Roberts Financial Officer Dr Yunnan Gao Website Officer and Past Chair
Mei Ling Cheah Event Co-ordinator and Young ICorr Officer Stephen Tate Observer and Past Chair
Aberdeen Branch Positions for 2022-2023 Session.
Planned expansion of hydrogen pipeline network in Europe.
Influence of hydrogen on ‘Fitness for Service’ assessment.
Influence of hydrogen on ‘Fitness for Service’ assessment.
New sealing material – materials selection and the galvanic series.
New sealing material – induced corrosion evaluation.
Fire safe testing for flanged assemblies.
Process of CUI and impact on industry.
Example of installation to vessel with cyclic temperature operation.
New Aberdeen Committee 2022-2023 with retiring Branch Members (circled) – Dr Olubayo Latinwo
(last Vice Chair) and Hooman Takhtechian (last Chair).
