New Corrosion Sensor

Industry News

Researchers at Bournemouth University have developed and patented a new corrosion sensor that they say could improve safety and reliability of large structures including bridges and pipelines, as well as vehicles and machinery.
According to the University, the sensor can detect defects and risks in infrastructure at a much earlier stage than the methods currently used, and could therefore result in reduced costs as well as improved safety.

This sensor works on the same principal as health screenings, ie aims spot “health” risks in vehicles and mechanical structures before corrosion reaches an advanced and dangerous stage, and could avoid costly, lengthy repairs, and hopefully prevent structures from being scrapped altogether, continued the University.”
Other industrial corrosion sensors require cables to be plugged in to a computer, which requires someone in site during maintenance. The device is wireless so it can be attached to a structure and its readings can be continuously monitored off-site.

The technology has reportedly been granted patents in the United Kingdom and the United States. Professor Khan and his team state they are keen to work with partners to roll it out across industry, engineering, and construction companies.
More information can be found at,

https://www.bournemouth.ac.uk/news/2023-01-12/new-sensor-can-prevent-defects-major-structures-reaching-costly-dangerous-levels

 

Can digital monitoring systems redefine workers’ safety and health?

Industry News

The implementation of digital monitoring systems for occupational safety and health (OSH) such as apps, cameras and wearables can make workplaces safer. Whether the objective is proactive (prevention) or reactive (mitigation), their success often hinges on the accuracy of the information they collect and analyse. It is just as important to equip employers and workers with the information they need to weigh up the advantages and disadvantages, and to facilitate a good implementation.

Two new reports explore the challenges and opportunities of smart digital monitoring systems for OSH. One report delves into the types, purposes, and uses of digital monitoring systems. The second presents best practice examples to successfully integrate new monitoring systems at the workplace.
These reports, can be found at, https://osha.europa.eu/en

Fellow’s Corner

Fellows Corner

This series of articles is intended to highlight industry-wide engineering experience, guidance, and focussed advice to practising technologists. It is written by ICorr Fellows who have made significant contributions to the field of corrosion management. This issue features the problem of galvanic corrosion in tanks, by Chris Googan, antiCORR (Anticorrosion Engineering Ltd).

Galvanic Corrosion – Getting the Message Across
Readers of Corrosion Management will be familiar with the perils, and mitigation, of galvanic corrosion. However, the engineering world at large is often unaware of the pitfalls. This article illustrates this with three case histories drawn from the effluent treatment industry. What is interesting is, not so much that the problems arose, but the conflicting remedial measures recommended by (so-called) corrosion experts called in
to help.

Case 1 – Poultry Processing
The first case was a waste-water treatment tank at a UK poultry processing facility. As can be seen in Figure 1, this included stainless steel processing equipment which was electrically earthed to the tank. The effluent treated was warm, intentionally aerated and, being relatively chloride-rich, was highly conducting. The tank supplier recognised this as a galvanic corrosion situation, and that it was made all the more damaging by the very high ratio of the stainless steel area to that of carbon steel at lining defects. Accordingly, the supplier warned the owners of the problem, whilst at the same time prudently withdrawing its warranty.

In response, the owners declined to invest in corrosion expertise. Guided by their accountant, they elected to remedy the situation by cathodic protection (CP), a plausible but, in this case, optimistic approach. Dispensing with the cost of any CP evaluation or design, some small anodes were procured. It is, however, by no means clear how, or indeed if, these anodes were actually installed. In any event, the outcome was all too predictable. Within a matter of weeks, the tank was leaking like a sieve (Figure 2), its role having changed from effluent treatment to effluent dispersal!

Fortunately, this amusing case was not particularly costly. Since the tank was relatively small, the pragmatic remedy was to rebuild it in GRP.

Case 2 – Municipal Refuse Treatment
The second case involved several very large effluent aeration tanks constructed for municipal refuse treatment facilities in northwest Europe. Even before formal handover, the tanks were found to be springing leaks, to the consternation of the owners and the exasperation of the environmental authority. Investigation revealed dramatic holes in the shells (Figure 3).

The facility EPC contractor interpreted the problem as defective lining, and called in lining experts. Time and money were then invested in carrying out lining repairs in the hope that this would remedy the problem. Unfortunately, it seems the lining experts had forgotten their galvanic corrosion lessons. They missed the fact that the very well-lined carbon steel tanks contained multiple bare stainless steel nozzles. As in Case 1, the cathode to anode area ratios were enormous, so the galvanic corrosion penetration was very rapid (the steel effectively undergoing electrochemical machining). Improving the quality of the lining on the carbon steel breached a cardinal rule of managing galvanic corrosion, which is to coat the cathode. All the re-lining work achieved was that the tanks developed leaks even more quickly when returned to service.
Eventually corrosion expertise was called up. The solution was straightforward: paint the stainless steel, and install a modest sacrificial anode provision. Unfortunately, however, the EPC contractor was unwilling to engage in what it regarded as the “untried” technology of CP. Facing litigation, it took the financially punishing step of demolishing the tanks and rebuilding them in polymer-lined reinforced concrete.

Case 3 – Beverage Manufacturing Effluent
In many ways, Case 3 was similar to Case 2. It involved a number of large aeration tanks for treating effluent produced by a major European beverage manufacturer. Again, the carbon steel tanks were very well lined, but they contained stainless steel inlet piping and aeration equipment. Some credit is due to the designers who recognised the potential for galvanic corrosion. They addressed it, in accordance with good engineering practice, by ensuring that the stainless steel piping and diffusers were electrically isolated from the tank (or so they thought).

Experience tells us that a corrosion engineer can always call for electrical isolation between tanks and piping. But, in practice, the electrical engineers will always be working to achieve the opposite for the purpose of electrical safety. Thus, although the piping was electrically isolated at the point of entry to the tanks, both piping and tank walls were bonded into the common site electrical earthing system. So, notwithstanding the design intent, a galvanic cell with an adverse cathode to anode area ratio was created. Inevitably, galvanic corrosion occurred and the tanks leaked (Figure 4).
Unlike the EPC contractor in Case 2, the Owner of this facility called in corrosion, rather than lining, expertise. The corrosion specialist advised installing CP. This was accepted by the owner, and a competent contractor was engaged to supply a simple, but effective, system of sacrificial anodes suspended from cantilevered brackets fixed to the tank rim (Figure 5).

The tanks were patch-repaired and returned to service. When they were inspected five years later, the tanks were found to be in good condition. Corrosion of the tank walls, galvanic or otherwise, had been effectively suppressed.

Corrosion Community Responsibility
Doubtless, those involved in these three cases are now more aware of galvanic corrosion, and how not to manage it, than previously. Unfortunately, there remain too many engineers who, although competent in their own discipline, find themselves taking galvanic corrosion engineering decisions without even a rudimentary comprehension of the basic principles. Therefore, the question for corrosion professionals is, are we doing enough to get the right messages to the right people?
Chris Googan

Figure 1
Figure 2
Figure 3
Figure 4
Figure 5

 

Corrodere Academy offering Inspector courses with ICorr accreditation

Corrodere Academy offering Inspector courses with ICorr accreditation

Industry News

Well established online training company, Corrodere Academy, are now offering Pipeline Coating Inspector and Insulation Inspector courses with ICorr accreditation.

Corrodere Academy offer globally recognised qualifications in the protective coatings industry including Train the painter, coating inspector and specialist courses. This is the first time ICorr accredited Pipeline and Insulation Inspector courses have been available online, saving students 50% of time and money in comparison to classroom learning.
The importance of monitoring pipelines
Pipelines are energy lifelines, making almost every daily activity possible. They play a huge role in our everyday lives and are essential to the world’s industries. The world’s transportation would come to a complete stoppage without them as
they carry everything from oil and gas to fresh water.

Course content includes an overview of the pipeline industry, pipeline corrosion, cathodic protection and coatings, quality assurance and control, safety, and pipeline inspector duties, recommended practices and international standards and environmental considerations.

This qualification opens extensive career opportunities in the oil and gas, subsea, fresh water, diesel and petrol and jet
fuel industries.

The importance of monitoring insulation
One of the hottest topics in the protective coatings industry, insulation has been used for centuries to keep heat in and cold out or vice versa. The energy saving and environmental benefits that come from proper insulation are hugely significant. By making buildings and process systems more energy efficient, insulation helps reduce the amount of fossil fuel combustion needed to heat and cool homes, businesses, and factories. That, in turn, decreases the amount of carbon dioxide emitted into the atmosphere.

Course content includes a history of insulation systems, corrosion under insulation, insulation design, standards and specification, quality assurance and control, safety and insulation inspector duties, insulation application and conducting coating surveys.

These distance learning courses, when completed satisfactorily, lead a certificate of achievement accredited by ICorr, which is valid for 5 years.

For more information, contact
the team on 01252 732233 or
info@corrodere.com

A Conversation with Outgoing President Bill Hedges

A Conversation with Outgoing President Bill Hedges

Blogs

A Conversation with Outgoing President Bill Hedges

Reflection on a Presidency that Passed By Too Fast

Bill Hedges recently stepped down as the President of the Institute of Corrosion, handing over to Stephen Tate. Bill will continue to be involved as Immediate Past President for two years.

Having completed his two-year appointment as President, we caught up with Bill to get his insights into what it is like to be President of the Institute of Corrosion. We’re sure you’ll find what he said to be interesting and enlightening, as well as entertaining!

“Bill, what inspired you to become involved with the Institute of Corrosion?”

“Well, I’ve spent my entire career working in the area of corrosion and corrosion management. A great career, aided by the advice and help of many fellow professionals. This generosity has always inspired me to do the same for others and support our field of engineering.

“I guess, in many ways, it started when I lived in the United States. I was very involved with AMPP (formerly NACE). On returning to the UK in 2012, I wanted to support the Institute of Corrosion as well. In 2018, I was honoured to be elected as the Vice President. After this I became President in 2020, and handed over the presidency to Stephen Tate in 2022. I’ll now remain as Immediate Previous Past President for the next two years.

“It’s a great leadership system, spanning six years in each presidential cycle, from Vice President to President to Immediate Past President. It helps to ensure that the leadership is consistent, innovative, and forward-looking.”

“The last couple of years have been a rollercoaster ride. What were some of the biggest challenges you faced during your tenure as president?”

“A rollercoaster is putting it mildly!

“Clearly, the COVID-19 pandemic was a major challenge – as it was for everyone in all walks of life.

“One of the great benefits of the Institute of Corrosion is the networking opportunities it provides, but, with COVID-19, all our face-to-face meetings had to stop.

“This was frustrating, but, like many organizations, this cloud had a silver lining. Our rapid switch to virtual meetings enabled more people to attend meetings and seminars – it’s very time efficient for delegates. Another benefit is that it helps us to reduce our carbon footprint, and sustainability is a key motivator in the world of corrosion.

“The global downturn was also a concern. Unable to run our classroom-based training courses meant we lost some revenue, though this has since recovered well.

“Finding individuals who have the time to get involved in the Institute is another challenge, given the busy and fast-paced nature of modern life. However, we are fortunate to have many dedicated members who are willing to get involved – the rewards of being a part of this really are something.”

“How did you measure the success of the Institute during your time as president?”

“As the president, I had a few key metrics that I used to gauge the success of the organization.

“Among the most straightforward was the growth in membership numbers and the financial stability of the organization. For example, the number of members we now have on LinkedIn has grown from virtually zero to more than 10,000. Another key indicator was the positive feedback I received from members.

“However, I should point out that all of the positive results we have achieved during my time as Vice President and President is a testament to the efforts put in by the council and staff as well as myself. No man is an island.”

“That’s a great point, Bill, and leads us nicely on to the next question. What do you consider to be the Institute’s greatest accomplishments during your time as president?”

“Of course, I am proud to have seen the Institute overcome several challenges and come out stronger. The team effort has been colossal during the most challenging time that most people can remember.

“Some of our greatest accomplishments included surviving the Covid-19 pandemic and global economic crisis; introducing virtual meetings; refreshing our training courses; developing new courses in Passive Fire Protection (PFP), Microbiologically Influenced Corrosion (MIC), and Corrosion Under Insulation (CUI); and ISO 17024 compliance for many of our courses.

“We’ve also established strong relationships with our partners (such as ABRACO) and, as I said earlier, made strides in social media with over 10,000 followers on LinkedIn.

“Additionally, our Young Engineer program continued to thrive and our cathodic protection (CP) training centre was opened, which was a major milestone.”

“That’s quite a rollcall of achievements. How do you see ICorr evolving in the next few years, Bill?”

“In the coming years, I see ICorr continuing to grow and evolve as we introduce new training opportunities and expand our online and classroom courses, developing more speciality and engineer-level offerings.

“Already, one-third of our membership is based outside of the UK, and I think we will continue to explore how we can offer greater connectivity and opportunities for these. We are investing in new IT systems. This will make it easier for all members to access our services and keep their details updated.”

“You’ve spoken of the role of the Council and staff in the activities and success of the Institute. How did you work with them during your tenure as President?”

“Working with the council and staff was one of the highlights of my presidency. ICorr’s day-to-day operations are managed by the President, with support from the other four Trustees, and we met monthly or as needed.

“The council, made up of committee chairs and branch chairs (26 in total), was incredibly supportive, and I always valued the feedback I received from them. A wonderful team to work with.

“I couldn’t have done any of this without the three staff members in our office. They are an essential part of our team, and I was grateful for the administration and organizational support they provided. We rely on them heavily.”

“The Institute’s mission is crucial. How did you ensure it was upheld during your tenure as president?”

“You’re spot on: ensuring that the Institute of Corrosion’s mission is upheld is essential. It’s a top priority and it’s this priority that makes it relatively easy to ensure we focus on the mission.

“The President is held accountable by the Trustees and the Council. I always made sure to consult with them and stay on track with our mission. By working together, we were able to achieve our goals and maintain the integrity of the Institute – no matter what this mad world threw at us!”

“Working together seems to be a theme here, Bill. Tell us, how do you involve members of the organization in decision-making processes?”

“For some of the big ideas or decisions I would ask for feedback via email or through my bi-monthly column in our Corrosion Management Magazine.  For this purpose, I created the president@icorr.org email to encourage members to connect with me directly.  Many did and I responded to every email.

I also valued the wise counsel of my fellow Trustees, Council members and past presidents who always gave their time and knowledge generously.

“However, this is an area in which we can continue to improve. We always wrestle with the balance of asking our members for input versus overloading them with emails etc.”

“Only two more questions, Bill. The first is how did you balance your responsibilities as President with your other (personal and professional) commitments?”

“My wife asks me the same question ─ but with a slightly different tone to yours!

The truth is that I’ve always liked to be busy. Being the President of the Institute of Corrosion was simply a part of this. It did take more time than I anticipated, though maybe that was partly my fault as I love to get involved with ideas and projects. 

“Being President has been incredibly rewarding, especially when we came through Covid and I was able to get out and meet with our members again ─ but I was also delighted to hand over to Stephen at the end of my two-year term!”

“We can imagine. And on this note, what advice would you give to the incoming President to help them succeed in their role?”

“I’ve spoken to Stephen about his ‘new life’ as President, so he knows this already: delegate more!

“There are two benefits to delegating. First, it reduces the workload of the President. But at least as important is that delegating provides great opportunities for others to contribute. This is especially the case with some of our fantastic younger members who are incredibly enthusiastic.

“But the most important advice I can give is to make sure you enjoy your time as President. It’s a fantastic role, and I have been extremely privileged to have been given the opportunity to fulfil it. But those two years – they pass by in a flash.”