Chris Lynch: Worthy Recipient of the Paul McIntyre Award 2022

Chris Lynch: Worthy Recipient of the Paul McIntyre Award 2022

Blogs, Corrosion Engineering Division, PFP

Giving Back in Corrosion Engineering

First awarded in 2017, the Paul McIntyre Award is our premier award in the field of corrosion engineering. It is presented to a senior corrosion engineer by the President of the Institute of Corrosion at the Corrosion Engineering Division’s Working Day and Symposium.

In addition to the recipient being a senior engineer, the criteria includes that he or she is a leading practitioner in his or her field who has advanced European collaboration and the development of international standards.

This year, we returned to an in-person Working Day held at the National Railway Museum in York. It certainly proved to be a Working Day and Symposium to Remember, especially for Chris Lynch, who received the Paul McIntyre Award at the end of the morning’s session.

Paul McIntyre – an inspiration to those who follow

Dr Paul McIntyre was determined, invariably polite and accommodating, and had an endearing, dry sense of humour. His career spanned industry, asset management, and editorial work, as well as working on standardisation within the industry.

After graduating from the University of Newcastle-upon-Tyne, Paul spent the initial stages of his career in industry. He moved south in 1978, to join the Central Electricity Research Laboratories in Leatherhead. As Group Leader, he spearheaded studies into stress corrosion, localised corrosion, and corrosion fatigue in conventional and nuclear power plants.

Later in his career, Paul became involved in asset management and remaining life assessment of components, including the development of remedial methodologies such as reliability, availability, and maintenance (RAM) and reliability centred maintenance (RCM).

Between 1996 and 2006, he was the editor of the British Corrosion Journal, though editorial work was not his only foray into the written word in the corrosion industry. Paul authored around 60 published papers and over 200 technical reports.

Paul was never one to rest on his laurels, and thrived on demanding work. If he wasn’t at work, he was deliberating, or brainstorming, or advising. Between 2004 and 2010, he worked as consultant in the Electrochemistry and Corrosion group at NPL. He put his insight and engineering experience to work in producing critical analysis of a wide range of failure investigations including fracture of wind turbine bolts and corrosion pitting in desalination plants, as well as providing informed corrosion control guidance to industry.

Paul also had nearly 30 years of participation in corrosion standardisation as a member of BSI and ISO committees. This included time served as Chair of ISO/NFE 8 Corrosion of metals and alloys, and UK representative on the equivalent ISO committee TC 156 and within that being secretary of WG 2 Stress Corrosion Cracking and member of WG 7 Accelerated Corrosion Tests.

He made an immense contribution as Scientific Secretary of the EFC.

He was also on the Council of the Institute of Corrosion from the early 2000s, specialising in standards work and pan-European activities.

In 2003 Paul was awarded the T. B. Marsden Prize of IOM3 for his considerable achievements in promoting standards, education, and publishing in corrosion and materials. In citation for the award, the Chair of ISO TC 156 said, “Paul has provided more input into the development of ISO standards in the corrosion field than any other individual”.

Unfortunately, Paul was diagnosed with secondary liver cancer in 2012, and, despite his spirit and fight, he sadly passed away in 2012.

The Paul McIntyre Award is a befitting celebration in his memory, and an inspiration to all those who follow him.

Chris Lynch

Chris Lynch graduated from the University of Leeds in 1990.

He began his working career as a junior corrosion engineer at Aberdeen Corrosion Engineers Limited, and remained in the north of Scotland for more than 10 years. Extensive travel took him into Europe and the Middle East, while working onshore and offshore.

Employed by Corrpro Companies Europe Limited in 2005, he is now Senior Engineering Manager and responsible for cathodic protection engineering, site services, and the power unit design personnel.

Like Paul McIntyre, Chris is dedicated to his work and an avid learner. He also believes it is important to give back to the industry he loves and that has rewarded him well.

Also like Paul McIntyre, Chris has served on many committees and with industry bodies. He is Chair of a BSI committee, and has presented training and development courses. He has an international outlook, and thrives on exchange of information with his peers from around the globe. A Chartered Engineer, his rollcall includes:

  • Working on numerous training committees
  • Course presenter of ICorr training schemes
  • Currently a member of the Cathodic Protection Governing Body (CPGB)
  • Level 4 CP Specialist of buried and marine structures and internal surfaces
  • Fellow of the Institute of Corrosion
  • Chair of GEL/603 which is the British Standards Institute (BSI) committee for Cathodic Protection
  • Works on various Working Group activities for ISO and CEN
  • Member of CEOCOR
  • Member of the Marine Corrosion Forum

In accepting the Paul McIntyre Award, Chris said:

“I would like to thank those who have voted for me to receive the Paul McIntyre Award for 2022. This is a great honour for me.

“I would like to dedicate it to all the people who have contributed to my success, many of whom I have met whilst doing the work that Paul himself did tirelessly and for so many years himself.

“It is wonderful that my work with GEL/603 and with ISO and CEN standards committees and working groups has been recognised with this award. The work is so varied and with communities such as CEOCOR, the approach is unique and informal.

“To be honest, it is not work at all. It is fun.

“There is much to be gained in international standards work and I have built up friendships with peers and experts across Europe and the wider world. I have gained so much more than can be taught on courses or read in presentations, papers, or visiting exhibitions.

“I believe we all have something to share. Perhaps an experience we have had that is unique or a set of interesting data we have gathered; or a job that went wrong that others would benefit from in hindsight.”

The similarities between Dr Paul McIntyre and Chris Lynch are uncanny. A worthy recipient of our most prestigious corrosion engineering award.

To learn more about the Institute of Corrosion Awards, click here.

To discover how you can become a member of the Institute of Corrosion, and ways in which membership can help develop your career, or how you can give back to the industry by sharing your knowledge and experience with those who are developing theirs, please contact us.

Corrosion Engineering: A Working Day to Remember

Corrosion Engineering: A Working Day to Remember

Blogs, Corrosion Science Division, PFP

5 Talks, 4 Working Group Sessions, 1 Prestigious Award, and a New Chair… Phew!

The corrosion engineering community was able to get together and do what they do best at the Institute of Corrosion’s Corrosion Engineering Division (CED) Working Day and Symposium in April. Discuss latest trends, share knowledge, and brainstorm ideas and concepts.

Held at the magnificent National Railway Museum in York, this was the latest in a series of CED Working Days that offer delegates exceptional networking opportunities – as well as a chance to visit the museum.

A welcome to introduce a sad farewell

Nick Smart, Chair of CED, welcomed the delegates to the event and introduced the speakers. This was the last Working Day and Symposium that Nick has introduced, as, after 15 years of excellent service as the CED Chair, he is stepping down.

Nick’s shoes will be challenging to fill, and the meeting showed their appreciation for his unstinting efforts and contribution throughout his years at the helm. A sad but celebratory farewell, and a warm welcome to the incoming Chair.

Introducing the Corrosion Engineering Division’s new Chair

Before the main proceedings began, Nick Smart introduced the delegates to the CED’s new Chair, Danny Burkle.

While Nick will be a hard act to follow, we’re incredibly lucky to have Danny taking over the steering of the CED.

A business development engineer, Danny’s prime responsibilities in his role at LBBC Baskerville include developing business strategy, business, and product range for innovative corrosion testing autoclaves to simulate realistic field environments within several high-pressure and high-temperature applications and industries.

His Doctorate in mechanical engineering, which he completed at the University of Leeds, focused on corrosion mechanisms involved in carbon dioxide corrosion, and protecting carbon steel assets against corrosion by forming natural corrosion products. The industry-focused research, sponsored by BP, was based on real-life engineering problems.

With both academic and industry experience, Danny’s role as CED Chair could help to forge closer relationships between research and industry.

Knowledge transfer in five presentations

Through the day, delegates were treated to five presentations around this year’s theme of ‘Knowledge Transfer and the Management of Infrastructure Corrosion and Management’:

1.     Hot dip galvanizing for specification and use in infrastructure projects

Presented by Desmond Makepeace of the Galvanisers Association, this talk began by describing the galvanising process, with reference to the appropriate standard EN ISO 1461.

Desmond discussed a variety of defects, which of these can be tolerated, and factors affecting the quality of galvanising, including coating thickness, renovation, adhesion, joining-bolting, duplex systems, maintenance, venting of hollow sections, and overlapping sections. He also discussed how the atmosphere affects corrosion of galvanised structures.

2.     Best management practices to transfer knowledge to ensure integrity assurance optimisation for oil and gas production

One of the highlights of the Working Day, this Young ICorr talk was given by Izabela Gajewska. Izabela was a member of the winning team of the 2020 cohort of the Institute of Corrosion’s Young Engineer Programme (YEP) (which you can read about in our article ‘A case study for all young corrosion engineers – it could be you’).

Izabela discussed the nature of knowledge transfer, and the best practices to ensure this happens effectively and successfully – such as planning, work experience, mentoring, specialised training, attending conferences, and so on. She spoke about creating an effective mentoring strategy, delivery of training, and the value of external training courses in areas including coating, passive fire protection, cathodic protection, and risk assessments.

3.     The consequences of climate change for corrosion

Chris Atkins of Mott MacDonald gave a thought leadership talk, discussing his ideas around climate change and corrosion. For example, can we rely on historically established corrosion rates as emissions of carbon dioxide are increasing? An ensuing reduction in the pH of natural waters could make them more aggressive to concrete, though it may reduce the corrosion rate of galvanised steel.

Temperature increases reduce the dissolved oxygen content in water, but Chris demonstrated how this temperature increase does not automatically produce an increase in corrosion rates – and a reduction in carbon dioxide levels from today’s elevated levels is likely to reduce atmospheric corrosivity.

The real issue? As far as Chris is aware, no one is taking a global view of the effect of climate change on corrosion, and this leads Chris to ask one last question: is this an opportunity for the Institute of Corrosion to take a leading role?

4.     Academia and industry: How can we advance corrosion science and engineering together?

“Academics want to publish. Companies want to make money.”

Old thinking.

Richard Barker of Leeds University addressed this in a thought-provoking talk that pointed to research around this topic, as well as opportunities and challenges that exist for academia and commercial operations to collaborate more effectively.

While academia has the time and resource to produce new knowledge which can be used commercially, barriers that exist include complexity of communication to share knowledge and the complexity of initiating and continuing collaboration.

Perhaps the biggest challenge is trust. Industry must trust scientists, but the complex and ever-changing nature of large bodies of academic research makes this challenging for many businesses. However, we are seeing that some companies are developing strategies to identify and reach out to research groups for collaborative projects – and creating collaborative success.

The conclusion? Yes, there are challenges that exist, but these can be overcome with the correct approach from both sides. If we can do this, then there are significant benefits to be accessed from greater collaboration between academia and industry.

5.     Radioactive waste disposal – where corrosion science meets corrosion engineering

In the first presentation of the afternoon session, Nick Smart gave his last CED Working Day and Symposium presentation as Chair.

Nick discussed the three levels of radioactive waste, and discussed the various research that supports the corrosion engineering and safety assessment aspects of radioactive waste management.

Describing corrosion issues that exist (such as atmospheric external corrosion of stainless steel waste containers during interim storage, the corrosion behaviour of waste uranium, aluminium and Magnox after encapsulation in cement, and the long-term corrosion of waste containers after disposal in deep geological repositories), he pointed out that the UK’s total nuclear waste inventory would fill Wembley Stadium.

Nick discussed the two main concepts for geological disposal of high-level waste, and the challenges that exist within diverse global geological environments – key environmental considerations when disposing of radioactive waste underground include oxygen concentration, chloride and sulphide concentrations, radiation levels and microbial activity.

Nick outlined the analytical techniques that are used to characterise the corrosion behaviour and corrosion rates of candidate waste container materials in long-term in situ experiments conducted under representative conditions, and how such studies can be supported by comparison with the corrosion of natural analogues, such as archaeological artefacts like the Anglo-Saxon Coppergate Helmet currently exhibited in the Yorkshire Museum.

The session concluded with a short talk by Stuart Bond from AMPP. He discussed the development of revised standards being conducted by AMPP (a merger between SSPC/NACE was rolled out in January 2021).

The Working Group Meetings

At the end of the talks, delegates had an opportunity to visit the National Railway Museum and attend Working Group Meetings. This year the following groups held sessions:

·       Nuclear Corrosion Group

Chaired by Nick Smart, the Nuclear Corrosion Group met to discuss a wide range of corrosion issues arising during the storage of nuclear waste. These included assessment of pitting corrosion in stainless steel during storage in atmospheric conditions, the effects of microbial corrosion on cast iron under damp conditions, and the potential for galvanic corrosion of stainless steel in contact with graphite in cementitious environments.

·       Coatings Group

There was plenty to discuss in this group, chaired by Phillip Watkinson. This included:

  • The impending review of the Coatings Technical Information Documents (CTID), created in 2016-17
  • The transfer of NACE Coatings Standards to AMPP
  • A suggestion by Douglas Mills that EIS measurements (ISO 12944) be reviewed
  • Phillip Watkinson tabled that two Paints and Varnishes Standards (BS EN ISO 4628-1:2003 and 4628-2:2003) should also be reviewed

It was agreed that an interim meeting would be held ahead of next year’s CED Working Day.

·       Cathodic Protection Group

Acting Chair Chris Lynch directed discussion around subsea CP systems and performance of flush fit aluminium deep sea anodes on complex piping systems. This included current distribution, current density, anode installation methodology and expected performance along with coatings, anode corrosion products, and calcareous deposits.

·       All Energy Group

Chaired by Steve Paterson, all those present contributed to a positive discussion about the purpose of the group, which has been formed by adding renewables to the previous Oil and Gas Group. Items covered included:

  • Production of documents
  • Mentoring of Young ICorr members
  • Information exchange via networking
  • Engagement with other organisations like AMPP

After an update with regards to standards, it was agreed that another meeting would be held in October.

The Paul McIntyre Award

As is customary at the CED Working Day and Symposium, before the group broke for lunch, the President presented the Paul McIntyre Award.

This year’s recipient of this prestigious award, the premier engineering award of the Institute of Corrosion, was Chris Lynch, who has worked tirelessly for many years and made many outstanding contributions to many aspects of corrosion engineering. You can read more about the award and Chris’s contributions in our article ‘Chris Lynch – Recipient of the Paul McIntyre Award 2022’.

Don’t miss out on the benefits of the CED

The CED is a driving force within the corrosion industry. It shares news, views, and learning to the Institute’s membership, via several channels, including:

Chairs of individual Working Groups liaise with counterparts at other corresponding Working Groups in international bodies. The Working Groups also provide a mechanism for members to collaborate effectively; for example, by jointly preparing documents that are of immediate and practical use to them in their field of activity. Such documents are downloadable within the Members Area of the ICorr website.

If you are not already a member of the Institute of Corrosion, check out our membership page to learn how to become a member and immediately begin to enjoy the many benefits of membership of the Institute of Corrosion.

The 63rd Corrosion Science Symposium at Electrochem 2022: All You Need to Know

The 63rd Corrosion Science Symposium at Electrochem 2022: All You Need to Know

Blogs, Corrosion Science Division, PFP

Who Will Be Presented the Lionel Shreir and Galloway Awards This Year?

The Corrosion Science Symposium has been on a long journey through Covid. The 61st Symposium was forced to move online in 2020. While it was a remarkable success in its new format, we had hoped to return to business as usual in 2021. We did our best, but with the Covid laws that existed last year, the best we could do was a hybrid 62nd symposium – a residential option with live streaming, while ensuring we could deliver to our international membership and others in the corrosion community.

This year we are back to how our membership meets best, and in some style – and we’re seeking your input!

In person, and in Edinburgh

The 63rd Corrosion Science Symposium will be held as part of Electrochem 2022, a conference organized by the Royal Society of Chemistry’s Electrochemistry and Electroanalytical Sensing Systems interest groups, and the Society of Chemical Industry’s Electrochemical Technology Group.

As part of this, our Corrosion Science Symposium will take place on the 5th and 6th September. It’s the perfect opportunity for students and researchers in corrosion science and engineering to get together, network, and discuss their work. You’ll have the chance to share news, views, and ideas, and improve your own learning and knowledge.

What better city for our symposium than Edinburgh? What better venue than the John McIntyre Conference Centre?

This purpose-built conference and meeting venue can accommodate up to 330 delegates. With state-of-the-art audio visuals, a configurable plenary room, four large meeting rooms, executive boardrooms, a stunning view across Arthur’s Seat, and an exceptional bar for end-of-day socialising, this is a superb setting.

It’s not the place, it’s the people. It’s you.

Edinburgh’s John McIntyre Centre is a stimulating place for us all to meet. But not as stimulating as the people who gather here.

With delegates expected from around the world, you’ll be in the company of some of the finest and most forward-thinking, up-and-coming minds from all areas of corrosion science and engineering.

Presentations and discussions have never failed to inspire at the symposium, and the friendly, informal environment is highly conducive to making new acquaintances ─ and beginning life-long friendships within the industries we serve.

An opportunity to recognise excellence in the field of corrosion

The Institute of Corrosion’s Corrosion Science Symposium isn’t only an event for informal learning and networking. It has become synonymous with recognising student talent.

There are two awards directly connected with the Symposium: the Galloway Award and the Lionel Shreir Award.

The Lionel Shreir Award – Last call for submissions

This award is presented to the student who gives the best presentation at the Corrosion Science Symposium. It is awarded to the student(s) judged to have performed best across the following criteria when making their presentation:

  • Distinctiveness, originality, and creativity of research – impact on corrosion discipline
  • Knowledge of corrosion science and practice
  • Clarity of presentation and rapport with the CSS audience
  • Clarity when answering questions

All student presenters at the Corrosion Science Symposium are eligible to win this award of a certificate and cheque for £125.

Could you be this year’s Lionel Shreir Award winner?

To be considered to present at the Corrosion Science Symposium, please submit a 200-word abstract that details a 10-minute talk you would like to give at this year’s symposium before 8th July 2022. We’ll let you know if yours has been selected for presentation in plenty of time ahead of the symposium.

For the opportunity to be awarded the highly sought-after certificate and cash prize, send your abstract to j.a.wharton@soton.ac.uk.

The Galloway Award – We’re seeking submissions

Originally presented for either the best essay submission or work project report, the Galloway Award was first presented in 1976, and reinstated in 1998 in memory of Jack Galloway, a founder Member of the British Association of Corrosion Engineers (BACE) and former Chair of BACE Council.

The award of a certificate, a cheque for £300, and publication of the winning article in the Institute’s Corrosion Management magazine is given to the submission of the best submitted or published paper from the previous 12 months.

Have you produced award-winning work?

We are seeking submissions of copies of students’ published or submitted papers from the last 12 months. The student should be the primary author of the paper. Supervisors may nominate students. Submissions for the award will be judged on the following criteria:

  • Distinctiveness, originality, and creativity of research – impact on corrosion discipline
  • Contribution to corrosion science and practice
  • Clarity of presentation

As well as receiving the Galloway Award, the winning student will be invited to present his or her work at the Symposium.

Submissions should be made to the Corrosion Science Division Chair, Dr Julian Wharton by email to j.a.wharton@soton.ac.uk.

If you would like further information about the Institute of Corrosion awards, please click here.

To learn more about Electrochem 2022 and register to attend the event, please click here.

Passive Fire Protection Courses: An Update from ICorr

Passive Fire Protection Courses: An Update from ICorr

Blogs, PFP

PFP Training to Suit You

The Covid pandemic has taken its toll on all industries around the world. It has disrupted business and delayed projects, but crucial learning, such as passive fire protection courses, cannot be ignored.

Here at ICorr, we continued to work with our partners behind the scenes to ensure that as the world returns to normality (whatever the so-called ‘new normal’ is), we can ramp up the sharing of corrosion knowledge, experience, and expertise. This includes delivery of an increasing range of corrosion training courses, qualifications, and certifications.

In this article, we provide an update on the Passive Fire Protection Courses that provide training to meet industry needs.

PFP is crucial, but competency is lacking

It is crucial that we protect facilities against fire by using high-performing passive fire protection. In high-risk facilities, such as oil and gas installations, this protection is most commonly offered by  epoxy intumescent coatings, protecting the structural steel from extreme heat and providing full corrosion protection as an added benefit.

In recent years, the industry has identified a shortfall of early-stage technical competency in PFP systems. This has led to higher risks, lower safety, and extra costs – all of which could be avoided by improving competencies in the application and inspection of PFP.

Training and qualification to improve expertise in PFP

The Institute of Corrosion (ICorr) came together with PFPNet and IMechE Argyll Ruane to design and deliver the new PFPNet Competency Framework, which is expected to be mandated by owners and stakeholders as a requirement for projects and operations. Central to this is the core PFP training required to improve (and prove) PFP competencies:

  • PFPNet has written the courses
  • ICorr has qualified them
  • IMechE Argyll Ruane is delivering the training globally

After delays caused by Covid, the PFP training courses are now in full swing, and being offered in a variety of training delivery solutions around the world.

Global training options to suit you

Understanding both the need for this specialized training and the challenges for individuals and groups to receive it, the PFP courses have been developed and adapted to suit individual needs in Europe, the Middle East, and Southeast Asia. Course delivery includes the following:

  • PFP Level 2 courses are now running in India and China
  • There are two PFP level 3 courses planned in Australia in April, and others expected through the Australasia Region to follow the Operators’ lead
  • A PFP Level 3 course will soon be delivered in the Netherlands

Learning methods available include:

Inspector Level 2

The PFP L2 Inspector course is designed as an online or classroom course and can be adapted to be delivered as a combination.

Inspector Level 3

The PFP L3 Inspector course has been adapted to provide a blended learning experience with around 30-40 hours’ online learning, and three days of classroom, followed by a Peer Review within 28 days.

Do you require PFP training/accreditation?

These unique courses are designed to qualify inspectors of epoxy intumescent coatings, with a cementitious PFP course to follow shortly. The course and qualification will evidence your competence to understand and inspect PFP installations in both new and retrofit installations.

Owner operators should also attend these courses, as there will be a need to build the course into specifications, and thus make certain that PFP is fully considered, and that the design and application of PFP meets standards and best-practice requirements as they evolve and improve.

Fabricators/applicators will also benefit from the course, as they will need to have fully trained inspectors. And, of course, inspectors who work for inspection houses will also need to be qualified to meet the market requirement.

To learn more about the PFP courses, and how you can register for your preferred learning style and availability, contact either John Dunk at PFPNet or David Mobbs at ICorr.

Passive Fire Protection Courses: An Update from ICorr

A Passive Fire Protection Course is Critical: The Experts’ View

Blogs, PFP

We Asked the Questions You Want Answered

A passive fire protection (PFP) course is critical for asset integrity and health and safety of employees. Poorly applied PFP systems put at risk both, as well as adding huge costs to the industry when rectification must be executed.

The Institute of Corrosion has been working with PFPNet to address these issues. The outcome is the Fire Protection Coatings Inspector Training Programme, led by the evolution of needs within the oil and gas industry.

Together with PFPNet, we’ve spoken to many industry experts, including:

  • Shivas Lindsay, Fixed Gas Platforms Process Safety Lead & Technical Authority, Woodside Energy
  • Bill Hedges, Chief Engineer, Materials & Integrity Management, BP
  • Sebastien Viale, Paint and Insulation Group Leader at Technip Energies
  • David Stowers, Associate Consultant at PFP Specialists
  • Gautam Arya, Managing Director at Muehlhan Middle East Holding Limited
  • Sarah Vasey, Global Project Director at Sherwin-Williams
  • David Mobbs, Business Development Manager at Corrosion Integrity Management Ltd
  • Gareth Hinds, President of the Institute of Corrosion
  • Simone Thurlbeck, Visiting Professor, University of Manchester and Director at PFPNet
  • John Dunk, Director of PFPNet and Passive Fire Protection Specialists

Why do we need this PFP course?

“The PFP market over the past 10 years has become much more competitive,” says Bill Hedges. Though he says that more suppliers entering the market is a good thing, he adds, “This also means that they’re not able to provide the inspectors we need at our facilities when the PFP has been applied.”

“It’s become evident that the quality standards associated with PFP installation have become quite poor over the recent years,” says John Dunk. “Therefore, having a qualified inspector to inspect the installation becomes very much more important.”

What are the consequences of poorly applied PFP?

Poor installation of PFP systems can have extreme consequences. The financial cost of poorly applied PFP can be colossal, and PFP is critical for health and safety and asset integrity.

“If passive fire protection has been badly applied, it means that we don’t know how it would act in a fire. Therefore, the safety of personnel and facilities could be undermined,” says Shivas Lindsay.

“It could also lead to corrosion under the passive fire protection, which is a problem,” says Bill. “If we need to repair it, it’s very expensive. We estimate it can cost anywhere between 10 to 100 times the original cost if we have to go back and repair.”

Why are current inspection regimes missing PFP installation defects?

The need for an upgrade in PFP inspection competency across the entire industry is highlighted by many of the experts we have spoken to.

“The main reason we miss defects is because we don’t have enough experienced inspectors to find them,” continues Bill. “We find this to be especially true in more remote parts of the world, where we’re constructing many of our facilities these days.”

Simon Thurlbeck remarks, “In my experience of inspecting lots of PFP systems over the last 20 or 30 years, I’ve found many errors and mistakes in the way things have been done.”

“Some people have the misconception that passive fire protection is just like regular paint – even the paint you might apply in your own house,” says Bill. “That’s far from the truth.”

Improving PFP inspector competence

“There’s a clear gap in the market in passive fire protection. We’re looking to raise the bar and support industry to set higher standards for people who are qualified to inspect work on passive fire protection systems and sign off work on passive fire protection systems,” says Gareth Hinds.

Introducing the Fire Protection Coatings Inspector Training Programme

The comments from these experts give a flavour of the desire within the industry for a huge upgrade in the training and competency of PFP inspection. Which is why the Institute of Corrosion (ICorr) and PFPNet have developed a market-leading Fire Protection Coatings Inspector Training Programme specifically aimed at the training of inspectors who inspect installation of hydrocarbon passive fire protection coating materials.

“We’ve really tried to write the course in a way that people are going to absorb it and enjoy it,” says Sarah Vasey.

“The main purpose of this course is to properly qualify inspectors of hydrocarbon passive fire protection coatings used to resist hydrocarbon fires,” says David Stowers. “It’s not a fire engineering course, but we do start with an overview of the effects of fires on plants and structures – and, hence, the need for PFP.”

The course isn’t a PFP application course, either, but it does look in detail at the application and quality control requirements of the most widely used hydrocarbon PFP materials. The course also covers installation issues that influence how well PFP will withstand operational and environmental demands.

“At the end of the course,” says Simon, “there’s quite a detailed examination that covers all the course materials that participants have heard over the previous few days.”

“Then there is a peer review,” says Sarah, who is excited by the panel of people who will be conducting it. “People in the industry who we look up to,” she says.

Sebastien sums up the real-world benefits of this training when he says, “It’s great to have people like PFPNet putting together a course that will improve the knowledge of inspectors. For me, this is improving safety.”

Who should attend the course?

“The people who will benefit from this course in the first instance are those inspectors who are currently practising PFP inspection on major projects,” says David Mobbs.

“We’re looking for those who have a minimum Level 1 Paint Inspector course. We would like to have seen them work in the PFP industry for a minimum of three years,” confirms Sarah.

In addition to these early-stage course participants, John Dunk says, “the course could also be of interest to engineers or other parties who just want to understand passive fire protection and its installation.”

Those who will benefit from this course include:

  • Owner-operators who will need to build the course into specification, to ensure that PFP is fully considered and that the design and application of PFP meets improving standards and industry best practice;
  • Fabricators and applicators who will need to have their inspectors competently trained, demonstrating that they are committed to maintaining improved standards of application and inspection; and
  • Inspection houses who will need to have trained inspectors ready to meet the market requirement.

In summary

Developed by highly experienced industry experts – people who really understand the needs of the industry – this course will raise the competence of persons responsible for inspecting and signing off on the quality of installation of such systems, covering epoxy intumescent and cementitious PFP systems in the hydrocarbon industries.

With the need for improved PFP inspection, there is a career path for people in this discipline. This comprehensive Fire Protection Coatings Inspector Training Programme will be the springboard for all those who want to develop their career in this area.

We cover the course content in more detail in our article ‘PFP Course for Inspectors – Finally, Training That Meets Industry Needs’.

For more information, contact either John Dunk at PFPNet or David Mobbs at ICorr.

Passive Fire Protection Courses: An Update from ICorr

PFP Course for Inspectors – Finally, Training That Meets Industry Needs

Blogs, Latest News, PFP

PFP Inspection Training Developed by Industry Experts for the Industry

In the last few weeks, we’ve published several articles about passive fire protection. These include:

In this article, we briefly review the reasons why a comprehensive, market-leading PFP course for inspectors is considered essential by the oil and gas industry. We also examine the nuts and bolts of the new Fire Protection Coatings Inspector Training Programme that has been launched by the Institute of Corrosion and PFPNet.

PFP is failing too often

Market dynamics have reduced the level of qualified inspection that helped to ensure correct application of PFP systems before plant is commissioned.

Greater competition in the coatings market has pressured margins. A consequence of this is that suppliers of epoxy intumescent and cementitious PFP coatings no longer provide on-site technical services free of charge. Combined with the drive for the oil and gas industry to reduce project costs, there has been a reduction in available competence to ensure quality installations.

Additionally, there has been a tendency to treat PFP coatings like paint, despite specialist skills and understanding required for quality PFP installation.

The result of these factors has been a decline in the quality of PFP application. In turn, this leads to failure of PFP with the associated financial and human cost impacting the industry.

The huge cost of poorly installed PFP

The cost of correcting poorly-applied PFP systems can be huge. Where installations are sited offshore or in remote locations, maintenance and repair costs can be up to 20 times more expensive than when performed in the construction yard.

Currently, 85% of coating failures occur within one to three years. Most of these failures occur because of:

  • Incorrect specification choice
  • Poor surface preparation
  • Poor application
  • Climatic conditions

Inspection of PFP systems and applications should capture the issues that lead to such failures before they happen – thus reducing rectification needs and costs.

PFP is critical for health and safety and asset integrity

Protecting an asset from fire protects the asset’s integrity, helping to achieve your paramount priority – the safety of your people.

However, many lives have been lost in offshore fires and explosions over the years – lives that may have been saved if PFP had not failed. When compared to paint, PFP coatings are much more complex.

There are many stages in the application process and specific skills and controls are needed to ensure that final installation meets the requirements for the lifetime of the asset.

PFP inspection is a critical exercise

With PFP playing such a key role in keeping people safe and the added financial risk of requiring rectification of poorly installed PFP systems, inspection of PFP is a critical exercise that can help reduce costs and save lives.

Yet, the industry itself knows there is a massive shortfall of experienced people to perform PFP inspections, especially in remote locations. Hence the need for new, improved, comprehensive training for PFP inspection. Training that will meet the standards expected by the industry, and that equips PFP coating inspectors with the expertise to identify risks of failure before they occur – thus reducing the industry’s costs, improving its safety record, and saving lives.

What expertise does the Fire Protection Coatings Inspector Training Programme deliver?

This is the most comprehensive course available anywhere in the world – developed by industry experts for the industry, in response to the industry’s needs.

Accredited by the Institute of Corrosion and PFPNet, the course has four main modules:

  • Online, which is designed as a pre-learning module to ensure all candidates understand the basics of corrosion and corrosion protection
  • 4½ days of classroom study with an industry expert
  • A predominantly written examination which will take half a day at the end of the classroom sessions
  • A Peer Review in line with all L3 qualifications

In total, course attendees will spend 10 to 20 hours training online, and around 40 hours in the classroom.

The course will be delivered through the Institute of Corrosion’s normal channels via IMechE Argyll Ruane, and additionally through the PFP manufacturers to meet the demand from global operators.

The course will be invigilated, and the exam papers collected to be marked. The tutors, invigilators and exam markers are all independent. The Peer Review will be an online meeting arranged within one month of completion of the course.

Successful candidates will be recognised as being highly professional in the inspection of PFP and accredited by the industry as the only standard specific and meaningful to the application and inspection of PFP systems.

In brief, elements covered in the training programme include:

  1. Role and Duties of a PFP Inspector
  2. Introduction to PFP
  3. Normative Documents
  4. Classification Society Type Approval
  5. Qualification of PFP Systems
  6. PFP Materials and Systems
  7. Epoxy PFP Degradation Mechanisms
  8. Fire Performance and Defective Application
  9. Pre-Job Meeting
  10. Surface Preparation
  11. Epoxy PFP Extent and Thickness Details
  12. Epoxy PFP Application Equipment
  13. Final Thickness Determination
  14. Examples of Application Defects
  15. Reporting
  16. Health and Safety

The agenda is similar for the cementitious PFP course with specifics on these types of materials replacing the epoxy specific items on the above list.

How will this course impact the oil and gas industry?

The course will provide the industry with inspectors specifically trained in the inspection of PFP. Thus, it will raise standards in pre-commissioning application of PFP coatings. The industry should benefit from a decrease in the amount of re-work on this safety-critical area of a project build, leading to significant cost savings.

The training programme has been developed by industry experts in collaboration with PFPNet – the industry body dedicated to raising standards in the specification, testing, use, application, and maintenance of Passive Fire Protection systems.

Who should take the Fire Protection Coatings Inspector Training Programme?

The course will benefit anyone who is involved in PFP, but specifically those involved in inspection. Training delegates will come from owner/operators and engineering houses, but in the main from fabricators, applicators, and inspection houses, as well as private inspectors.

In the first instance, prospective candidates for the course are likely to be those currently working on PFP installations who wish to upgrade ahead of others. Inspectors who know their trade should pass with flying colours.

The general requirement to be considered for this training will be to have at the least L1 Paint Inspector qualification and a minimum 3 years in the industry. As with all L3 courses, all potential candidates will be vetted to ensure suitability.

For more information, contact either John Dunk at PFPNet or David Mobbs at ICorr.

Or register for the launch of this exciting new training programme here.