Corrosion & Materials December 2013

Official

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Vol 38 No 6, December 2013 ISSN 1326-1932

Inside this Issue: Meet the…Technical Group Chairs Industry Insight: Forensic Corrosion Engineering Project Profile: HMB Endeavour Hull Preservation Project Profile: Getting it Right – The First Time Project Profile: Case History: Canusa 3-Layer Heat Shrink Sleeve System Used on QSN3 Project University Profile: The University of New South Wales Research Paper: Corrosion Reversed: Deposition of Elemental Copper and Silver in Marine Concretions

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Proudly presented by:

Major Sponsor:

Darwin Convention Centre

21–24 September 2014

www.acaconference.com.au

FIRST ANNOUNCEMENT & CALL FOR PAPERS CALL FOR PAPERS

DARWIN

Submissions are now welcome on all aspects of corrosion and corrosion control for Corrosion & Prevention 2014.

Papers are subject to peer review and if accepted will be published in the Conference Proceedings. Critical dates for acceptance of abstracts and papers are:

Darwin is a fascinating, tropical modern city, with a fusion of people and cultures which engender a unique and friendly laid back lifestyle. Soak up Darwin’s balmy weather while enjoying the diversity of food and culture in the city’s many markets, restaurants and bars. Explore the region’s dramatic history in the many museums and galleries, sail beautiful Darwin harbour at sunset, cruise next to crocodiles or swim in the crystal clear waterholes of Litchfield National Park.

Close of Abstracts: 31st January 2014 Acceptance of Abstracts: 14th February 2014 Receipt of Papers: 2nd May 2014

SUBMIT AN ABSTRACT Please refer to www.acaconference.com.au to submit a 200-300 word summary of your proposed paper by the close of abstracts (31st January 2014). Waldron Smith Management, a professional conference management company based in Melbourne will be managing the abstract and paper submission process for Corrosion & Prevention 2014.

GUIDE TO SUBMISSION Papers submitted to the Corrosion & Prevention 2014 Conference must be unpublished works. It is the responsibility of the author to obtain necessary clearance/ permission from their organisation. Copyright of the paper is assigned to the ACA. Abstracts should include the names of all authors, an appropriate title and a brief summary.

All authors whose papers are accepted are required to attend the conference to present.

Darwin Conference Centre

p.2 CORROSION & MATERIALS

Darwin has a population of over 100,000 people and boasts a lively mix of more than 50 nationalities. This vibrant capital has a youthful energy you will find hard to resist and is noted for its consistently warm to hot climate throughout the year. Darwin is the gateway to the Australian outback and some of the country’s best tourism experiences. Progressive, vibrant and energising, Darwin is a breath of fresh air that will always prove irresistible to all who visit.

The Northern Territory is a place with landscapes as diverse as they come, from Uluru, the spiritual heart of the Australian continent in the dry Red Centre, to the teeming-with-wildlife tropical wetlands of the Kakadu and Nitmiluk National Parks in the Top End. In many ways the Northern Territory is the most quintessentially Australian of all the Australian States, and there is a little bit of everything for everyone. www.travelnt.com

TECHNICAL TOPICS

CONFERENCE COMMITTEE

Corrosion and Prevention 2014 invites technical papers on all subjects related to corrosion. The conference will bring together leading researchers and industry practitioners who combat corrosion on a daily basis. Diverse technical streams will showcase the latest developments in corrosion, ranging from fundamental corrosion science to hands-on application. Submissions may include research papers, posters, review papers and case studies related to the technical streams listed below.

George Curran

Advances in Sensing and Monitoring Cathodic/Anodic Protection Coatings Concrete & Architecture Integrity Management Manufacturing & Production

Erwin Gamboa Andrew Hargrave Brian Hickinbottom Raman Singh Dean Wall

SPONSORSHIP AND EXHIBITION Sponsorship will enable your company to make a significant contribution towards the success of Corrosion & Prevention 2014. In return, the conference offers strong branding and exposure in a focussed and professional environment. As with every Conference, the exhibition will be an integral part of the activities. It provides an opportunity for organisations to come face to face with the delegates; providing a marketplace to increase your organisation’s visibility and to showcase and demonstrate your products and services.

Marine Corrosion Oil & Gas Sustainability, Environment & Energy Water & Wastewater

INDUSTRY SECTORS This conference will have material of value to those working within the following industries, or related areas: Aviation Concrete Structures and Buildings Defence Education and Research

YOUR HOSTS The Australasian Corrosion Association Inc (ACA) is a membership based, not-for-profit, industry association, promoting the co-operation of academic, industrial, commercial and governmental organisations in relation to corrosion and its mitigation. The ACA disseminates information on all aspects of corrosion and its prevention by promoting lectures, symposia, publications and other activities. www.corrosion.com.au The mission of the ACA is to disseminate knowledge to enable best practice in corrosion control thereby ensuring all impacts of corrosion are responsibly managed, the environment is protected, public safety is enhanced and the performance of economies improved.

Manufacturing Marine Mining Oil & Gas Power Transport Water and Wastewater

CONTACT The Australasian Corrosion Association Inc PO Box 112 Kerrimuir, Victoria, Australia, 3129 Ph: +61 3 9890 4833 Fax: +61 3 9890 7866 Email: conference@corrosion.com.au www.acaconference.com.au

December 2013 www.corrosion.com.au p.3

CONTENTS

The Australasian Corrosion Association Inc The Australasian Corrosion Association Inc (ACA) is a non-profit membership based organisation akin to a “learned society”. The ACA was established in 1955 to service the needs of Australian and New Zealand companies, organisations and individuals involved in the fight against corrosion. It is dedicated to ensuring all aspects of corrosion are responsibly managed, protecting the environment and ensuring public safety.

ACA members are drawn from a wide cross section of industries united by their common interest – to reduce the impact of corrosion in Australasia.

The ACA is a founder member of the World Corrosion Organization

6

President’s Message

7

ACA 2014 Training Calendar

8

Executive Officer’s Message

10

News

16

ACA Standards Update

22

New Product Showcase

25

Technical Event Review: Water & Waste Water Seminar Series 2013 Investigation of Corrosion in the Water & Wastewater Industries

26

ACA Coating Inspection Certificate

28

ACA Corporate Members

Front Cover Photo: McElligotts Partners Pty Ltd recently completed the relining of 1.6 km’s in length and 3 metres in diameter of tunnel for the Sydney Catchment Authority. Photo supplied by McElligotts Partners Pty Ltd.

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ISSN 1326-1932 Published by The Australasian Corrosion Association Inc. ABN: 66 214 557 257 Editor Ian MacLeod – Western Australian Museum ian.macleod@museum.wa.gov.au Associate Editors Research: Bruce Hinton – Monash University bruce.hinton@monash.edu Professional Practice: Willie Mandeno – Opus International Consultants, willie.mandeno@opus.co.nz News: Wesley Fawaz – The Australasian Corrosion Association Inc, wesley.fawaz@corrosion.com.au

Reviewers Andy Atrens – University of Queensland Nick Birbilis – Monash University Frederic Blin – AECOM Lex Edmond Harvey Flitt – Queensland University of Technology Maria Forsyth – Deakin University Rob Francis Warren Green – Vinsi Partners Graeme Kelly – Corrotec Services Grant McAdam – Defence Science & Technology Organisation David Nicholas – Nicholas Corrosion Graham Sussex – Sussex Material Solutions Tony Trueman – Defence Science & Technology Organisation Geoffrey Will – Queensland University of Technology David Young – University of New South Wales

Advertising Sales Wesley Fawaz – The Australasian Corrosion Association Inc, wesley.fawaz@corrosion.com.au Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Subscriptions Print Version: ISSN 1326-1932 Subscription rates: Within Australia: AU$72.60, incl GST Outside Australia: AU$77, excl GST posted airmail The views expressed in Corrosion & Materials are those of the individual authors and are not necessarily those of the ACA. Publication of advertisements does not imply endorsement by the ACA. Copyright of all published materials is retained by the ACA but it may be quoted with due reference.

The Australasian Corrosion Association Inc PO Box 112, Kerrimuir, Victoria 3129, Australia Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Email: aca@corrosion.com.au Internet: www.corrosion.com.au

CONTENTS

32

Meet the…Technical Group Chairs

34

Coatings Group Member Profile

35

Industry Insight: Forensic Corrosion Engineering

40

Project Profile: HMB Endeavour Hull Preservation

42

Project Profile: Getting it Right – The First Time

44

Project Profile: Case History: Canusa 3-Layer Heat Shrink Sleeve System Used on QSN3 Project

46

University Profile: The University of New South Wales

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Research Paper: Corrosion Reversed: Deposition of Elemental Copper and Silver in Marine Concretions

54

Suppliers and Consultants

Corrosion & Materials Corrosion & Materials is the official publication of The Australasian Corrosion Association Inc (ACA).

Published bi-monthly, Corrosion & Materials has a distribution of 2,500 to ACA members and other interested parties. Each issue features a range of news, information, articles, profiles and peer reviewed technical papers. Corrosion & Materials publishes original, previously unpublished papers under the categories “Research” and “Professional Practice”. All papers are peer reviewed by at least two anonymous referees prior to publication and qualify for inclusion in the list which an author and his or her institution can submit for the ARC “Excellence in Research Australia” list of recognised research publications. Please refer to the Author Guidelines at www.corrosion.com.au before you submit a paper to Wesley Fawaz at wesley.fawaz@corrosion.com.au with a copy to bruce.hinton@monash.edu ACA also welcomes short articles (technical notes, practical pieces, project profiles, etc) between 500 – 1,500 words with high resolution photos for editorial review. Please refer to the Article Guidelines at www.corrosion.com.au before you submit a paper to Wesley Fawaz at wesley.fawaz@corrosion.com.au

ACA Operations Board President: Andrew Hargrave

ACA Branches & Divisions Auckland Division: Grant Chamberlain

64 21 245 9038

Executive Officer: Wesley Fawaz

Newcastle: Karen Swain

Operations Chairman: Paul Vince

New South Wales: Jim Galanos

61 2 9763 5611

Senior Vice President: Mohammad Ali

Queensland: Cathy Sterling

61 7 3821 0202

61 0 418 854 902

ACA Technical Groups Cathodic Protection: Bruce Ackland

61 3 9890 3096

Coatings: Matthew O'Keeffe

61 437 935 969

Concrete Structures & Buildings: Frédéric Blin

61 3 9653 8406

Mining Industry: Ted Riding

61 3 9314 0722

Junior Vice President: John Duncan

South Australia: Dennis Richards

61 0 419 860 514

Immediate Past President: Allan Sterling

Tasmania: Grant Weatherburn

61 0 418 120 550

Directors: Kingsley Brown Graham Carlisle Matthew Dafter Peter Dove John Duncan Fred Salome Dean Wall

Taranaki Division: Ron Berry

64 27 671 2278

Research: TBA

Victoria: John Tanti

61 3 9885 5305

Water & Water Teatment: Matthew Dafter 61 419 816 783

Wellington Division: Monika Ko Western Australia: Gary Bennett

64 4 978 6630 61 0 408 413 811

Petroleum & Chemical Processing Industry: Fikry Barouky 61 402 684 165

Young Corrosion Group: Erwin Gamboa

61 403 523 771

* all the above information is accurate at the time of this issue going to press.

PRESIDENT’S MESSAGE

my attendance of the local Tasmanian Branch meeting in Hobart that I was asked to consider being the President for 2014 pending the ACA Board’s acceptance. The ACA Board ensures the person nominated has necessary experience in the field of corrosion prevention. Really I am unknown to many of the members across Australia and New Zealand and a brief introduction is warranted.

I am a mechanical engineer that provides engineering services for the mining, oil & gas and power industries specialising in pipelines and pressure vessels with over 20 years’ experience.

And yes I am a technical person who works in the industry based in Launceston Tasmania.

Andrew Hargrave President

Hello and welcome to the December 2013 Corrosion & Materials issue. As many of you are aware and some who may not, the 2013 conference recently held in Brisbane also meant the annual change of ACA President. Allan Sterling has completed his time and a new President for 2014 has taken up the mantle.

It’s a pleasure to be the ACA President for 2014. I would like to thank Allan Sterling (2013 President) for the smooth transition. It was back in 2012 during

It was the time spent with Brian Martin way back in the early 2000’s in Tasmania that I became aware of the importance to maintain and monitor the pipeline assets per my responsibility as a pipeline engineer. I was soon presented with the opportunity to become an ACA member and be involved with the local Branch and the technical excellence the ACA offers. Since my involvement with the ACA I have received training in the fields of coatings and cathodic protection and so I fully support the ACA in corrosion prevention and technical excellence. Really the ACA is a great and dynamic association, that is, great people with potential to develop further. One example of this is that our growing membership provides the best training opportunities in corrosion prevention.

The Tasmanian Branch will be hosting the 2014 conference in Darwin (Northern Territory) Australia. This may seem bizarre but it is an opportunity to promote the ACA in the Northern Territory that has no Branch of its own.

Also, an ACA conference has not been held in Darwin (Northern Territory) before. The Darwin venue is first class and has the capacity to accommodate the event. Darwin is on the door step of Asia and the world and will attract international interest. With the Darwin conference only 9 months away there is much work to be done. Call for papers has commenced and closing of abstracts is 31st January 2014.

As President I will endeavor to attend Branch meetings across Australia and New Zealand, promote the Darwin conference, attend ACA Board meetings and hope to represent the ACA at the NACE conference in the USA. Really my highest priority is to support and represent the ACA members as the 2014 President.

We hope you enjoy this issue and I look forward to meeting as many ACA members across Australia and New Zealand during my time as President.

Thank you.

Andrew Hargrave ACA President 2014

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p.6 CORROSION & MATERIALS

ACA 2014 TRAINING CALENDAR

ACA 2014 Training Calendar Corrosion Technology Certificate

Cathodic Protection Monitoring

Mbr Status

Fee

GST

Total Fee

AU Mbr

$1704.55

$170.45

$1875.00

AU Mbr

$2018.18

$201.82

$2220.00

AU Non Mbr

$1868.18

$186.82

$2055.00

AU Non Mbr

$2367.27

$236.37

$2600.00

NZ Mbr*

$1685.00

NZ Non Mbr

$1865.00

NZ Mbr* Melbourne

$2020.00

NZ Non Mbr

April

$2370.00 07th - 11th

Sydney

July

21st - 25th

Brisbane

November

10th - 14th

Melbourne Brisbane

March

03rd - 06th

July

14th - 17th

Fee

GST

Total Fee

Introduction to Protective Coatings

AU Mbr

$2018.18

$201.82

$2220.00

Mbr Status

Fee

GST

Total Fee

$2367.27

$236.37

$2600.00

AU Mbr

$550.00

$55.00

$605.00

AU Non Mbr

AU Non Mbr

$672.73

$67.27

$740.00

NZ Mbr*

$500.00

NZ Non Mbr

$680.00

Melbourne

February

10th

Darwin

September

11th

Mbr Status

Fee

GST

Total Fee

NZ Mbr* Melbourne Brisbane

$963.64

$96.36

$1060.00

$1209.09

$120.91

$1330.00

$965.00

NZ Non Mbr

$1210.00

$1645.45

$164.55

$1810.00

NZ Mbr*

11th - 13th

Sydney

June

02nd - 04th

21st - 25th

AU Mbr

AU Non Mbr

February

July

Total Fee

$1485.00

Melbourne

17th - 21st

GST

$135.00

$1650.00

March

$2370.00

Fee

$1350.00

NZ Non Mbr

NZ Non Mbr

Mbr Status

AU Mbr

$1350.00

$2020.00

Corrosion & CP of Concrete Structures

AU Non Mbr

NZ Mbr*

Sydney Brisbane

May

21st - 22nd

August

07th - 08th

Darwin

September

24th - 26th

ACA/ACRA Corrosion & Protection of Concrete Structures

Perth

December

8th - 10th

Mbr Status

Mbr Status

Fee

GST

Fee

GST

Total Fee

AU Mbr

$963.64

$96.36

$1060.00

Total Fee

AU Non Mbr

$1209.09

$120.91

$1330.00

Coatings Selection and Specifications

AU Mbr

$1350.00

$135.00

$1485.00

NZ Mbr*

$965.00

AU Non Mbr

$1645.45

$164.55

$1810.00

Sydney

June

19th - 20th

NZ Mbr*

$1350.00

NZ Non Mbr

$1650.00

Brisbane

November

27th - 28th

Brisbane

April

28th - 30th

Perth

July

28th - 30th

Coatings Inspection Refresher Mbr Status

Fee

GST

Total Fee

AU Mbr

$550.00

$55.00

$605.00

AU Non Mbr

$672.73

$67.27

$740.00

NZ Mbr*

$500.00

NZ Non Mbr

$680.00

Darwin

September

New Zealand

November

NZ Non Mbr

$1210.00

Fee

GST

Total Fee

AU Mbr

$1336.36

$133.64

$1470.00

AU Non Mbr

$1568.18

$156.82

$1725.00

NZ Mbr*

$1335.00

NZ Non Mbr

$1568.00

Darwin

September

16th - 20th

NACE - Coatings Inspection Program CIP Level 2 Mbr Status

Fee

GST

Total Fee

AU Mbr

$3400.00

$340.00

$3740.00

AU Non Mbr

$3883.36

$388.64

$4275.00

NZ Mbr*

$3395.00

NZ Non Mbr

$3900.00

Perth

February

10th - 15th

Brisbane

March

10th - 15th

Melbourne

March

24th - 29th

Adelaide

May

12th - 17th

Sydney

July

14th - 19th

New Zealand

August

18th - 23rd

Darwin

September

15th - 20th

Melbourne

October/November

27th - 01st

Perth

December

01st - 05th

Resits NACE – Coating Inspector Program Level 1 & 2 Mbr Status

Fee

GST

Total Fee

AU Mbr

$909.09

$90.91

$1000.00

AU Non Mbr

$1145.45

$114.55

$1260.00

NZ Mbr*

$910.00

NZ Non Mbr

$1165.00

Examination Tests will be conducted to coincide with scheduled programs – contact ACA for details

All registration fees are payable in Australian Dollars.

NACE - Coatings Inspection Program CIP Level 1 Mbr Status

Fee

GST

Total Fee

AU Mbr

$3400.00

$340.00

$3740.00

AU Non Mbr

$3883.36

$388.64

$4275.00

NZ Mbr*

$3395.00

NZ Non Mbr

$3900.00

Perth

February

03rd - 08th

Brisbane

March

03rd - 08th

20th

Melbourne

March

17th - 22nd

21st

Sydney

April

07th - 12th

Introduction to Cathodic Protection

Mbr Status

Cathodic Protection Advanced Mbr Status

Protective Coatings Quality Control

NACE – Peer Review CIP Level 3

Adelaide

May

05th - 10th

Perth

May

26th - 31st

Mbr Status

Fee

GST

Total Fee

Melbourne

June

16th - 21st

AU Mbr

$550.00

$55.00

$605.00

Sydney

July

07th - 12th

AU Non Mbr

$672.73

$67.27

$740.00

New Zealand

August

11th - 16th

NZ Mbr*

$500.00

NZ Non Mbr

$680.00

Darwin

September

08th - 13th

Melbourne

March

12th

Melbourne

October

20th - 25th

Brisbane

July

11th

Perth

November

24th - 29th

All registrations are subject to ACA’s published terms, conditions and policies. * All NZ courses are GST free For up-to-date course scheduling, please refer to www.corrosion.com.au

December 2013 www.corrosion.com.au p.7

EXECUTIVE OFFICER’S MESSAGE

As 2013 draws to a close, and with the festive season now upon us, I would like to firstly acknowledge some of the valuable contributions that have been made to the corrosion community throughout what has proven to be a very successful and at times challenging year for the ACA.

has accomplished in 2013 with some notable achievements including (but not limited to):

To the members of the Board who over the past 12 months have so willingly and unselfishly donated their time to the Association - may you all enjoy a well-deserved break this Christmas.

And a special acknowledgement to the contribution of Graham Sussex and Geoffrey Will over the past 6 years who have served on the Board.

ormation of the new conference F technical committee

To all the Branch committees, your dedication to our association at the local level has been pivotal in the ongoing development and growth of the ACA. And to all the other many volunteers of whom there are too many to list, thank you for your support in reviewing papers, presenting at events, etc.

Thank you to the lecturers who have to juggle their own work commitments to pass on their knowledge and help the ACA provide a crucial service to the corrosion industry.

So with all this support, we should reflect positively on what the ACA

Over 40 training courses conducted to over 650 students Regular events in Darwin

ver 500 attendees at the ACA O Corrosion & Prevention Conference in Brisbane chieving a membership of over 2,000 A with continued membership growth in all Branches aunch of the ACA membership L recognition program for 10+, 25+ and 50+ years of membership ver 30 events including YCG, O Roadshow, Technical Groups and International Seminar Series nline member only access to the O Corrosion Technology Publication 12-part series ngoing financial support of ACA O Foundation activities

From all the team at ACA, we wish you and your staff a Merry Christmas and a prosperous New Year!

Thank you to the staff in the ACA office who have all worked extremely hard this year and they should be proud of their team efforts throughout 2013. Thank you for making the transition into my new role a smooth and enjoyable experience.

Welcome to Tracey Winn who recently was appointed as Marketing & Communications Manager. Tracey’s role in the office will be to publish Corrosion & Materials and Corrosion Matters and to effectively promote the ACA activities while raising our profile within the many industries we serve. Tracey comes to the ACA with great experience and I am sure her role will have a positive impact on the ACA in 2014.

2014 will no doubt bring many more achievements and challenges, and I know we are all looking forward to maintaining the momentum and building on the future growth of the ACA. Until then, I wish you all a very Merry Christmas, a safe and prosperous New Year, and I look forward to catching up with you all next year.

Wesley Fawaz Executive Officer wesley.fawaz@corrosion.com.au

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ACA Foundation Ltd has awarded 17 scholarships in 2013, please join with us in congratulating the following scholarship recipients: ACA Corrosion Course Registration Scholarship – Round One, valued at $2,000 each

International Travel Scholarship, valued at $12,500 each

Tim Fairbairn, CIPS

Mike Rutherford, Freyssinet Australia P/L

Hamid Fatemi, RMS

Dean Ferguson, GHD

Adrian Vinnell, Aurecon David Sunjaya, Savcor Agus Effendy, Select Solutions Post Graduate ACA Conference Attendance Scholarship, valued at $1,400 each Rainier Catubig, Deakin University Rouzbeh Karimi, Curtin University Vinod Pathan, Curtin University

International Conference Scholarship, valued at $3,500 each Matthew Dafter, Hunter Water Australia P/L Post Graduate Cash Scholarship, valued at $2,500 each Amy Spark Tim Sherman Certificate III in Surface Preparation and Coatings Applications Scholarship, valued at $5,000 each

Jessica Lyndon, Monash University

Bradley Knott, McElligotts (Tas) P/L

Roja Soleimani Amiri, Curtin University

Nikita Lewis, Favcote P/L

An additional 5 scholarships for the ACA Corrosion Course Registration Scholarship – Round two will be announced in December.

The ACA Foundation Ltd. 2014 Scholarship Program is due for release in April/May 2014.

The success of the 2013 Foundation Scholarship Program is due to the hard work of a number of committed volunteers and the ongoing generosity of the Foundation donors – on behalf of the scholarship recipients we say thank you.

December 2013 www.corrosion.com.au p.9

NEWS

ACA board elected for 2014 The ACA Council was convened on Sunday, 10 November 2013 in conjunction with the Association’s conference in Brisbane.

Retiring President Allan Sterling announced the results of elections and appointments made by Council at the annual general meeting conducted on the Tuesday of the conference. The ACA’s management team for 2014 is comprised of:

President Andrew Hargrave (TAS)

Chairman Paul Vince (SA)

Immediate Past President Allan Sterling (QLD)

Directors: Kingsley Brown (SA) Graham Carlisle (WA) Matthew Dafter (NCL) Peter Dove (VIC) John Duncan (NZ) Fred Salome (NSW) Dean Wall (TAS)

Senior Vice President Mohammad Ali (NSW) Junior Vice President John Duncan (NZ)

Standards New Zealand Review and Update The New Zealand Government has announced in October 2013 a decision to restructure arrangements for New Zealand standards development. The brief announcement follows a review of New Zealand’s Standards system last year. The purpose of the review was to: d evelop proposals for a viable and well-functioning standards system that meets the needs of business and regulators into the foreseeable future'.

In its statement the New Zealand Government advises that the review decisions include: A new Standards model will replace the Standards Council and Standards New Zealand.

p.10 CORROSION & MATERIALS

Standards approval will be undertaken by an independent statutory board.

Standards development will be undertaken by an independent statutory officer within the Ministry of Business, Innovation and Employment (MBIE).

Independent committees will continue to comprise industry and technical experts, consumer representatives and regulators.

A Standards Bill is expected to be introduced to Parliament in early 2014 which will make the necessary legislative changes.

The New Zealand Government Cabinet paper states “MBIE (New Zealand Ministry of Business Innovation and Employment) will continue to have discussions with Standards Australia in the implementation phase to ensure that the issues it has identified will be resolved satisfactorily”. The Standards Australia issues include the integrity of the joint standards development process, copyright, operational arrangements and governance.

In the meantime, joint Australian/New Zealand standards development will continue in the usual way.

There is more information on the New Zealand Standards website www.standards.co.nz/news/ Policy+Review.htm

NEWS

C&P2013 Brisbane The ACA’s annual conference took place recently on the 10-13 November 2013 in Brisbane at the Brisbane Convention & Exhibition Centre with over 500 attendees.

The conference brought together international, regional and national experts to discuss and explore strategies, approaches and options for mitigating corrosion. In addition to hearing the latest research and business concepts through conference presentations, meeting participants also participated in technical group forums to exchange ideas as well as a 70 booth

exhibition of the industries product and service providers.

Many of the conference’s volunteers, committee members and conference office staff tirelessly worked together for much of the year in preparations to fully utilise all four days of the Annual Conference including the usual social functions as a continuous celebration and commemoration of the ACA and the corrosion industry.

CD-ROMs with all the conference papers are available to purchase from the ACA office for $90 including postage.

A CD-ROM booking form can be downloaded at www.corrosion.com.au or by requesting a copy via email to aca@corrosion.com.au A full review and compilation of photos from the 2013 conference will appear in the 2014 February issue of Corrosion & Materials.

The ACA thank all of the speakers for their excellent, informative presentations and contributions.

Vale: Frank Thompson Frank Thompson passed away on the 16th August 2013. Frank was a great contributor to the Australasian Corrosion Association Victoria Branch committee and was President in the early 1990’s.

Frank worked for Shell between 1969 and 1994 starting as an Area Inspector before progressing to Chief Inspector in 1974. Between 1982-1995, Frank was the Materials Development and Refinery Corrosion Engineer at Shell’s

International Central Engineering Office in The Hague. Frank returned to Australia to the Geelong Refinery in 1985 taking up the position of Head of the Inspection & Auditing Section.

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December 2013 www.corrosion.com.au p.11

NEWS

Fitness test for corrosion protection coatings The internal coatings of oil treatment plants have quite a lot to handle: aggressive chemical substances, high temperatures and pressures, as well as sand and stone particles that stick to the tank walls. Over time, this causes the steel linings to corrode, which is why the coatings of tanks, separators, and pipelines must be renewed on a regular basis. However, how long the material “holds” depends on the individual levels of stress it is exposed to. A single coating is not necessarily equally wellsuited to every application. But until now, there has been no systematic analysis of the materials available on the market. Such a comparative analysis would allow plant operators to assess a material’s suitability for different types of stress.

vicinity of the drilling hole. In this part of the plant, it is especially important that the coating is able to withstand the mechanical stress caused by abrasion.

However, chemical factors also put the material under stress, among them saline solutions such as the reservoir water that is pumped out of the ground with the crude oil during extraction. To effectively protect the underlying steel surface, coatings that are exposed to this solution require high chemical resistance and a good level of impermeability. “The saline solution is separated from the oil in the separator later on,” says Gurr. “For plant sections that are located downstream of the separator, resistance to the saline solution is, in most instances, not as important.”

Researchers at the Fraunhofer Institute for Mechanics of Materials IWM are now working to close this gap. In a project sponsored by the DGMK German Society for Petroleum and Coal Science and Technology, researchers in Freiburg have come up with a test program that assesses corrosion resistance in different stress scenarios.

The program closely replicates real treatment conditions. “In the different sections of the plant, the coating material is exposed to completely different conditions,” says Dr. Matthias Gurr of the IWM. For instance, sand or stone particles are generally present in the extracted mix in the immediate

Taking the effects of condensation into account To assess the corrosion resistance of coatings in a laboratory environment, the researchers apply a number of different tests. In the autoclave test, for instance, researchers put a material sample together with a medium – such as an oil-saline mix – in a gas-tight container and expose it to temperatures up to 150 degrees Celsius. For most materials, the critical temperature limit for heightened susceptibility to corrosion is far lower. While the test is state of the art, not all conditions that actually occur in a treatment plant can be simulated. For instance, in containers

that do not have additional insulation, thermally induced stress and the effects of condensation also have an influence on materials, as there can be stark differences in temperature between the container’s exterior and interior walls. To create such a difference in temperature in laboratory conditions, the researchers use special Atlas cells. To seal these steel pipes, material samples are pressed into their open ends. “As a result, the coating becomes part of the container wall,” says Gurr. While the medium is heated up on the inside of the cell, the researchers can use a cooling circuit to regulate the ambient temperature downward.

The experts are compiling their results in a comprehensive table.

With its help, plant operators will one day be able to find out at a single glance which materials are best suited for specific stress parameters.

The researchers aim to test coating materials under real conditions at a treatment plant, and talks are currently underway with several industry partners from the project consortium.

Gurr and his team are hoping to have the initial results in about two years.

“Correlating our lab tests with the field experiments in this way would form an important basis for concrete forecasts about the life cycle of coating systems in the future,” says Gurr.

Appointment of lead structural/ civil engineer, Newcastle Vinsi Partners are delighted to announce that Barry Gentle has joined their Newcastle Office as a Lead Structural/Civil Engineer.

Barry has over 19 years experience in the fields of Structural and Civil Engineering with both contractors and consultants. In the UK, he managed numerous underpinning and remedial repair projects for domestic properties suffering subsidence, and also carried out the structural design for a £3M sports hall.

p.12 CORROSION & MATERIALS

He has worked in Australia since the year 2000, and has been responsible for the design of many reinforced soil structures for road, rail and mining applications. He has also worked abroad, providing reinforced soil design tuition and design verification for a highways project in Bangkok, as well as supervising site works for a dump wall at a mine in Papua New Guinea. Work on a number of significant projects across industry sectors such as rail, desalination, and mining was also undertaken.

Throughout his career Barry has gained experience in various methods of project procurement and has acted as Project Manager on a variety of projects.

Barry was previously based at PB Newcastle and managed the structural engineering, drafting, and water engineering teams.

NEWS

Best Practice/Project Paper Award Announced The recipient of the inaugural Best Practice/Project Paper Award for papers published in Corrosion & Materials was recently announced.

With three possible papers for the award this year, it was judged that Chris Weale of GHD for his paper ‘East Drop Structure Assessment and Rehabilitation’ which was published in the June issue of Corrosion & Materials would be awarded the $1,000 cash prize.

Ian MacLeod, Editor of Corrosion & Materials and one of the judges of the award said “this paper was not necessarily appealing to the average reader but one of great importance in the management of deterioration in the fundamental infrastructure that supports our cities. The description of the problem and the detailed

discussion of the operational and installment issues were well done.

The images in the article were very clear and this helped remove any confusion about the nature of the work being done and the value of the remediation process to the client and the community as a whole.

The author made the good point that it is due to the public distaste for the smell of hydrogen sulphide that the naturally venting of the same has become unfashionable or socially unacceptable and that as a consequence the corrosion issues have been exacerbated.”

To be eligible for the award in 2014, practice/project papers must be submitted to Brendan Pejkovic at bpejkovic@corrosion.com.au by 31st August 2014 for editorial review.

Chris Weale (left) receives a certificate as part of the award from Graham Sussex (right).

December 2013 www.corrosion.com.au p.13

NEWS

SpecSource Global Launched A new web-based platform for the corrosion sector delivers exclusive content from leading industry experts, scientific research, industry news, new regulations and standards, event news, an innovative career center, and more.

Temerity TechMedia has launched SpecSourceGlobal.com Lou Frank, owner of Temerity TechMedia, and former publisher of the industry journal CoatingsPro, leads a team of highly experienced Web communications professionals in the effort.

The SpecSource Global audience includes owners, engineers, inspectors and related contractors across a range of industries, geographies, and Associations. The platform will serve industries most affected by corrosion, including oil and gas, marine ship building, power generation and distribution, water and wastewater, chemical processing, and bridge and port authorities.

“After two years of industry research, an array of needs is being met under one platform, and I am thrilled with the release of SpecSource Global on so many levels,” Frank said.

“The community told us they want best-practice insights, and the latest information on protective coatings, materials, and technologies. They also want quick reference to standards across multiple organizations, industries, and geographies in an easy-to-use online platform. This is exactly what SpecSource Global and CoatSTR (the new standards search tool) will deliver,” Frank said.

“Our new online resource serves the collaborative, multi-industry corrosion community concerned with solving complex scientific challenges in an evertougher regulatory environment. At the core is a brilliant group of experts and advisors,” Frank added.

The platform features technical articles by experts, white papers, coatings failure analyses, industry and product news, fieldwork best practices, case studies— and coming soon, newly adopted standards and regulations, training and event calendars, a uniquely designed

career center, and an interactive roundtable for community discussions on key issues affecting corrosionprogram management.

Louis D. Vincent, well-known industry author and past president of NACE International, serves on Temerity’s board of advisors. He has been deeply involved in the creation of SpecSource Global and was the spark behind the creation of CoatSTR. “We’ve pulled together a group of top-notch experts to contribute bestpractice content, each with 30+ years of experience spanning the public and private sectors most affected by infrastructure corrosion,” said Vincent.

“The greatest value of SpecSource Global is the ability to find real-world solutions, specifications perspectives, and events and jobs. Especially key, however, is the ability to search standards through the new online tool, CoatSTR. Users will be able to do this on a global basis, wherever the job site may be,” Vincent added.

3D LAser scAnnIng

Pipeline Integrity Assessment • Corrosion and denting 3D colour mapping • Corrosion depth measurement, dimensions & positions • Estimated burst pressure calculations

Contact the team at Russell Fraser Sales to request a quote today:

Tel: 02 9545 4433 Fax: 02 9545 4218 Email: rfs@rfsales.com.au Web: www.rfsales.com.au

p.14 CORROSION & MATERIALS

NEWS

ACA welcomes new members Corporate Bronze G Squared Solutions graeme.gummow@g2sol.com.au G Square Solutions is a newly formed consultancy focused on cathodic protection and hazardous voltage mitigation for the pipeline industry.

The founder, managing director and principal consultant is Graeme Gummow who invented the variable conductance drainage bond (VCDB) in the early 1980s, was technical assistant to John Mulvany when DCVG technology was originally

commercialised, and has gone on to develop extensive skills and experience in analysis, investigations, specifications, reporting, mitigation design and mathematical modelling of cathodic protection and the management of hazardous voltages on metallic pipelines.

Phoenix Protective Coatings www.phoenixlimited.com.au Phoenix Protective Coatings provides site service, Blasting & Coasting, Rapid Response Crews and Constant Maintenance Services to a variety

of industrial organisations and the Department of Defence for repairs and maintenance of ships and submarines.

STR Inspection Services www.strinspectionservices.com STR Inspection Series are uniquely qualified to assist its clients with Asset Management and Welding QA/QC. Their staff have over 30 years’ experience in industries including Oil & Gas, Pulp & Paper, Chemical, Petrochemical, Mining & Power Generation.

Individual/Student/Retired Members Name

Company/Institution

William Aislabie Elliot Baker

PFP Systems

Location

Name

Company/Institution

Location

QLD

Ben Jones

i2t

VIC

QLD

Chris Jones

Engineering & Design Group

NSW

Steven Kemp

S Kemp Co

QLD

Jason Kuenz

Jason's Painting

QLD

Kok Toong Leong

QSM Associates

Singapore

Michael Lo

Monash University

VIC

QLD

Jonathan McLachlan

JM & SM Services

QLD

WA

Alexander Mackie

Murphy Pipe & Civil Gas

WA

ACT

Tariq Mahmood

Timothy Belford

QLD

Gregory Bradley

QLD

Keith Bryce

EonCoat Australia

Robert Bouwknegt Peter Carey

WA CPE Systems

Graeme Chalmers Michael Chapman Ian Cumming

WA

IRC

VIC

SA

WA

Alexander Martin

ApplusRTD

WA

Damien Curtis

Contract Resources

NSW

Medhi Medkalchi

McConnell Dowell

NSW

Philip Dixon

Protector

NSW

Dmitry Mezhubovski

WA

Daniel Du Preez

Mineral Technologies

QLD

Ryan O'Neill

QLD

VIC

James Oosthuizen

WA

Ashish Patel

Steve Currie

Travis Farnell Graeme Fox

Applus RTD Pty Ltd

Timothy Fysh Joel Forsyth

QLD Transfield Worley

Seyed Mohammad Ghadimi

VIC

Trent Robson

WDS

QLD

Rhys Rogers

Construction Techniques

New Zealand

Jason Ross

Hatch

WA

Russell Skinner

AGC

WA

Karl Smith

Newmont Boddington Gold

WA

VIC

Edward Stuttard

Strategic Sampling

QLD

Alan Todhunter

Todhunter Mateirals Solutions

NSW

Nathanael Vivian

Australian Remote Painting & Maintenance Services

NT

WA

Monash University

VIC

Leo Hatzismalis

Incospec & Associates

NT SA

Corrosion Specialists

Curt Hendricks

WA Monash University

Jessie Hamilton

Trevor Henderson

QLD

Cong Qiu

NSW

Christine Head

LJ Technical Services

QLD

Peter Herbert

John Holland

QLD

Michael Hogan

Origin Energy

VIC

Kelvin Hohn

KH Design

QLD

Stephen Hooker

MT&C Engineers

NSW

Alexander Hughes

Kaefer Novacoat

QLD

Clifford Walker

Welfab Inpsection Coy

VIC

QLD

Xiaojin Xia

Monash University

VIC

New Zealand

Christian Zaymund

VIC

Xian Zhou

Ross Hunt Kenneth Johnson Michael Johnson

TBS Farnsworth

QLD Monash University

VIC

December 2013 www.corrosion.com.au p.15

ACA STANDARDS UPDATE

ACA Standards Update Welcome to the sixth corrosion related standards report for 2013.

This Standards report focuses on Water & Waste Water & Corrosion.

As previously this is in two stages, namely:

' galvanize' or ‘galvanized’ or galvanizing’.

1. A global standards and publication focus at 19 November 2013, searching through SAIGLOBAL Publications at https://infostore. saiglobal.com/store, for all current publications and standards relating to the ACA Technical Groups, with this editions group focuses being the “Water & Waste Water” Technical Group.

' electrochemical' or ‘electrolysis’ or ‘electroplated’.

These results are shown in Tables 1a & 1b.

2. A SAI Global search, as previously, at http://www.saiglobal.com/online/ for new standards, amendments or drafts for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and standards and amendments for ISO & IEC published from 18 September 2013 to 19 November 2013, using the key words and key word groups: ‘durability’. ‘ corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’. ' paint’ or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’.

‘cathode’ or 'cathodic'.

3.

DR AS/NZS 2312.1

Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 1: Paint coatings

DR AS/NZS 2312.2

Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 2: Hot dip galvanizing

DR AS 2832.1

Cathodic protection of metals - Part 2: Pipes and cables

‘anode’ or ‘anodic’. ' corrosion' and 'concrete' or ‘concrete’ and ‘coatings’.

These results are shown in Table 2.

Summary 1. Through SAIGLOBAL Publications at https://infostore.saiglobal.com/store there were for: Focus 1a – Water & Corrosion As shown in Table 1a, 287 Publications found against the search phrase “Water & Corrosion”; 0 from AS or AS/NZS. Focus 1b – “Waste Water” & Corrosion As shown in Table F1-1b, 6 Publications found against the search phrase “Water & Waste Water & Corrosion”; 1 from AS or AS/NZS.

These results are shown in Table 2 below.

A copy of this report can be downloaded from the ACA’s website www.corrosion.com.au

2. Across SAIGLOBAL online Standards Publications there was a total of 57 listings of new standards, Drafts and Amendments, found issued from to 18 September 2013 to 19 November 2013; 3 ASNZS Drafts;

Stage 1 Report on SAIGLOBAL Publications at https://infostore.saiglobal.com/store, for all current publications and standards relating to “Water & Waste Water” Technical Group.

Table 1a. For Titles search on https://infostore.saiglobal.com/store on 19 November 2013 for Water & Corrosion there were 287 citations, a sample of which is shown below, with none from Australian Standards Table 1a. Title search by publisher with keywords ‘Water & Corrosion’ – 287 publications found, 0 from AS/ASNZS. Results by Publisher German Institute for Standardisation (Deutsches Institut für Normung)

28

Association Francaise de Normalisation

19

Nederlands Normalisatie Instituut

16

Osterreichisches Normungsinstitut

16

British Standards Institution

14

Polish Committee for Standardization

14

Standardiserings-Kommissionen I Sverige

14

US Military Specs/Standards/Handbooks

14

Belgian Standards

13

National Standards Authority of Ireland

12

p.16 CORROSION & MATERIALS

ACA STANDARDS UPDATE

Norwegian Standards (Norges Standardiseringsforbund)

12

Asociacion Espanola de Normalizacion

11

Comite Europeen de Normalisation

11

Danish Standards

11

Italian Standards

11

Swiss Standards

11

Ford Motor Company

10

American Society for Testing and Materials

8

Interstandard (Russia)

7

International Organization for Standardization

6

NACE International

6

Korean Standards Association

5

Standardization Administration of China

3

Japanese Standards Association

2

Verlag des Vereins Deutscher Ingenieure

2

American Water Works Association

1

Brazilian Standards

1

Bureau of Indian Standard

1

Compressed Gas Association

1

Det Norsk Veritas

1

DVS-VERLAG GmbH, Verlag für Schweissen und verwandte Verfahren

1

Germanischer Lloyd

1

SAE International

1

Schiffbautechnische Gesellschaft E.V.

1

UK Ministry of Defence standards

1

Verlag Stahleisen GmbH

1

Results by Subject – Metallurgy – 144 results Corrosion of metals

142

Ferrous metals

1

Non-ferrous metals

1

Results by Subject – Construction materials and building – 73 results Installations in buildings

70

Elements of buildings

1

Protection of and in buildings

1

Structures of buildings

1

Results by Subject – Fluid systems and components for general use – 70 results Pipeline components and pipelines

69

Valves

1

Results by Subject – Manufacturing engineering – 26 results Surface treatment and coating

26

Results by Subject – Petroleum and related technologies – 26 results Hydraulic fluids

20

Lubricants, industrial oils and related products

5

Fuels

1

Results by Subject – Civil engineering – 10 results External water conveyance systems

10

Results by Subject – Shipbuilding and marine structures – 7 results Shipbuilding and marine structures in general

7

December 2013 www.corrosion.com.au p.17

ACA STANDARDS UPDATE

Results by Subject – Energy and heat transfer engineering – 5 result Solar energy engineering

3

Nuclear energy engineering

2

Results by Subject – Paint and colour industries – 5 result Paints and varnishes

4

Paint coating processes

1

Results by Subject – Environment. Health protection. Safety – 4 results Water quality

3

Protection against fire

1

Results by Subject – Chemical technology – 3 results Products of the chemical industry

3

Results by Subject – Domestic and commercial equipment. Entertainment. Sports – 3 results Domestic, commercial and industrial heating appliances

3

Results by Subject – Road vehicles engineering – 2 results Road vehicle systems

1

Electric road vehicles

1

Results by Subject - Clothing industry – 1 result Headgear. Clothing accessories. Fastening of clothing

1

Results by Subject – Electrical engineering – 1 results Rectifiers. Converters. Stabilized power supply

1

Results by Subject - Generalities. Terminology. Standardization. Documentation – 1 result Vocabularies

1

Results by Subject – Health care technology – 1 result Medical equipment

1

Results by Subject – Metrology and measurement. Physical phenomena – 1 result Electricity. Magnetism. Electrical and magnetic measurements

1

Results by Subject – Rubber and plastic industries – 1 result Manufacturing processes in the rubber and plastics industries

1

Results by Subject – Testing – 1 result Test conditions and procedures in general

1

Results by Publication ASTM STP1086-90

Corrosion In Natural Waters

ASTM STP1300-97

Corrosion Testing In Natural Waters: 2nd Volume

NACE 34108:2008

Review And Survey Of Alkaline Carbonate Stress Corrosion Cracking In Refinery Sour Waters

PN 76/H-04621:1976

Corrosion Of Metals - Outdoor Test In Inland Waters

PN 76/H-04622:1976

Corrosion Of Metals - Copper Index Aggressiveness Of Natural Waters - Test Method

GL VI-10-1:2010

Additional Rules And Regulations - Part 10: Corrosion Protection - Chapter 1: Coating Of Ballast Water Tanks

GOST R ISO/TR 10217:2010

Solar Energy - Water Heating Systems - Guide To Material Selection With Regard To Internal Corrosion

BIS IS 1154:2000 (R2005)

Temporary Corrosion Preventive Fluid, Soft Film, Solvent Deposited, Water Displacing Specification

ASTM STP179-56

Symposium On High-purity Water Corrosion

GB/T 18175-2000

Determination of corrosion inhibition performance of water treatment agents - Rotation specimen method

GOST 18597:1973

Motor Fuel - Corrosion Testing Under Water Condensation Conditions

GB/T 24517-2009

Corrosion of metals and alloys - Outdoors exposure test methods for periodic water spray

SAE AMS 3066:2001 (R2010)

Compound, Corrosion-inhibiting, Water-displacing, Soft Film, Aerosol Canned

p.18 CORROSION & MATERIALS

ACA STANDARDS UPDATE

NACE 46107:2007

Control Of Corrosion, Deposition, And Microbiological Growth In Recirculating Water Systems In Buildings

DEFSTAN 68-10/5:2003

Corrosion Preventive: Water Displacing Nato Code: C-634 Joint Service Designation: Px-24

Table 1b. For Titles search on https://infostore.saiglobal.com/store on 19 November 2013 for “Waste Water” & Corrosion there were 6 citations, with one from Australian Standards Table 1b. Title search by publisher with keywords ‘Waste Water & Corrosion’ – 6 publications found, 1 from AS/ASNZS. Results by Publisher Osterreichisches Normungsinstitut

3

British Standards Institution

1

NACE International

1

Standards Australia

1

Results by Subject – Fluid systems and components for general use – 4 results Pipeline components and pipelines

4

Results by Subject – Manufacturing engineering – 3 results Surface treatment and coating

3

Results by Subject – Construction materials and building – 1 results Installations in buildings

1

Results by Subject – Metallurgy – 1 result Iron and steel products

1

Results by Subject – Rubber and plastic industries – 1 result Reinforced plastics

1

Results by Publication NACE SP 01 00:2008

Cathodic Protection To Control External Corrosion Of Concrete Pressure Pipelines And Mortar-coated Steel Pipelines For Water Or Waste Water Service

ONORM B 5013-3:1994

Corrosion Protection By Organic Coatings For Water And Waste Engineering In Residential Areas - Testing Of Protective Materials And Requirements

ONORM B 5013-2:1990

Corrosion Protection By Organic Coatings For Water And Waste Water Engineering In Residential Areas; Assessment Of Corrosion Probability And Protection Of Cement-bound Materials

ONORM B 5013-4:1997

Corrosion Protection By Organic Coatings For Water And Waste Water Engineering In Residential Areas - Testing Of Corrosion Protection And Requirements

AS 3572.1-2002

Plastics - Glass filament reinforced plastics (GRP) - Methods of test - Preparation of glass filament reinforced plastics test specimens

BS EN 1124-1:1999

Pipes and fittings of longitudinally welded stainless steel pipes with spigot and socket for waste water systems. Requirements, testing, quality control

Table 2 Standards for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and Standards and Amendments for ISO & IEC PUBLISHED from 18 September 2013 to 19 November 2013 for: New standards, amendments or drafts for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and Standards or Amendments for ISO & IEC PUBLISHED between 18 September 2013 to 19 November 2013 Key word search on ‘durability’- 2 corrosion related citations found; all related to solar collectors; None from AS or AS/ NZS ISO/FDIS 22975-3

Solar energy - Collector components and materials - Part 3: Absorber surface durability

MIL F 48616/101:1977 Notice Coating, Low Reflectance On Germanium, 8.0 To 11.5, Micrometers, High Durability, Special 3 Validation Requirements For - Notice 3 Validation Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 21 citations found; 2 drafts from AS/NZS ISO/DIS 11972

Corrosion-resistant cast steels for general applications

ISO/DIS 17224

Corrosion of metals and alloys - Test method for high temperature corrosion testing of metallic materials by application of a deposit of salt, ash, or other substances

ISO/DIS 17245

Corrosion of metals and alloys - Test method for high temperature corrosion testing of metallic materials by immersing in molten salt or other liquids under static conditions

December 2013 www.corrosion.com.au p.19

ACA STANDARDS UPDATE

ISO/DIS 17248

Corrosion of metals and alloys - Test method for high temperature corrosion testing of metallic materials by embedding in salt, ash, or other solids

ISO/DIS 17918

Corrosion of metals and alloys - Evaluation of selective corrosion of alloys by visual inspection and hardness measurement

ISO/DIS 18086

Corrosion of metals and alloys - Determination of AC corrosion - Protection criteria

I.S. EN ISO 11997-2:2013

Paints and Varnishes - Determination of Resistance to Cyclic Corrosion Conditions - Part 2: wet (salt Fog)/dry/humidity/uv Light (iso 11997-2:2013)

DR AS/NZS 2312.1

Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 1: Paint coatings

DR AS/NZS 2312.2

Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 2: Hot dip galvanizing

13/30252115 DC BS ISO 11972

Corrosion-Resistant Cast Steels For General Applications

13/30259829 DC BS ISO 17245

Corrosion Of Metals And Alloys - Test Method For High-Temperature Corrosion Testing Of Metallic Materials By Immersing In Molten Salt Or Other Liquids Under Static Conditions

13/30259830 DC BS ISO 17248

Corrosion Of Metals And Alloys - Test Method For High-Temperature Corrosion Testing Of Metallic Materials By Embedding In Salt, Ash, Or Other Solids

13/30259880 DC BS ISO 17224

Corrosion Of Metals And Alloys - Test Method For High-Temperature Corrosion Testing Of Metallic Materials By Application Of A Deposit Of Salt, Ash Or Other Substances

13/30264734 DC BS ISO 17918

Evaluation Of Selective Corrosion Of Alloys By Visual Inspection And Hardness Measurement

13/30266756 DC BS ISO 18086

Corrosion Of Metals And Alloys - Determination Of Ac Corrosion - Protection Criterion

13/30291492 DC BS En 16602-70-20

Space Product Assurance - Determination Of The Susceptibility Of Silver-Plated Copper Wire And Cable To "Red-Plague" Corrosion

BS EN 15280:2013

Evaluation Of A.C. Corrosion Likelihood Of Buried Pipelines Applicable To Cathodically Protected Pipelines

BS EN 62716:2013

Photovoltaic (Pv) Modules - Ammonia Corrosion Testing

QPL 81309 Revision Sep 2013

Qualified Product List Of Products Qualified Under Performance Specification - Mil-Prf-81309 Corrosion Preventive Compounds, Water Displacing, Ultra-Thin Film - Revision Sep 2013

PD ISO/TR 16335:2013

Corrosion Of Metals And Alloys - Corrosion Tests In Artificial Atmospheres - Guidelines For Selection Of Accelerated Corrosion Test For Product Qualification

A A 59935/4:2013

Conical Seals, Crush, 37 Degree Flared Tube Fitting, Corrosion Resistant Steel

Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion– 28 Publications found; 1 AS Amendment ISO 16474-1:2013

Paints and varnishes - Methods of exposure to laboratory light sources - Part 1: General guidance

ISO 16474-2:2013

Paints and varnishes - Methods of exposure to laboratory light sources - Part 2: Xenon-arc lamps

ISO 16474-3:2013

Paints and varnishes - Methods of exposure to laboratory light sources - Part 3: Fluorescent UV lamps

ISO 16474-4:2013

Paints and varnishes - Methods of exposure to laboratory light sources - Part 4: Open-flame carbon-arc lamp

ISO/FDIS 3233-2

Paints and varnishes - Determination of the percentage volume of non-volatile matter - Part 2: Method using the determination of non-volatile-matter content in accordance with ISO 3251 and determination of dry film density on coated test panels by the Archimedes principle

ISO/DIS 3233-3

Paints and varnishes - Determination of the percentage volume of non-volatile matter - Part 3: Determination by calculation from the non-volatile-matter content determined in accordance with ISO 3251, the density of the coating material and the density of the solvent in the coating material

ISO/DIS 8502-12

Preparation of steel substrates before application of paints and related products - Tests for the assessment of surface cleanliness - Part 12: Field method for the titrimetric determination of water-soluble ferrous ions

ISO/DIS 8502-2

Preparation of steel substrates before application of paints and related products - Tests for the assessment of surface cleanliness - Part 2: Laboratory determination of chloride on cleaned surfaces

I.S. EN ISO 11997-2:2013

Paints and Varnishes - Determination of Resistance to Cyclic Corrosion Conditions - Part 2: wet (salt Fog)/dry/humidity/uv Light (iso 11997-2:2013)

p.20 CORROSION & MATERIALS

ACA STANDARDS UPDATE

I.S. EN 13438:2013

Paints and Varnishes - Powder Organic Coatings for hot dip Galvanised or Sherardised Steel Products for Construction Purposes

I.S. EN ISO 15528:2013

Paints, Varnishes and raw Materials for Paints and Varnishes - Sampling (iso 15528:2013)

I.S. EN 16402:2013

Paints and Varnishes - Assessment of Emissions of Substances From Coatings Into Indoor air Sampling, Conditioning and Testing

DR AS/NZS 2312.1

Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 1: Paint coatings

13/30250128 DC BS EN ISO 8502-2

Preparation Of Steel Substrates Before Application Of Paints And Related Products - Tests For The Assessment Of Surface Cleanliness - Part 2: Laboratory Determination Of Chloride On Cleaned Surfaces

13/30250436 DC BS EN ISO 8502-12

Preparation Of Steel Substrates Before Application Of Paints And Related Products - Tests For The Assessment Of Surface Cleanliness - Part 12: Field Method For The Titrimetric Determination Of Water-Soluble Ferrous Ions

13/30266799 DC BS EN ISO 3233-3

Paints And Varnishes - Determination Of The Percentage Volume Of Non-Volatile Matter Part 3: Determination By Calculation From The Non-Volatile-Matter Content Determined In Accordance With Iso 3251, The Density Of The Coating Material And The Density Of The Solvent In The Coating Material

BS EN 13438:2013

Paints And Varnishes - Powder Organic Coatings For Hot Dip Galvanised Or Sherardised Steel Products For Construction Purposes

BS EN ISO 15528:2013

Paints, Varnishes And Raw Materials For Paints And Varnishes - Sampling

ISO/FDIS 10683

Fasteners - Non-electrolytically applied zinc flake coatings

ISO/FDIS 16691

Space systems - Thermal control coatings for spacecraft - General requirements

I.S. EN 1953:2013

Atomising and Spraying Equipment for Coating Materials - Safety Requirements

DR AS/NZS 2312.1

Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 1: Paint coatings

DR AS/NZS 2312.2

Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 2: Hot dip galvanizing

BS EN 1953:2013

Atomising And Spraying Equipment For Coating Materials - Safety Requirements

QPL 23236 Revision Sep 2013

Qualified Product List Of Products Qualified Under Performance Specification - Mil-Prf-23236 Coating Systems For Ship Structures - Revision Sep 2013

QPL 23377 Revision Oct 2013 Qualified Product List Of Products Qualified Under Performance Specification - Mil-Prf-23377 Primer Coatings: Epoxy, High-Solids - Revision Oct 2013 QPL 46058 Revision Sep 2013

Qualified Product List Of Products Qualified Under Performance Specification - Mil-I-46058 Insulating Compound, Electrical (For Coating Printed Circuit Assemblies) - Revision Sep 2013

QPL 85285 Revision Oct 2013 Qualified Product List Of Products Qualified Under Performance Specification - Mil-Prf-85285 Coating: Polyurethane, Aircraft And Support Equipment - Revision Oct 2013 Key word search on 'galvanize' or ‘galvanized’ or galvanizing’ –3 Standard Publications found; 1 draft from AS/NZS. I.S. EN 13438:2013

Paints and Varnishes - Powder Organic Coatings for hot dip Galvanised or Sherardised Steel Products for Construction Purposes

DR AS/NZS 2312.2

Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings - Part 2: Hot dip galvanizing

BS EN 13438:2013

Paints And Varnishes - Powder Organic Coatings For Hot Dip Galvanised Or Sherardised Steel Products For Construction Purposes

Key word search on 'corrosion' and 'concrete' or ‘concrete’ and ‘coatings’ – 0 Standard Publications found Key word search on ‘cathode’ or 'cathodic' -2 publications found; one Draft nbfrom AS of AS/NZS DR AS 2832.1

Cathodic protection of metals - Part 2: Pipes and cables

BS EN 15280:2013

Evaluation Of A.C. Corrosion Likelihood Of Buried Pipelines Applicable To Cathodically Protected Pipelines

Key word search on 'anode' or ‘anodes’ or ‘anodic’ –0 Standard Publications found Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ - 1 Standard Publications found; None from As or AS/NZS ISO/FDIS 17081

Method of measurement of hydrogen permeation and determination of hydrogen uptake and transport in metals by an electrochemical technique

Keyword Search on 'anodize' or ‘anodized’ - 0 Publications found

December 2013 www.corrosion.com.au p.21

NEW PRODUCT SHOWCASE

SHOWCASE Leading German coating and protection specialist appoints Australian distributor German industrial coatings specialist Voelkel Industrial Products LLC (VIP) has appointed EIC Australia to be its distribution agent in the Australian and New Zealand markets.

VIP is a leading manufacturer of a range of new technology protective coatings, sealants and adhesives that find applications across a wide range of industrial markets.

Headquartered in Munich Germany, VIP has manufacturing operations in Germany, Dubai and India.

The VIP range of Polyurea, polyurethane and polyaspartic based high build instant curing coating products provide end users with superior protection and shorter shut down times.

EIC Australia has been established specifically to house a portfolio of trusted industrial coating, passive fireproofing and thermal insulation products for this market. In addition to the VIP range of Polyurea products, EIC Australia will also represent UK based Darchem Engineering’s range of flexible and rigid Passive Fire Protection enclosure solutions.

For more information: Paul Sonego T: +61 7 5478 9056 M: +61 488 749522 E: psonego@eicaustralia.com www.eicaustralia.com

Olympus OmniScan SX OmniScan SX launched with nationwide Olympus roadshow Olympus Australia has recently introduced the OmniScan SX, phased array(PA) flaw detector. To coincide with the launch, Olympus presented a series of seminars and workshops at centres around Australia. The presentations were supported by displays of phased array technology and hands-on demonstrations, with several of the seminars co-hosted by the Australian Institute of NonDestructive Testing.

The OmniScan SX features an easyto-read 21cm touch screen that maximizes visibility and represents a true breakthrough in making phased array technology more accessible to new users of this technology. The

p.22  CORROSION & MATERIALS

intuitive interface provides smooth menu selection, zooming, gate adjustments, cursor movements, text and value input.

For further information, please contact: Australia www.olympus-ims.com Dorthe Svarrer, Sales & Marketing Coordinator Industrial Business Division Telephone: +61 (03) 9265 5467 E-Mail: IBDinfo@olympus.com.au New Zealand www.olympus.co.nz Faizal Sahib Ph (+64) 9 836 9993 E-Mail: info@olympus.co.nz

NEW PRODUCT SHOWCASE

SHOWCASE "SoyGel" Professional Paint Stripper "SoyGel" is an industrial strength and consumer friendly paint, sealer & urethane stripper. The low evaporation rate and its gel formulation make it possible to remove several layers in one application.

no odour. It can be used on concrete, brick, stone, metal & wood surfaces.

Apply a thick coat (approx 3mm) by brush or airless sprayer ( 519 tip or similar). If "SoyGel" is left to sit outdoors, cover with a light plastic to prolong the strippers wet time.

Common uses: concrete hard surface sealer removal, acrylic, enamel & latex removal, lead-based paint removal, single & most two part epoxy removal, urethane & varnish removal.

For further information contact:

"SoyGel" is 100% biodegradable, noncaustic & non-hazardous, virtually

Let's Clean Pty Ltd Tel. 02-9451 8422 or E-mail: info@letsclean.com.au or visit www.letsclean.com.au

Rust Bullet ColorShell Rust Bullet are to release their new ColorShell - Safety Colours.

Rust Bullet is an environmentally friendly product which when properly applied & cured will provide years of protection. Rust Bullet contains no lead, no zinc, no chromates, & no heavy metals.

UV resistant, chip resistant, scratch-resistant & chemicalresistant, Rust Bullet is a one-step, multiple coat process. www.rustbullet.com.au

New Sigmacheck Hand-held Eddy Current Conductivity Meter Russell Fraser Sales Pty Ltd (RFS) launches the new SigmaCheck handheld Eddy Current Conductivity Meter from Ether NDE, UK. The SigmaCheck features a large, colour, LCD display and lightweight ergonomic design (350g), making it extremely portable. Suitable for use

by NDT inspectors or engineers, the SigmaCheck meets the requirements for conductivity measurements in the Aircraft manufacture and maintenance fields and has been globally well received. Typical applications include material verification/metal sorting, heat

treatment verification, heat or fire damage investigation, non-ferrous metal manufacturing, determining the purity composition of materials and assessment of ageing of aluminium profiles.

To request a quote or more information about the SigmaCheck contact Russell Fraser Sales (RFS): T: +612 9545 4433 F: +612 9545 4218 E: rfs@rfsales.com.au Web: www.rfsales.com.au

December 2013 www.corrosion.com.au p.23

NEW PRODUCT SHOWCASE

Global Advancements in Environmentally Friendly Abrasive Blasting Mackay company Engineered Surface Preparation (ESP) has embraced the latest global advancements in environmentally-friendly blasting equipment with the introduction of the Pinovo range of tools to business operations. Pinovo supplies solutions for the maintenance and surface treatment of industrial installations, providing a dust free alternative with low noise emission and superior surface quality.

is a walk behind vacuum blasting tool intended for larger areas in flat, horizontal surfaces and the fourth tool will be the PiSys100, a recycling and waste recovery unit.

The four Pinovo tools ESP will incorporate into the business includes, the PiSys 100, the PiPoint, the PiConnect and the PiWalk.

The PiPoint is a hand held vacuum blasting tool, primarily intended for small areas with difficult access and difficult geometries. The PiConnect is a hand held blasting tool intended for spot and sweep blasting. The PiConnect has several adapters to be used on different geometries. PiWalk

Mackay 205 Boundary Road Paget QLD 4740 Australia T +61 7 4952 2401 F +61 7 4952 2461

ESP is a locally owned company specializing in preparation, remediation & coating of steel & concrete assets.

Engineered Surface Preparation

Gladstone 16 Tank Street Gladstone QLD 4680 T +61 7 4972 8932 F +61 7 4972 2481

Solid Solutions, Proven Results...

ESP Delivers!

• • • • •

oncrete & Steel Remediation C Ultra High Pressure Water Jetting Abrasive Blasting & Industrial Coatings Enviropeel Specialist Coating Removal

TRA S U A

N I FIRST

LIA

Introducing the Pinovo blasting tool system.

The first environmentally friendly solution, now in Australia and only delivered by the professionals at ESP. • • • •

European Technology No flying grit or dust Noise reduction Blast material consumption reduced by up to 90% MACKAY 205 Boundary Rd, Paget GLADSTONE 16 Tank St, Gladstone www.espqld.com.au

p.24 CORROSION & MATERIALS

CALL TODAY 07 4952 2401

TECHNICAL EVENT REVIEW

Keynote Speaker Carol Powell

Investigation of Corrosion in the Water & Wastewater Industries In October, the ACA ran a series of seminars across Australasia investigating corrosion in the water and wastewater industries. Supported by the ACA Foundation, the six-part series was aimed at all sectors of the water industries, from asset owners to designers to maintenance personnel.

However crevices such as flange faces under suitable gaskets materials, pressfittings and other mechanical joints have posed few problems in lowchloride potable waters, she said.

UK metallurgy specialist Carol Powell, C Eng, FIMMM, MarEST was the keynote speaker. Complementing Carol’s presentations were a range of actual case studies, presented by local practitioners representing companies associated with the water and wastewater treatment industries such as Sydney Water and Melbourne Water.

Carol explained throughout the series that when raw water is used for hydrostatic testing of pipelines and storage tanks, then left to stand for a number of weeks, there is a potential for inappropriate bacteria to colonise the asset and microbiologically influenced corrosion (MIC) can begin.

This is usually found where welds have not been cleaned of heat tint, and once this is removed corrosion resistance is greatly improved.

Stainless steels are ideal for water and wastewater applications, since they don’t need extra coatings to be corrosion resistant - although they are not immune to it. 304L and 316L are generally the most appropriate grades in water industry applications, with duplex and superaustenitic stainless steels recommended for more demanding areas.

“It’s very important to drain and dry stainless steel systems after hydrotesting, if the equipment is not going back into service immediately,” says Carol. “If this is not possible, regular flushing of the system should limit potential MIC problems. Ideally potable waters, steam condensates where available or filtered waters should be used for hydrotesting rather than raw waters.”

Using the wrong grade of stainless steel for a purpose is a common mistake, said Dr Jonathan Morris CEng, MIMMM at the Auckland seminar. For example, using the wrong grade in areas with high chlorine or hydrogen sulphide levels will significantly shorten the asset’s life, as will combining incompatible metals with stainless steels.

Research into chlorine damage of stainless steels suggests there are few problems when chlorine is injected into the process stream and good mixing occurs. Corrosion can however occur when there has been long term, excessive dosing or where the concentrated chlorine has been injected against the metal wall.

“Corrosion, if it occurs, is usually found at crevices but this can be avoided by correct grade selection for the chlorides present in the waters; guidelines are available to assist in this” explained Carol. “Attention to detail during fabrication including the use of good welding and inspection procedures can help as inferior welding and/or a poor surface finish can also encourage corrosion.

Wastewater treatment plants all contain very poisonous, flammable and corrosive hydrogen sulphide gas, yet corrosion rates of 304L and 316L grades have been found to be “negligible” when moist hydrogen sulphide is present and temperatures are near-ambient.

However, if moist hydrogen sulphide and chlorides are present in closed systems like pipes, there’s a risk of

localised pitting and crevice corrosion at “elevated” temperatures for 304L and 316L grades. When condensates include dissolved sulphur dioxide as well, the increased acidity means more corrosion resistant grades like austenitic (eg. 904L) or duplex (eg. 2205) grades should be considered for use.

Duplex stainless steels are roughly twice as strong as austenitic stainless steels and also have better resistance to localised corrosion, explained Les Boulton of the Nickel Institute. They have high chromium (19–32%) and molybdenum (up to 5%) percentages and lower nickel contents than austenitic stainless steels.

In summary from the seminar series, the most important aspects to ensure the longest life for stainless steel are: arefully select the alloy grade for the C conditions ow carbon grades should be used for L welded fabrications void crevices when possible by good A design ollow good fabrication practices, F particularly by removing weld heat tint S ystems which are not put into service directly after hydrotesting, or see down time, should be drained and dried in order to avoid potential problems, especially if raw waters are used. If this is not possible, the waters should be circulated regularly lowing conditions should be F maintained wherever possible xidising chemicals should be well O mixed with the water stream to avoid exposure to aggressive chemicals enting or regularly washing V down of areas where chlorine vapours can collect.

December 2013 www.corrosion.com.au p.25

COATING INSPECTION CERTIFICATE

Coating Inspection Certificate Up until 2005 The Australasian Corrosion Association Incorporated conducted a 5 day Coatings Inspection Certificate Course. It was designed to provide the requisite skills and knowledge to inspect protective coatings following the requirements of Australian/New Zealand Standards.

The list below contains the names of qualified ACA Coatings Inspectors who have satisfied the requirements to be issued with an ACA Coatings Inspection Certificate and who have ‘refreshed’ their certificate within the 5 year time frame required by the ACA Council.

Some inspectors have cross – accredited to the internationally recognised ACA Coating Inspectors

NACE Coatings Inspection Program. In those cases, the validity of their ACA certification has been reconfirmed.

Every care has been take to ensure that at the time of publishing the information is correct. The Australasian Corrosion Association Incorporated does not accept any responsibility for any consequences which may arise from the use of this information. Those wanting to engage a Coatings Inspector should rely on their own judgement and if necessary seek other advice as to whether the person has suitable work experience and references for the work proposed.

No legal liability for negligence or otherwise can be accepted by The Australasian Corrosion Association Incorporated for the information or the use of the information contained in this listing.

If you have any queries please contact The Australasian Corrosion Association Incorporated directly on +61(0)3 9890-4833 or via email to aca@corrosion.com.au.

Please note: this list is current as at 18 November 2013

John Cooke

3235

31/12/2018*

Wayne Ferguson

893

31/12/2017

466

6/07/2016

Nathan Fernance

2219

30/01/2014

Jerry Forslind

1129

31/10/2014

Phillip Foster

2254

3/08/2014

Name

Cert.

No.

Expiry Date

Cameron Cooper

Richard Adams

1230

19/04/2015

Darrel Craig

2810

3/08/2014

Kamran Armin

4232

28/02/2016

Dean Crase

4137

6/07/2016

Dennis Ashman

390

30/01/2014

4197

31/12/2017

Rob Francis

720

31/12/2017

Peter Atkinson

3234

31/07/2015

Michael Crowley

11/06/2014

11/06/2014

12/08/2015

3492

3773

2211

Jay Cumner

John Paul Fraser

Trevor Baensch Travis Baensch

4209

12/08/2015

Dean Currie

2092

3/08/2014

Robert Freedman

76

31/12/2017

Stuart Bayliss

247

31/12/2018

David Daly

7343

31/12/2016

Brett Gale

3774

12/08/2015

Ben Biddle

1279

28/02/2015

Cheryl Dalzell

3940

19/04/2015

David Gates

2599

19/04/2015

Mark Blacklock

3501

2/07/2015

Roman Dankiw

872

30/11/2013

Collin Gear

2623

31/12/2017

Timothy Blair

2088

31/01/2014

Robert de Graaf

719

31/12/2017

Ian Glover

393

28/02/2015

Michael Boardman

John Dixon

1118

11/06/2014

1051

31/12/2017

Robert Glover

1362

31/12/2017

Trevor Domin

4031

11/06/2014

Matthew Boyle

1429

30/04/2016

88

3/08/2014

Peter Donovan

1888

30/01/2014

Frederick Gooder

Kingsley Brown

2603

31/10/2015

Peter Dove

1203

30/11/2014

Wayne Gray

3606

2/12/2014

Sean Anthony Burke

3428

31/12/2018

Ray Grose

2956

31/12/2017

Phill Dravitski

1593

31/03/2015

Paul Haggerty

1433

31/10/2014

19/04/2015

Kenneth Dunn

1296

6/07/2016

Jim Haig

394

12/08/2015

3386

31/12/2018

Ray Harcourt

1326

23/04/2014

Elliot Burns

972

Micah Butt

2397

31/10/2016

William Dunn

Luis Carro

2212

31/12/2017

Nick Edwards

1992

2/12/2014

Brian Harris

1054

31/12/2018*

155

30/11/2015

Peter Hart

1

31/10/2015

Terry Carroll

1477

11/06/2014

Dave Elder

Wayne Clarke

3603

11/06/2014

Todd Elkin

3402

19/04/2015

Darrin Hatton

3206

30/01/2014

Ian Clifton

1160

31/07/2014

John Elomar

4204

19/04/2015

Shane Hawker

7342

31/12/2016

4130

2/07/2015

Rohan Healy

3184

31/12/2017

2086

6/07/2016

Bronte Henning

178

31/10/2016

Gregg Cobban

2213

2/12/2014

Tony Emery

Rod Cockle

1410

30/11/2015

Tony Evans

p.26 CORROSION & MATERIALS

COATING INSPECTION CERTIFICATE

Clayton Henry

1595

31/12/2017

Bradley Marsh

3232

30/11/2015

Kevin Sellars

7352

31/12/2017

Chris Heron

1619

31/05/2016

George Martin

669

2/07/2015

Kevin Sharman

627

30/11/2015

Don Herrigan

4033

12/08/2015

Garry Matthias

1481

30/04/2016

Tracey Sherman

1829

31/12/2018*

Greg Hill

1434

30/11/2016

4352

6/07/2016

Douglas Shipley

2221

2/07/2015

Shaun Hinks

3208

23/04/2014

David McCormack

Michael Sillis

844

31/12/2017

Frank Hiron

2888

31/12/2018

Peter McCormack

4353

31/12/2017

John Simoni

3596

2/12/2014

Matt Hollywood 1744

31/05/2014

Brett Meredith

2218

30/11/2015

Gary Smith

2512

3/08/2014

Paul Howe

3177

30/01/2014

Andrew Miles

1031

30/09/2014

Trevor Smith

1035

31/12/2017

Paul Hunter

2988

31/12/2017

Wayne Mitchell

3357

2/07/2015

Laurence Snook

1526

31/12/2017

Jeffrey Hurst

1746

31/12/2018

John Mitchell

1042

31/12/2017

2960

31/12/2018

Vic Monarca

2053

6/07/2016

Dragan Stevanovic

Bryan Moore

462

23/04/2014

Neil Stewart

1358

31/12/2017

Steven Stock

3923

6/07/2016

Wessel Mulder

7351

31/12/2017

Lex Stolk

3216

31/10/2014

Peter Myatt

1907

11/06/2014

Steve Storey

3176

30/01/2014

Peter Nicholson

4086

12/08/2015

Raymond Street

3173

31/05/2016

Stephen Nixon

2256

31/12/2017

Peter Sutton

3183

31/12/2017

Eric Norman

7430

31/12/2016

Junior Tiaiti

2991

3/08/2014

Dennis O'Loughlin

7353

31/12/2017

Russell Tierney

2000

2/12/2014

Mark O'Sullivan

4059

30/01/2014

Dennis Tremain

1036

31/12/2017

Gerald Owen

7341

31/12/2016

Andy Vesco

3783

19/04/2015

Clifford Parkes

3607

2/07/2015

Paul Vince

7355

31/12/2017

David Walters

1910

11/06/2014

Troy Ward

2571

30/01/2014

Paul Weston

2129

23/06/2014

Mark Weston

883

31/12/2017

Charles Wheeler

3943

19/04/2015

Geoffrey White

75

31/10/2016

Gary Whittle

1794

31/10/2014

Craig Williams

4176

12/08/2015

Geoff Woodman

1171

31/07/2014

Gary Hussey

3984

2/07/2015

Clinton Iliffe

4034

12/08/2015

Basyl Jakimow Tom Jensen Robert Johnson

3230 2889 2625

23/04/2014 2/12/2014 31/12/2018*

Matthew Johnson

2359

12/08/2015

Robert Johnson

3354

12/08/2015

Michael Johnstone

2964

31/12/2018

Roger Kearney

1121

31/12/2018

Graeme Kelly

721

31/12/2017

Donald Kirchner

1905

11/06/2014

Rick Pascoe

2605

23/04/2014

Robert Kirkham

2009

30/01/2014

Steve Pearce

2269

2/12/2014

Leonard Kong

3538

3/08/2014

Mervyn Perry

268

31/12/2017

Joseph Kowal

553

30/06/2014

1513

31/12/2017

Harry Kronberger

Lorraine Pidgeon

1516

2/12/2014

Graham Porten

2257

3/08/2014

Narend Lal

3355

11/06/2014

David Power

2487

19/04/2015

John Lane

1784

2/12/2014

Daniel Price

4129

30/06/2016

David Lepelaar

3356

31/12/2018

Brian Probert

1190

31/07/2014

3780

12/08/2015

Neil Alan Lewis

2598

31/12/2018

John Puljak

Daniel Lillas

4445

30/11/2014

Barry Punter

1843

31/10/2015

1862

11/06/2014

Peter Luke

3795

11/06/2014

James Rebetzke

Jonathan Mace

4035

6/07/2016

Greg Reece

3508

19/04/2015

Alistair MacKenzie

4191

31/12/2017

Tony Ridgers

421

30/11/2015

Spencer Macsween

Rick Roberts

1316

28/02/2016

3170

31/12/2017

Dean Rowe

4200

2/07/2015

Willie Mandeno

1216

31/12/2017

Stephen Sach

3013

30/01/2014

Tony Mans

3233

31/12/2017

Valentine Scriha 1896

12/08/2015

*These inspectors will attend an ACA Coatings Inspection Refresher on 12 December 2013 and this expiry date is subject to their successful completion of that course.

December 2013 www.corrosion.com.au p.27

ACA CORPORATE MEMBERS

ACA Corporate Members PLATINUM MEMBERS GOLD MEMBERS p.28 CORROSION & MATERIALS

Standard

Jotun blue

Black and white

ACA CORPORATE MEMBERS

ACA Corporate Members Corporate Silver

Corporate Bronxe

Action Alliance Group

4Resources

ALS Industrial - Power Services

A. S. Harrison & Co Pty Ltd

Applus RTD Pty Ltd Arup Pty Ltd Atteris Pty Ltd Aurecon Australia Pty Ltd

AB and P Abrasive Blasting & Painting ABSAFE Pty Ltd Acacia Corrosion Control ACTEW Corporation Limited Adtech FRP Pty Ltd

Australian Maritime Systems Ltd

Advanced Aqua Blasting

Core Group Ltd

AFL Services

CTI Consultants Pty Ltd

AGC Industries

E&A Contractors

Airservices Australia

Elite Concrete Protection & Repair

Akron Group NT Pty Ltd

Engineered Surface Preparation

Albany Port Authority

Extrin Consultants

Alfabs Protective Coatings Pty Ltd

Favcote Pty Ltd Galvanizers Association of Australia Geopave/Vic Roads Grange Resources (Tasmania) Pty Ltd Hobson Engineering

Alloy Yachts International Ltd Allunga Exposure Laboratory AMAC Corrosion Protection Pty Ltd Amog Pty Ltd Andersal Pty Ltd Anti Corrosion Technology

Hydro-Chem Pty Ltd

APA GasNet OPS Pty Ltd

Intercept Australia Pty Ltd

ARC West Group Pty Ltd

Kaefer Novacoat (WA) Pty Ltd

ArmorGalv (Aust) Pty Limited

LR Industrial Services

ASC Pty Ltd

M Brodribb Pty Ltd

AsClear Pty Ltd

Melbourne Water

Asset Integrity Australasia Pty Ltd

Oliver Spray Equipment

ATCO Gas Australia

Olympus Australia Opus International Consultants Ltd Origin Energy Orrcon Operations Pty Ltd

Ausblast Auscor Pty Ltd Austral Wright Metals Ausvic Pty Ltd BAE Systems Australia

Petro Coating Systems Pty Ltd

BASF Australia Ltd

Plant & Platform Consultants Ltd

Bayer Material Science Pty Ltd

Rhino Linings Australasia Pty Ltd

BCMG Pty Ltd

RKF Engineering Services

Bluey Technologies

Rosen Australia Pty Ltd

Bowhill Engineering

Rotafab Pty Ltd

BP Refinery (Bulwer Island)

Scientific Solutions Pty Ltd

BP Refinery (Kwinana) Pty Ltd

South Coast Surface Protection Supreme Steel Products Ltd SVT Engineering Consultants Transpacific Industrial Solutions Veolia Environmental Services

BRANZ Limited Brisbane Abrasive Blasting Buel Pty Ltd Bundaberg Sandblasting Pty Ltd C. P. Plating Pty Ltd Caltex Australia Petroleum Pty Ltd

Water Corporation of Western Australia

Caltex Refineries (QLD) Ltd

Worley Parsons Ltd

Cameleon Paints

continued over…

December 2013 www.corrosion.com.au p.29

ACA CORPORATE MEMBERS

Cathodic Anodes Australasia (CAA)

Greater Wellington Regional Council

CCM Group Australia

G Squared Solutions

CEM International Pty Ltd

Gummow Pty Ltd (T/A G Squared Solutions)

Centreport Limited

Halcrow Group Limited

Champion Technologies

HERA

Chevron Australia Pty Ltd

Hispec Industrial Coatings Pty Ltd

Chiron Chemicals

Holmes Consulting Group

City West Water

Horiso Pty Ltd

Clarkes Painting Services

Hunter Water Australia Pty Ltd

Clavon Pte Ltd

Hydro Flow Pty Ltd

Coating Industries Australia Pty Ltd

Hydro Tasmania

Commercial Industrial Painting Services Pty Ltd

idec Protective Coatings Pty Ltd

Contract Resources Pty Ltd

Inductabend Pty Ltd

CORE Water Management Solutions Pty Ltd

Industrial Composite Contractors

Corrosion Control System

Innovative Corrosion Management Pty Ltd

Corrosion Electronics Pty Ltd

Inspec Consulting Pty Ltd

Corrosion Specialists Pty Ltd

Inspection & Consultancy Services Ltd

Costin Roe Consulting

Integrated Petroleum Solutions

Couplertec Electronic Rustproofing

International Corrosion Services Pty Ltd

Crest Restoration Services Pty Ltd

Intertek Moody

CSIRO CMSE

Invensys Rail Pty Ltd

Dapcor Building Services Pty Ltd

Ionode Pty Ltd

DBP Transmission

IPCQ

Department of Transport and Main Roads

ITW AAMTECH

Dept for Manufacturing, Innovation, Trade, Resources and Energy

ITW Buildex

Dept of Infrastructure, Energy & Resources

Jacobsen Colourplus Ltd

Dept of Transport

Jeff Hort Engineering

Diagnostech Pty Ltd

Keppel Prince Engineering Pty Ltd

Doito Pty Ltd

KGB Protective Coatings

Doogood Specialised Coatings P/L

Korvest Ltd - Galvanising Division

DSTO

Kulin Group Pty Ltd

Dulux NZ Ltd

Linetech Consulting

Eddy Batur Industrial Painting

Liquigas Ltd

EM&I (Australia) Pty Ltd

Longmont Engineering

Emeco International

Loy Yang Power Ltd

Energy Safe Victoria

Lyttelton Port of Christchurch

Energyworks Ltd

M. Waters Abrasive Blasting Services

Esso Australia Ltd

Mac Coatings Pty Ltd

Firma Industries

Marden Corrosion Services P/L

Fremantle Ports

Mattioli Bros Pty Ltd

Fremantle Sailing Club

Maxcon Industries Pty Ltd

Freyssinet Australia Pty Ltd

McBerns Pty Ltd

Germanischer Lloyd (Australia) Pty Limited

McCoy Engineering Pty Ltd

Giovenco Industries (Aust) Pty Ltd

McElligott Partners Pty Ltd

Gippsland Cathodic Protection

McElligotts (QLD) Pty Ltd

Gippsland Water

McElligotts (Tas) Pty Ltd

Gisborne Abrasive Blast & Coatings 2000 Ltd

McKechnie Aluminium Solutions Limited

Gladstone Ports Corporation Ltd

Metal Spray Suppliers (NZ) Ltd

Gladstone Regional Council

Metal Spray Supplies Australia

GORODOK Pty Ltd

Methanex New Zealand Ltd

GPR Electrical (WA) Pty Ltd

Metrocorp Technologies

p.30  CORROSION & MATERIALS

ACA CORPORATE MEMBERS

Metz Specialty Materials Pty Ltd

Rightway Industrial Pty Ltd

Mighty River Power

RM Watson Pty Ltd

Mills Sign & Painting Service

Roads and Maritime Services

Mobil Refining Australia Pty Ltd (Altona Refinery)

Rust Bullet Australasia

MTK Consulting

Rust-oleum Industrial Coatings

Multicoat Pty Ltd

SGS NZ Ltd

Nalco Australia Pty Ltd

Shield Technology Pty Ltd

NDT Equipment Sales Pty Ltd

SICC SERVICES Pty Ltd

Neptune Asset Integrity Services Pty Ltd

Sika (NZ) Ltd

New Zealand Aluminium Smelters

Silver Raven Pty Ltd

New Zealand Steel Ltd

SLH Contracting (2008) Ltd

Newcastle City Council

South East Water Limited

NMT Electrodes (Australia) Pty Ltd

Southern Cross Building Products

Norblast Industrial Solutions Pty Ltd

Steelpipe Limited

North Queensland and Bulk Ports Corporation

STR Inspection Services

Northport Ltd

Structural Systems (Remedial) Pty Ltd

NPC Industries Pty Ltd

Sulco Limited

NSW Ports Kembla Operations

Summit Fertilizers

NZ Refining Co Ltd

SunWater Limited

Osborne Cogeneration

Sydney Trains

OSD Pipelines

Syntech Distributors Ltd

Outokumpu Pty Ltd

Tas Gas Networks

Outokumpu VDM Australia Pty Ltd

Tasmanian Ports Corporation Pty Ltd

Pacific Quality Corrosion Control

TasWater

Pacific Remedial Solutions

The Valspar (Australia) Corporation Pty Limited

Pacific Resins Pty Ltd

Thomas Contracting Pty Ltd

Paint N Colour

Tincone Pty Ltd

PCWI International Pty Ltd

Titanium Electrode Products (Australia) Pty Ltd

Pentair Water Solutions

Total Corrosion Control Pty Ltd

Phillro Industries Pty Ltd

Total Paint Protection

Phoenix Protective Services (NSW) Pty Ltd

Total Surface Protection

Pipe Management Australia

Townsville Port Authority

Polymer Group Ltd

Transend Networks Pty Ltd

Port of Portland

Transfield Services

Prendos New Zealand Ltd

Transpower New Zealand Ltd

Preservation Technologies

Tristar Australia Pty Ltd

ProDigital Pty Limited

Tropical Reef Shipyard Pty Ltd

Prokote Pty Ltd

Undersea Construction Ltd

Pumpline Pty Ltd

Universal Corrosion Coatings Pty Ltd

Pumpsec Ltd

Valicote Pty Ltd

QLD Painters & Maintenance Services Pty Ltd

Vector Gas Limited

Quality Maritime Surveyors Pty Ltd

Vincent Painting

Queensland Bulk Water Supply Authority t/a Seqwater

VT Industrial Coatings

Queensland Rail

WAG Pipeline Proprietary Ltd

Queensland Sugar Limited

Wairau Paint Centre Ltd

Queensland Urban Utilities

Wannon Region Water Corporation

Reinforced Earth Pty Ltd

Willall Industries Pty Ltd

Renfay Projects

Woodside Energy Ltd

Reno Blast

Yarra Valley Water

Resene Paints Ltd Rheem Australia Pty Ltd

Corporate Member list accurate as of 22/11/2013

December 2013 www.corrosion.com.au p.31

MEET THE…TECHNICAL GROUP CHAIRS

Meet the: Petroleum & Chemical Processing Industries Please provide your Name, Company, Job Title Fikry Barouky, Principal Materials & Corrosion Consultant, Anti Corrosion Technology (ACT) Pty Ltd Tell us about your day to day employment and how it relates to corrosion prevention 38 years work experience national and international dedicated to all aspects of materials engineering and corrosion control focusing on the Oil & Gas production processes.

I am the founder and the principal engineering consultant of ACT, which is considered the unique engineering knowledge hub managed by an efficient team of corrosion experts from all around the world.

ACT is the sole agent and exclusive distributor of STOPAQ B.V. the pioneer of manufacturing the visco elastic corrosion protective coatings and sealants.

Water Please provide your Name, Company, Job Title Matthew Dafter, Hunter Water Australia Pty Ltd, Corrosion Engineer Tell us about your day to day employment and how it relates to corrosion prevention My main role is to provide pipeline condition assessment services to Hunter Water Corporation. For the most part my role involves undertaking proactive assessment of buried pipelines to determine their current condition. I also do undertake a considerable amount of failure analysis when assets fail. I am also currently completing postgraduate

p.32 CORROSION & MATERIALS

Focusing on the pipeline integrity, I work jointly with the asset owner and the operator to identify the corrosion mechanisms and to develop a comprehensive risk directed corrosion management program from the design phase to decommissioning to enable assessing and evaluating of the pipeline’s service life expectancy.

I am currently nominated by one of the key oil producers worldwide to study and develop a new technology in Nano-coatings with selected academic associations. The study will be completed in 2016 and the results will enhance the corrosion prevention in the upstream production operations.

How long have you been volunteering for the ACA? I have been a member in ACA since 1991. In 1992 I was nominated by WA Branch committee to be a member in the steering committee and the editor of the monthly “newsletter”.

I was a member of the technical committee in most of the C&P conferences as a reviewer of the technical papers in various streams.

From 2009 to the current year I was nominated by ACA to chair the “Petroleum & Chemical Processing Industries” Technical Group. research on electrochemical testing of ferrous materials in soils, which will have some positive outcomes for the assessment and corrosion prediction of underground assets.

How long have you been volunteering for the ACA? I have been volunteering for the ACA since 2009 serving on the Newcastle Branch committee and, since 2011, on the operations board of the ACA. I have been active in the Water Technical Group since my very first ACA conference in 2005.

How does your involvement with the ACA help you achieve your own personal and professional goals?

Through the ACA I have been exposed to a broad spectrum of people and an incredibly interesting array of

How does your involvement with the ACA help you achieve your own personal and professional goals?

I consider ACA is the knowledge hub of materials and corrosion control expertise for all the industries in Australasia.

All the technical events and the annual C&P conference assist to streamlining a mega network of specialization and experiences in all corrosion aspects.

With the wealth of the professional courses that ACA offers to the industries, the availability of certified specialists is helping to grow up and improve the output and proactive participation in making Australia the leader in materials engineering and corrosion control.

What do you hope to achieve in your term as Technical Group Chair?

In 2009 I managed, with the help of the steering committee, to change the technical the name of the Technical Group from “Refining Industries” to “Petroleum & Chemical Processing Industries”. That was a key step to see a lot of new members joining from the oil and gas various operations Australasia wide. Today, the Technical Group has significantly increased the number of its members).

technical topics. These interactions served as the inspiration for me to pursue research opportunities to hopefully contribute to the broad knowledge base on corrosion within the ACA. The networking opportunities within the ACA are also fantastic; I have found that if you come across something you can’t resolve yourself, there will be an ACA member within the organization that can help you!

What do you hope to achieve in your term as Technical Group Chair?

My hope is to promote and foster presentation of various case studies and technical advancements for use within the water industry. Failure cases studies can be particularly interesting at the conference each year.

MEET THE…TECHNICAL GROUP CHAIRS

Concrete Structures & Buildings Please provide your Name, Company, Job Title Dr Frédéric Blin, AECOM, Associate Director and Team Leader Tell us about your day to day employment and how it relates to corrosion prevention My role entails the management of a team that provides client-support devices including Strategic Asset Management and Durability/Materials Engineering. I am in regular contact with clients to ensure that the advice we provide in relation to their deteriorating

Mining Please provide your Name, Company, Job Title Ted Riding, Jotun Australia Pty Ltd, Technical Manager Tell us about your day to day employment and how it relates to corrosion prevention Our company is a manufacturer of protective coatings and is based in Australia on the previous Dimet site who pioneered the use of Inorganic Zinc Silicate coatings - both as a manufacturer and applicator.

My regular role is the management of the product formulations and the selection and specification (including

Coatings Please provide your Name, Company, Job Title Matthew O’Keeffe, International Paint, Marketing and Business Development Manager ISEAA Tell us about your day to day employment and how it relates to corrosion prevention

assets or the design of new structures is tailored to their needs and objectives.

I am the director of a number of our projects where I work to ensure that they are delivered satisfactorily to our clients. At a technical level I review documents the team produces. Our work is centred around assets life cycles and how to help clients get the best value out of them; as such corrosion prevention is a key aspect of our work and thus we have a number of materials/ corrosion specialists in our local and national team.

How does your involvement with the ACA help you achieve your own personal and professional goals?

How long have you been volunteering for the ACA?

My aim is to work with our committee's secretary Warren Green, our committee's members and ACA officers to generate healthy technical discussions on topic of key relevance to our industry in seminars and forums.

I have been volunteering with the ACA as a chair of our Concrete Structures and Buildings for over 3 years and I have also been reviewing papers particularly for ACA conferences. surface preparation and application methods) of suitable products for defined corrosive service conditions.

Included in this role is the evaluation of product performance by on site surveys and field assessments and the support of professional applicators through training and advice.

How long have you been volunteering for the ACA? I have been involved with the ACA as a volunteer for approximately 25 years.

How does your involvement with the ACA help you achieve your own personal and professional goals?

Being involved with the ACA gave me the opportunity to continue to learn and grow technically as well as network with a wide range of professionals interested to share lessons and advice on corrosion identification and prevention.

What do you hope to achieve in your term as Technical Group Chair?

engineering design firms, steel fabricators, third party inspectors and coating applicators. This gives a very broad perspective on the total role played by protective coatings and the many competing objectives present when determining a suitable corrosion control strategy. There is a personal satisfaction in being part of the process of doing something beneficial to many parties and the professional benefit is the continuous improvement possible in drawing on the skill and experience of others.

What do you hope to achieve in your term as Technical Group Chair?

Involvement with the ACA allows contact with the various stake holders in the corrosion mitigation area asset owners, consultant specifiers,

Mostly the wish is to facilitate discussion and information sharing at a level where commercial barriers are lowered and candid exchange of views is possible through the forum of the Mining TG.

Marketing, specification and sales of high performance anticorrosive coatings systems.

Good networking and opportunities to exchange information (road shows in particular).

How long have you been volunteering for the ACA?

What do you hope to achieve in your term as Technical Group Chair?

I have been volunteering with the ACA for 2 years.

Better engagement with the professional coating contractors in our industry.

How does your involvement with the ACA help you achieve your own personal and professional goals?

COATINGS GROUP MEMBER PROFILE

QIC Protective Coatings Q: In what year was your company established?

A: QIC was established during November 1993.

Q: How many employees did you employ when you first started the business?

A: We had 25 employees working both yard and site based.

Q: How many do you currently employ?

A: Depending on project requirements we can have anywhere from 15 to 50 running over various projects.

Q: Do you operate from a number of locations in Australia?

A: Our Head Office is in Brisbane but we work anywhere in Australia, Pacific Islands and South East Asia.

Q: What is your core business? (e.g. blasting and painting, rubber lining, waterjetting, laminating, insulation, flooring etc.)

A: Our core services we offer range from scaffolding, surface preparation comprising in abrasive blasting (dry, wet and vacuum) or Water Jetting both High and Ultra High Pressure Water Jetting up to ( 3200 Bar or 46,000 psi ) then protective coatings ranging from enamels to two packs ( epoxies and urethanes ) and more in-depth to plural component application of Elastomeric Polyurethanes and other plural component required coatings.

We also apply passive fire protection coatings and conduct QA\QC services to 3rd parties.

p.34 CORROSION & MATERIALS

Q: What markets do you cover with your products or services? eg: oil & gas, marine, chemical process, general fabrication, tank lining, offshore etc.

information are adhered to as per our clients requirements as we currently have 6 NACE Certified inspectors working in the field.

A: Oil and Gas, Petrochemical, Marine, Water and Waste Water Treatment plants, Tank linings, Mineral Sands and Chemical Process Plants, there isn’t much we don’t cover.

Q: What is the most satisfying project that you have completed in the past two years and why?

Q: Is the business yard based, site based or both?

A: We currently operate predominately on site, with only small projects done in our yard.

Q: What is your monthly capacity or tonnage that you can blast and prime?

A: As we mainly conduct work onsite it is very difficult to give rates as we are usually conducting re-paints or maintenance works.

Q: Do you offer any specialty services outside your core business? (eg. primary yard based but will do site touch up etc.)

A: There isn’t much we don’t do.

We cover scaffolding, encapsulation, surface preparation, application of all coatings. Ranging from Tanks, Bunds, Bridges, structural steel, machinery and Pipework.

We try to suit all our works to the client’s requirements such as in the current project we tailor made an automated pipe spool coating machine for the current CSG projects and are currently working on an automated field joint coating machine.

We also offer inspection services, ensuring ITP’s and other relevant

A: QCLNG has been a very rewarding project as we have recently designed and built an automated pipe spool coating machine capable of internal and external coatings. We have also in the final designing stage of an automated field joint applicator which we are working on at the present. We have also worked closely with the QA and operations department in resolving potential problems with their specification before it came to a head.

Q: What positive advice can you pass on to the Coatings Group from that satisfying project or job?

A: To think outside the box and no matter how big or small a job is make it your best.

Q: Do you have an internal training scheme or do you outsource training for your employees?

A: At present we currently outsource all training with the exceptions for our Apprentices and found this to be most rewarding and productive way to conduct our training.

Contact information for QIC Office ph 07 3393 4346 Office fax 07 3822 6514 Email sales@qic.net.au Aaron Sharman 0413 434 621 Email aaronsharman@qic.net.au

INDUSTRY INSIGHT

Forensic Corrosion Engineering Introduction The term forensics owes it origins to the latin word “Forensis” which means before the forum, effectively to present a criminal case before the forum which is analogous to the modern day courts. Edmond Locard (1877 to 1966) is often credited with being the father of modern forensics; the Locard “exchange principle” that “every contact leaves a trace” is still considered to be the first fundamental principles of forensic investigations.

Thanks to TV shows such as CSI the role played by forensic scientist is well-known; these investigators typically focus on understanding the scene of a crime or accident.

The scope of work of the forensic engineer is significantly wider, ranging from understanding the cause and sequence of events of industrial incidents to working to prevent future incidents from occurring. The forensic aspects of engineering are not new, the equivalent of modern forensic engineers have been investigating issues with engineering structures for as long as structures have been falling down. Many of the early pioneers of the modern discipline cut their teeth investigating the failures of bridges such as the Dee railway bridge in 1847 (Lewis & Gagg, 2004) and the Tay Bridge Disaster in 1879 (Lewis & Reynolds, 2002). It was these early investigations that laid the foundations for the modern approach, its analytical tools and techniques such as fractography and mechanical testing as well as the methodologies which modern forensic investigators rely on.

Forensic engineering is considered by many to be the investigation of materials, products, structures or components that fail or do not function as intended, the results being used for legal proceedings.

However, the role has expanded and today forensic engineers are also called upon to add their expertise in a much wider context. Forensic engineers still investigate incidents and issues but often the motivation is for internal learning, to enhance safety, to increase efficiency, to support malignance and asset integrity programmes and prevent similar issues from re-occurring rather than purely to provide evidence to the courts.

The term forensic in our context has now come to refer to the approach, methodologies and tools used rather than just the legal components.

The works of a forensic engineer are often sector specific, i.e. a forensic civil engineer may focus exclusively on issues associated with buildings, bridges or roads etc. Those with subject specific knowledge in for example materials, or more specifically corrosion, have the flexibility to work across sectors although a degree of sector specific knowledge is often required. The oil and gas sector, marine, defence and aerospace are perhaps largest employers of forensic engineers with corrosion specific domain expertise. It is in these sectors that the roles of forensic corrosion engineers have expanded and investigators are given the greatest opportunity to work on preventative as well as issue related projects.

People commonly ask why forensic engineers still have a job when we have so much historical knowledge on how materials and structures perform in service. The truth of the matter is that the world is a complex place filled with unknown variables which can dramatically influence the performance of a given material or system in service. Mother Nature tops the bill of variables with numerous examples of foiling designers plans to tame her: BP Deepwater Horizon blow out (Pritchard & Lacy, 2013) which resulted in loss of 11 lives, an estimated US$50 billion cost, a major environmental disaster and severe damage to BP reputation; the St Francis Dam collapsed (Shepherd, 2003) just hours after final inspection killing 450 people and burying the town of Santa Paula under 20 ft of debris, the Karlino oil eruption in 1980 with its subsequent fire took almost a month to extinguish depleting the majority of Poland’s oil reserves the Birkenhead Dock Disaster (Jarvis, 2011) was a tragedy that happened when a temporary dam collapsed during construction of the Vittoria Dock in Birkenhead killing 14 workers. The Fukushima nuclear accident reminded us all that the world can change very quickly (Wanga & Chena, 2012) and the extent of damage which can be caused is unimaginable until it occurs. While we can control the world around us to an ever increasing degree the forces of nature can, at a moment’s notice, can dominate any man-made construction.

The lesions we have learned from historical investigations are largely responsible for today’s materials and the technology we use in modern designs across all sectors. The forensic corrosion engineer has an important role to play

in mitigating the probability of future incidents and maximising learning from any issues which do occur What does it take to be a Forensic Corrosion Engineer?

Unlike forensic scientists who commonly study a forensic science focused degree at university, academic forensic engineering programmes are much less common. The main reason for this is that forensic engineers generally require a large body of experience in order to be effective.

Therefore it is not common to gain a post as a forensic engineer directly on graduation, rather it is much more common for a forensic engineer to have a higher degree, a string of professional qualifications after their name such as PE, CEng, NACE corrosion specialist, three or more jobs behind them and over 20 years of experience before formally starting a career as a forensic engineer. Forensic engineers need to have both high level subject expertise as well as a broad appreciation of the sector(s) in which they practice. It is for this reason that the profession is generally something we have to aspire to and work towards rather than something we take on at an early stage in our careers.

Just as important as academic qualifications and professional experience, the forensic materials engineer needs to possess a wide range of personal characteristics to deal with the rigours of the work. Perhaps the most important of these are: high ethical standards, uncompromising objectivity, an analytical mind, a methodical personality, excellent communications skills, the ability to translate complex ideas to a lay audience, the flexibility to handle a wide range of projects, the stamina to work to the requirements of a project, the focus required to deliver and the resilience and strength of character needed to stand up to criticisms and questioning. Along with these professional and personal attributes a forensic corrosion engineer also needs a very diverse background, including (Lewis G. L., 2003): n accredited engineering degree and A a subject specific (i.e. materials or corrosion) degree rofessional competence in the P subject area (e.g. materials, metallurgy, corrosion)

December 2013 www.corrosion.com.au p.35

INDUSTRY INSIGHT

Professional qualifications Extensive relevant practical experience Authorship of relevant publications Awards or peer recognition Investigation methodologies Vital to all branches of forensics is the importance of the investigation methods used and the way evidence is collected, handled, analysed and stored. At the most basic level a forensic materials engineer will follow a procedure similar to the MTIS forensic investigation procedureŠ summarised in Figure 1. Each stage of the process is heavily reliant on established procedures, practices and methods. At every stage it is important that the methodology is visible and that all stakeholders are able to trace the methods used to well established practices such as those defined in recognised standards such as ASTM, BSI and API. This is not only to give customers confidence in your findings, but also to protect your position should your findings need to be presented in a legal case.

CAUTION

The aim of the investigation stage (commonly termed field investigation) is to allow actual visual and handson observations at the site of the incident and to collect data and samples for subsequent analysis (Lewis G. L., 2003). Most experienced forensic engineers will engage in the investigation stage (be it in the field or the lab) by first digesting the information that is in front of them.

They will look, observe, identify, photograph, label, smell, touch and otherwise soak-in what information is available before establishing a plan of attack. They will normally have a very healthy fear of the next step, knowing that evidence could be lost or compromised if they move to the next stage of the investigation prematurely. Indeed it is important that all stakeholders are kept informed of the progress of the investigation and consulted, whenever possible, to ensure that evidence is not compromised before other parties have agreed to move forward. It is this need to consult all the key stakeholders before potentially compromising information which it is

CAUTION

CAUTION

one of the key differentiators between forensic engineering investigations and failure investigations. The second fundamental principal of the forensic materials investigation is therefore to consult all key stakeholders and attempt to draw consensus before potentially compromising evidence.

This is one of the main factors which slows the pace and increases the costs of forensic investigations relative to failure investigations which generally aim to uncover the cause of failure for internal purposes.

The second stage commonly focuses on the characterisation of the samples collected, this can take place both on site and in the laboratory, as a consequence the lines between the first two stages are commonly blurred.

At this stage sophisticated tools are often required, on site tools such as required such as ultrasonic, boroscopy, radiography as well as in lab tools such as the scanning electron microscope, spectrometers and mechanical testing machines. Although it may be surprising to some, frequently basic items such as a hand lens, colour charts

CAUTION

CAUTION

What are the expected deliverables

What has already been done

Defining assumptions & constraints

Close up inspection

Mapping the site

Review of documentation  & any case history

Collection of fixed samples

Taking on-site measurements

Taking replicas

Laboratory based characterisation

Fractography

Mechanical Testing

Analysis of findings

Fault tree analysis, FMEA etc

Model / Hypothesis building

Validation of findings

Questioning the evidence

Questioning assumptions

Defining the project

What is the aim of the project

Inspection

Visual inspection from a distance

Collection of samples

Collection of loose sample

Characterisation

CAUTION p.36  CORROSION & MATERIALS

Who are the personnel involved

Discussions with all relevant personnel

CAUTION

Figure 1: Summary of the MTIS Forensic Investigation Process.

Questioning our own findings

CAUTION

Reporting and recommendations

CAUTION

CAUTION

INDUSTRY INSIGHT

or a magnet can provide much of the information needed. When it comes to the characterisation of evidence forensic investigations are different from normal failure investigations in a number of critical ways. As there is always a possibility that a forensic investigation may lead to litigation it is important to preserve the evidence and carry out non-destructive testing only until the various stakeholders have agreed that the parts are not be needed for any further work (Liewis, Reynolds, & Gagg, 2004). This is not to say that destructive (or partially destructive) methods cannot be used, indeed they are frequently required, but rather that they should be used after all other works have been done and the consequences of doing destructive testing are made clear to all stakeholders.

Forensic materials engineers need to have expertise in a wide range of tools, some of these are sector specific such as corrosion coupons and sand probes in the upstream oil and gas sector.

Others are inherent in the materials subject knowledge such as microscopy and X-ray Diffraction. Above all the forensic materials engineer needs to use his own senses in an intelligent way. As Sherlock Holmes said “You see, but you do not observe”, the forensic materials engineer needs to do more than just see the evidence they need to observe and have the curiosity to track these observations back to the root of the issue. It does not matter which tool you are using, from a visual inspection, a metallurgical study or nanometre scale atomic probe microscopy, the key is to recognise what is important, what is real and to have the experience of knowledge needed to eliminate any

observations where confidence cannot be assured. Further, it is essential that they are well versed in the wide range of on-site non-destructive techniques which can provide valuable insights and perhaps more importantly that they appreciate the limitations of these techniques. It is also essential that forensic materials engineers are equally at home in the analytical laboratory as they are in the field. They need to have a strong tool box of characterisation and testing techniques and the expertise to use them appropriately. One of the most common mistakes made in the analytical lab is to put a sample in an expensive piece of equipment, press the needed buttons and take what the machine give you at face value. The forensic materials engineer will not believe the data alone, he will search for corroborating evidence and question the data before using it to formulate a hypotheses. A range of the most common characterisations methods include (for more comprehensive list (MTIS Sdn. Bhd, 2013): igital photography and image D analysis Scanning Electron Microscope Energy Dispersive X-ray Analysis X-ray flourescence X-ray diffraction Electron Backscatter Diffraction Mechanical testing capability Replication techniques (Figure 2)

ptical microscopy and O metallography ractography (Figure 3) and failure F investigation techniques It is the appropriate application of these tools which turns abstract samples into useful pieces of evidence that can help the team piece together a given scenario and understand ALL of the factors which led to the incident.

This leads into the next stage of the investigation which is associated with the analysis of all the findings.

The forensic engineer also needs to be well versed in a wide range of techniques that can be used to help understand the data in the context of the specific project. Tools such as fault tree analysis and failure mode effect analysis can be used to understand data while a wide range of statistical tools can be applied to understand the significance or importance of a given piece of data or hypothesis (Lewis, Reynolds, & Gagg, 2004). It is also important for the forensic engineer to understand the limitations of such pre-scribed methodologies. Many of these tools can be too linear and somewhat inflexible. When using them as a working mechanism, one must always keep active motors running in the background driven on flexibility of thought. Questions, assumptions and postulations all need to be answered and verified. Another important item is common sense. The third fundamental principle of forensic methods is most important here, that the “forensic materials engineers do not believe anything”; not the views of an individual, not a piece of data, not the Some plastic deformation

Secondary cracking

Probable overall direction of crack propagation Figure 2: SEM image of a replication taken from a corrosion pit in a Ti alloy.

Initiation sites and direction of crack propagation

Figure 3: SEM montage of a fracture surface from a 304L failed pipe.

December 2013 www.corrosion.com.au p.37

INDUSTRY INSIGHT

opinion of an expert, not the results of a characterisation experiment or other test. Rather, all information needs to be collected, analysed and validated against all available sources including: other pieces of information, the engineer’s background experience, the available literature, and the views of other experts and against common sense and the investigators instincts. Only then do we consider it to be evidence.

What do Forensic Materials Engineers Do? The work of a forensic engineer in any discipline is demanding and extremely varied, so if you are happiest knowing exactly what you are going to be doing every day then perhaps it is not a profession you should consider. The forensic materials engineer may find themselves working with the design team on a new project one day and carrying out sample collection from a routine maintenance shutdown the next. They could be giving a high level presentations to the ministry in the morning and grinding/polishing the surface of a pipeline in the afternoon, then suddenly they may have to drop everything and take a helicopter to the site of an offshore incident.

The work can be largely divided into the following broad categories: 1. In Design - Providing expertise at the design stage to help mitigate the risk of issues occurring (see Case Study 1). Here an experienced forensic materials engineer is at their most effective as they help prevent future incidents from occurring.

2. In Production - Providing advice to production teams on how changes in the nature of the product, maintenance practices or other aspects that may impact the integrity of the system.

3. In asset integrity -Providing technical assistance and advice during maintenance and inspection periods, to help identify unknown deposits or debris and understand the condition of the facility which can act as an early warning system.

4. Incident Investigation -Post incident investigation of fires, explosions, mechanical failures, leaks, loss of production, environmental contamination or the release of an unknown substance.

5. Failure investigation – Failure of specific components, either on-site extraction and a full investigation or

p.38 CORROSION & MATERIALS

just the laboratory based activities.

This type of project could involve fractography, positive materials identification, mechanical testing, debris or deposit analysis and a wide range of analytical techniques possibly examining samples down to the atomic level.

6. Property Validation - Metallurgical, Mechanical, Chemical or Physical testing of new designs or the materials selected for them in simulated environments and testing novel processes before they are rolled out or proving of hypotheses from an incident investigation.

7. Condition assessment - Supplying process or project performance reviews including scope, schedule, costs and design deviation analysis, schedule delay analysis, and review of construction and commissioning protocols or practices. All of these early stage evaluations can have a major impact on the performance of a system in service; therefore the forensic materials engineer’s views are highly valuable to mitigate the risk of future incidents.

8. Expert Witness - Providing Expert Witness accounts of projects they have worked on or forensic analysis of other people’s works in litigation, warranty claims, arbitrations, mediations and other court proceedings.

The following sections outlines a case studies to illustrate the work of forensic corrosion engineer.

Case study for Role 1 : The role of Forensic Materials Engineering in Design Forensic Materials Engineers have a key role to play in the design processes, in ideal circumstances the forensic corrosion engineer would be brought in to consult on the initial design.

In such circumstances the forensic corrosion engineer would have significant experience in the specific sector. However, it is more common to play a role in the redesign which takes place post incident i.e. when a component or system has failed and the owner of that systems would like a replacement which will not suffer the same fate. In 2011 MTIS Sdn. Bhd was requested to determine the root cause of a failed topside train on an offshore facility. It was found that a leak had occurred at a pipe elbow. The root cause of failure was identified as a complex erosion-corrosion mechanism through on-site investigation,

laboratory analysis of samples collected and validation of the finding through laboratory simulations. As part of the project the customer requested assistance in the exercise which followed to redesign the component to prevent a repeat of the failure.

The first stage was to provide the design team with knowledge of the mechanism of erosion-corrosion through a short training programme. In simplest terms the mechanism is a form of corrosion that is enhanced by the motion of a fluid. The classic examples typically occur at pipe bends (elbows), tube constrictions and features which alter the direction or velocity of the product (Levy, 1995). To occur, erosion-corrosion requires an active corrosion mechanism along with an erosive component which can disrupt the protective film that normally limits the further corrosion.

The erosive component can be either the fluid itself or suspended particles.

In this case the corrosive particles identified were associated with particles of a corrosion product formed in an up stream vessel, Figure 4 show an image of the vessel while Figure 5 shows an SEM image of the particles. Once fresh metal surface was exposed by the actions of the erosive particles the area became anodic with respect to the protected area surrounding it, and, due to the much larger cathode area the eroded area rapidly corroded. The system was inhibited well and so the passive layer regenerated quickly. However the continued action of the erosive particles combined with corrosion thinned area of the elbow (approximately 20cm in diameter) resulted in a pinhole leak at its centre.

The second stage of the project was to carry out an exercises which would allow potential solutions to be generated and evaluated. This exercise required designers, process personnel, corrosion control team and forensic corrosion engineers. The potential solutions considered are summarised in Table 1.

Based on the review, a new inhibition injection point upstream of the vessel where the erosive particles were being generated was recommended.

Enhancement of the inhibition system effectively eliminated the corrosion unit event in that region of the system. While flow assisted erosion of the protective layers still occurred to a degree, it was not sufficient to degrade the protective films and to date no further issues have been observed.

It is important to note that the recommendation was from the entire

INDUSTRY INSIGHT

Figure 4: Digital image of the inside of a corroding vessel which generated the erosive particles.

Figure 5: SEM image of eroding particles created inside the corroding vessel.

Potential Approaches

Advantages

Disadvantages

Comments

Lower fluid velocity (Bozzinia, Ricottib, Boniardic, & Melea, 2003) (aims to lower the impact of the erosive unit event so that normal protection measures are sufficient).

No redesign needed. Mitigates the effect of erosive unit event and should allow the generally effective inhibition practices to prevent further issues.

Undesirable from a process perspective as it would lower the production volume.

Dismissed

Improving the flow lines (focuses on removing burrs, making diameter changes more gradual, more relevant to this work increasing the angle of bends).

Simple if implemented only on the elbow joint.

Would also need to change the flanges and other system elements.

May move flow issues to further down the train.

Dismissed

Change the material used (the use of a more resistant alloy).

Simple to implement and relatively cheap over a small section.

May result in galvanic couples which shift the corrosion issue to none CRA components.

Inhibition system not designed for other materials so may not be as effective.

Dismissed

Application of a protective coating (protective coatings such as boronized surfaces are hard and resistant to erosion).

Simple to apply, relatively cheap, eliminates the effect of erosive unit event and are generally corrosion resistant.

Not tested in the specific environment. Lack of lack experience.

Possible

Remove the erosive particles (solving the corrosion problem upstream will remove the erosive unit event).

Does not require redesign of the elbow or train. Address the upstream corrosion problem and root cause.

Will require (after a separate review) the introduction of a new inhibition injection point.

Possible

Inclusion of impingement plates (effective a sacrificial plate which is used a physical barrier taking the brunt of the erosive particles).

Relatively cheap and quick to introduce. Would effectively remove the erosive unit event.

Would need to review the effects on fluid flow. Would require periodic replacement of plates.

Possible

Changing of inhibition mechanisms (Neville, Ramachandran, & Jovancicevic, 2003) (Neville & Wang, Erosion– corrosion mitigation by corrosion inhibitors—An assessment of mechanisms, 2009).

Relatively cheap and quick to introduce. Will effectively remove the erosive unit event.

Would need to review the effects on fluid flow. Would require periodic replacement of plates.

Possible

Table 1: potential design solutions to prevent future erosion corrosion. multidisciplinary team and the role of the forensic corrosion engineer in such projects is that of an advisor, it is the design engineers, the process engineers and the maintenance team which need to make the decision as together they have the system specific knowledge.

Closing Comments Forensic engineering is an exciting and rewarding profession; however it requires broad based experience and in-depth domain specific knowledge. The domains which Forensic Materials Engineering work in a diverse in their nature and the challenge the present. However, they

provide a valuable service to society by increasing our understanding and helping prevent future environmental disasters and mitigate loss of life.

Dr Andrew Spowage The University of Nottingham, Malaysia Campus

December 2013 www.corrosion.com.au p.39

PROJECT PROFILE

HMB Endeavour Hull Preservation Project Outline The ablative anti-fouling bottom paint on HMB Endeavour, a modernday replica of the vessel that took Captain James Cook on his 1768–71 voyage of discovery, desperately needed attention. Since commissioned in 1994 this 33.3-meter-long (length overall), splendid specimen of Australian maritime heritage has twice circumnavigated the globe, logged more than 170,000 nautical miles, visited 29 countries and numerous Pacific islands, and served as a floating educational museum in more than 100 ports of call. After 20 years of service, the original bottom paint was long overdue for replacement.

Australian National Maritime Museum selected Garden Island Naval Dockyard in Sydney Harbour for the haul out.

The project entailed precise and controlled abrasive blasting. On the basis of a select tender, Favcote Pty Ltd was awarded the task of preparing the hull for a new bottom paint system to be applied by a Thales Australia coatings crew.

Abrasive blasting the native-Australian Jarrah wood (eucalyptus marginata) planked hull presented several challenges. Specifications called for 416-square-meter bottom to be taken down to bare wood to achieve a finish equivalent to that produced by 80- to 120-grit sandpaper. Jarrah wood is tough, but maritime museum officials feared conventional grit blasting might damage the softer between-plank caulking. The project’s tight budget did not allow re-caulking of Endeavour’s hull.

In addition, Endeavour was scheduled

Close up of Sponge blasted timber.

p.40 CORROSION & MATERIALS

to sail in an upcoming Royal Australian Navy Fleet Review as part of their centennial celebration of the fleet’s arrival in Sydney Harbour. With only 10 days to abrasive blast 416 square meters of hull and to apply a sophisticated, multi-layered coating system with significant between-coat cure intervals, there would be no time to erect a typical full blast containment system. Finally, time constraints meant other trades would need access to the vessel and dockyard during the six days allotted for blasting. Producing plumes of abrasive blasting dust was not an option.

Project overseers ran a test to compare two abrasive blast methods. They taped off a pair of one-meter-square areas on the ship’s hull to serve as test patches. On test patch number one, conventional sandblast equipment utilizing garnet blast media removed the bottom paint down to bare Jarrah wood. But close examination revealed inconsistencies in the surface profile and that the blast had removed too much caulking. In addition, the dust levels were too high for blasting without massive containment structures, which would effectively bar other trades and push the project beyond the allotted time span.

Test patch number two was blasted with Sponge-Jet Silver 60 aluminum oxide.

The sponge-encapsulated media acted as a cushion to allow greater control.

Close inspection showed the blast achieved the specified bare-wood profile uniformly and without damaging the caulking. Since sponge-encapsulated media captures and confines 98 percent of typical airborne emissions normally

produced, an elaborate containment system was not required and other tradesmen would be allowed far more site access during the six-day blast.

Sponge-Jet equipment and media distributor, Melbourne based Rezitech, was contracted to provide materials in support of the blast.

Access The ship was hauled out and cradled in a graving dock from which the seawater had been pumped out. The blasting and coating crews accessed the ship’s hull by traversing a set of concrete stairs. Two fixed cranes on opposite sides of the graving dock lowered heavy equipment such as Sponge-Jet blasters and media recyclers; airless spray rigs, 1,224 palletized kilograms of Silver 60 aluminum oxide in 13.6 kilogram bags, and 590 litres of International Paint Ltd antifouling coating system.

At this Garden Island graving dock, a compressed air system runs inside the dock walls. Air-hose attachment points are located every 20 meters around the floor area, so no outside compressors needed to be brought in.

OH&S A risk assessment was performed and job safety analysis created in accordance with Favcote’ safety management system, certified by Det Norske Veritas, to ensure safe and efficient management of the project. Safety concerns, all met, on this project included: earing appropriate PPE including fall W protection gear while working from lifts and scaffolds

Favcote blast operators and ground crew.

PROJECT PROFILE

HMB Endeavour replica in dry dock. reventing injury to those on the P ground, due to objects dropped by those working from lifts and scaffolds, by requiring those working above to use lanyards to secure tools to body dhering to scheduled breaks during A 12-hour shifts, and rotating blast operators Challenges Airborne dust Abrasive sand blasting, the most common way to clean, remove coatings, and provide anchor profiles on ship hulls, decks, bridges, tanks, and compartments, would have required construction of an extensive containment system with limited access. Sand blasting creates dust comprised of crystalline silica and other airborne particulates that have a long history of creating respiratory problems as well as toxins present in the coating or substrate, which may be harmful or fatal when inhaled. Favcote avoided this health issue by using low-dust spongeencapsulated media that produces 98 percent less dust. While blast nozzle operators wore normal air-fed blast hoods, those working close by wore dust masks. Others in the yard and aboard ship were unaffected.

“Sponge-Jet creates little to no dust so most contractors and the ship’s staff were able to continue to work unaffected,” says Lee Woods, Health, safety, environment and quality coordinator for Favcote.

Recycling Fabric catchment tarps were placed under the areas being blasted. Favcote support workers periodically swept piles of spent sponge-encapsulated media and coating residue. The sweepings were sent through a Sponge-Jet

Sponge-jet abrasive blasting. recycler that separates spent media from contaminants. The abrasive media was reused eight or more times, saving money, time, and resources.

The contaminants, and spent abrasive media, were bagged, safely stored, and taken off site by an environmentally certified waste disposal company.

Time Constraints In order to meet the six-day deadline, Favcote senior supervisor Mitchell Harwood created several small crews comprised of abrasive blast nozzle operators and workers that vacuumed, swept, recycled spent abrasive, and operated machinery. Harwood’s approach was to divide the ship’s hull into six sections so that his crews could work independently, yet in a coordinated fashion. This methodology allowed other contractors, such as woodworkers who replaced several small sections of planking up to approximately 300 square centimeters, to know exactly when they could access specific areas, which in turn helped Favcote meet their deadline.

Coatings Multiple Thales Australia crews used airless spray equipment to apply on the hull an International Paint coating system comprising multiple coats Intertuf 203 tar-free vinyl initial coat (approximately 340 litres total), Micron Extra self-polishing anti-fouling paint (approximately 215 litres), and Trilux 33 white-coloured anti-fouling paint (approximately 34 litres) for trim. Care had to be taken to observe the Intertuf 203 recommended overcoating window (8 hours at 25C as per spec sheet). The Thales crews met the four day deadline.

Summary This repair project shows how the careful selection of materials

and processes, such as eschewing conventional abrasives in favor of lowdust, sponge-encapsulated media, can help planners overcome serious time and budget constraints. The project also illustrates how issues such as largescale containment, access to traditional blast zones, and health risks associated with airborne dust near conventional blast zones can present impediments to the timely completion of a project, in this case Endeavour’s participation in the prestigious Royal Australian Navy’s Fleet Review.

Favcote HSEQ coordinator Woods views this high profile project as a great triumph.

“Overall, in my personal opinion, the project was a huge success from start to finish,” Woods says. “The use of sponge encapsulated media was crucial in ensuring that our client’s concerns were met, and on time. From a certified company and inspector’s perspective, it could be seen that all staff involved in the application process were competent in their roles and applied the protective coatings as intended. A very uniform and consistent finish was achieved over the entire mass of the underwater hull.”

Perhaps more importantly, Endeavour Captain John Dikkenberg expressed pleasure with the results.

“It was good to see the ship out of water and restored to this high standard,” Dikkenberg says.

Sponge-jet Product manager John Dingley 0413 902 906 Favcote Managing Director Bruno Favretti 0418252345

December 2013 www.corrosion.com.au p.41

PROJECT PROFILE

Getting it Right – The First Time We all know there is a cost associated with corrosion, but the exact numbers are hard to quantify. Suffice to say there have been plenty of lessons learnt in the past that should enable us to maximise the value of every dollar spent on preventing corrosion.

It is a reasonable estimate that the cost to repair a coating system on site is roughly equal to the original painting price multiplied by a factor of 10. This may not be exact science, and variations and exceptions will occur, but should provide an indicative guide.

One important consideration that is often overlooked when repairs have to be carried out, is that the downtime of an asset can be far more important than the repair cost of the project.

these sections required a full blast to clean the steel and paint with a zinc rich primer and high build epoxy.

This repair job had to be staged to fit within council budgets. Having to split the project into multiple stages cost the client more money overall. A key technical lesson to take from this job is that the corrosivity under the bridge is a lot higher than above due to build up of contaminants. In highly corrosive environments such as these, barrier protection should provide a longer time to first maintenance than sacrificial protection.

This article is a summary of a few case histories, aimed at sharing some of these lessons. These learning’s (not failures) relate to many different aspects of a project, and can hopefully be utilised so these situations can be avoided in the future.

The galvanized steel under the deck was in much worse condition. It should be noted that this is a much more corrosive environment because salt deposits do not get washed off by the rain. The steelwork here will be wetter for longer also, as drying conditions will be much slower than steel exposed to sunlight.

All the sacrificial zinc protection is gone in these areas. The refurbishment of

p.42 CORROSION & MATERIALS

Indoor aquatic centres are challenging environments for sacrificial protection mechanisms. Stair structures are commonly galvanized, and can show signs of both white and red rust within relatively short time frames. Note that these bolts were galvanized (not stainless that was used at the base of the structure). From the photos you can start to appreciate the issues of refurbishment in this environment.

The corrosion is going to continue to develop and the asset will continue to deteriorate. This stair structure is to a water slide tower. Shutting this down for refurbishment will have an impact on revenue generation.

Consider also the costs of rectification, including access, conditions of surface preparation and coating (high humidity). The best option for this structure may well be replacement.

Other trades can also have an impact on the corrosion protection performance of a coating system. Allowing collection points around steel sections will create a corrosion cell. This may have originated from poor caulking, waterproofing, detailing or an incorrect specification.

Collection of pool water can result in corrosion starting under the floor surface, as the coating is being exposed to an environment it was not designed for. Initially, it may show up as a visual issue, but in time it will have structural or safety implications. These are important points to consider in this day and age of public liability insurance.

Again, the cost of rectification, particularly if sections of the floor have to be removed to treat or replace steel surfaces will be high.

Case Study 1.

The first case study is a footbridge on Port Phillip Bay, which was built in the early 2000’s. By 2009, there were some corrosion issues raising their heads.

This structure is right on the foreshore of Port Phillip Bay, copping the brunt of the prevailing west / south west winds over the water and their associated salt deposits.

This bridge consists of painted mild steel arches, galvanized stringers and supporting columns, stainless balustrade and galvanized turnbuckles. The painted mild steel surfaces were in reasonable condition, with isolated corrosion spots on the north - facing areas. In this location during the big northerly winds of summer, this may also get some old fashioned sand blasting. The collection points at the base plates are showing advanced corrosion.

shown in the photo is on a floor plate at the base of a staircase. The galvanized protection on the base plate has been consumed, and now the mild steel is protecting the stainless.

Case Study 2 Indoor aquatic centres present a challenging environment to prevent corrosion. We have potentially highly corrosive environments that can be frequently wet and do not get washed or cleaned with fresh water. Chemicals, which include chlorine, salt or ozone will all contribute to the corrosivity of the pool water. Dissimilar metal contact in these environments results in accelerated corrosion, particularly where the steel is exposed to collection / ponding of the pool water. The example

Galvanizing repair paints are also a potential source of problems. There have been examples of mild steel bracing sprayed with silver paint to make it look like galvanized steel. The problem is that most repair paints in spray cans do not contain high levels of zinc, so their performance will be limited. They should be considered more as a decorative coating than a true protective coating.

In highly corrosive environments like an aquatic centre, material selection

PROJECT PROFILE

and attention to detail during construction is paramount as the refurbishment process is complicated.

If a material is put into an environment it is not suited to, corrosion issues will surface quickly. Refurbishment works inside these types of venues often require the facility to be closed to enable work to be done properly.

Case Study 3 Perforated screens are another problematic situation that come up on a regular basis. There are a few different options for the base material selection, which consist of aluminium, mild steel and galvanized steel. The biggest issue with mild steel, centres around sharp edges and the difficulty in coating them. From the photos you can see the corrosion problem associated with coating this type of surface. This is now a situation that will require ongoing corrosion maintenance.

The best advice for perforated steel depends on what finish is required. If a coating is required, the best result will come from using a powdercoat and an aluminium surface. Otherwise galvanizing perforated mild steel is a viable option if colour is not a requirement, as galvanising gives a better build up on sharp edges compared to liquid coatings.

Case Study 4 Another scenario that has been encountered previously centres on site painting over an aged surface. This may be a refurbishment project, or a new construction which attempts to apply the final coat to steelwork on site after factory priming. The common ground is the time delay between priming and topcoating. One example is where new mild steel was abrasive blasted and had 2 coats of a 3 coat paint system applied in a factory.

The steel was then sent to site where it was erected and a heap of other trades went about their business in the construction of the building. The final topcoat was applied some 6-12 months later and some flaking was evident after a couple of years on some faces. This method was chosen by the builder to minimise handling damage and cut down on costs.

The issue with this technique is the time which elapses between factory painting and site painting. The recoat time of the intermediate coating may have been well and truly exceeded and the surface could have been exposed to all manner of contaminants. Over a 6 to 12 month period an epoxy coating will get baked on a steel surface, particularly over a summer, and may have started chalking. To recoat this aged surface will require substantial cleaning and preparation which should include abrasion and washing. A construction site may have other contaminants on the surface (eg; grout, silicone, etc). Good coatings practice demands the epoxy coating be washed, sanded and re-primed before topcoat application. In some projects, the site painter and construction manager may not have had a lot of exposure to Protective Coatings systems and the demands of achieving specific film builds.

Case Study 5 Balcony edges are another corrosion problem that frequently occurs. A steel section, typically PFC or UB gets used as part of the formwork when a slab is poured. In time the slab can shrink, and a gap forms between the steel and concrete interfaces. This allows water to enter, and a corrosion cell starts. This can result in staining appearing on the roof/soffit section of a residence.

There is a lot of work in repairing these complaints. Tiles have to be removed, concrete / grout chipped away, balustrading removed, safety considerations for working at heights, corrosion removed, coatings applied, water proof membranes and detailing installed and then tiles re-laid.

Compare these costs with an effective waterproof membrane and corrosion protection done properly during the construction program.

Summary In this industry, we are always learning.

The aim of this article is to present some of the lessons from the past, in the hope that it will save money and time in the future.

Daniel McKeown Dulux Protective Coatings

December 2013  www.corrosion.com.au  p.43

PROJECT PROFILE

Case History: Canusa 3-Layer Heat Shrink Sleeve System Used on QSN3 Project ‘It never rains but it pours’

The QSN3 Project required the construction of 940 kilometres x DN450 gas pipeline to loop existing pipelines from Wallumbilla in Queensland to Moomba in South Australia.

The QSN3 (Queensland South Australia NSW) pipeline project was a mammoth construction project with the design aim of transporting greatly increased volumes of coal seam gas to five separate markets:

Epic Energy invited Nacap in an Early Contractor Involvement (ECI) model to assist with the preparation of a budget to build the QSN3 project. The defining benefit of an ECI model is the ability to define scope in some detail and avoid scope surprises down the track.

Brisbane via Roma Brisbane Pipeline Gladstone via Queensland Gas Pipeline Mt Isa via Carpentaria Pipeline delaide via Moomba – Adelaide A Pipeline Sydney via Moomba Sydney Pipeline The Epic Wallumbilla compressor and metering station is now a critical junction and trading hub, receiving gas from 3 major gas fields, Fairview, Spring Gully and Berwyndale.

Designed by Worley Engineering this was a substantial venture given that the overall budget of the project would be equivalent to the net worth of the Epic Energy business at the time of build.

The Epic pipeline coating specification called for Dual Layer Fusion Bond Epoxy Coating (FBE) of 400 microns each to be applied by Bredero Shaw.

I nner layer of FBE to provide corrosion protection uter layer of FBE to provide O mechanical protection

Installing the Canusa GTS-65 Global Transmission Sleeve.

A high performance Field Joint Coating System was required to complement the pipeline coating to provide long life coating integrity.

Accordingly Epic specified the Canusa GTS-65 3-Layer Heat Shrinkable Field Joint Coating System that comprised; orce Cured Epoxy Primer with F controlled and verifiable application thickness eat Shrinkable Sleeve , Crystalline H Hot Melt Adhesive Lined Coating Specification Overview In 3-layer heat shrink sleeve systems, the epoxy primer is the primary corrosion barrier and, as such, is critical and must be applied with application, functionality and long term performance in mind.

Force cured systems have the advantage of being intact and available for inspection and testing prior to sleeve application.

Key Coating Specification Considerations In cold conditions, force cure systems use external heat sources to substantially cure the primer. Wet applied systems have long open times and may never cure properly I n hot environments, force cured systems will cure quickly, as desired.

Wet applied systems are time sensitive and may cure too quickly, resulting in a lack of sleeve adhesion. rior to sleeve application, cured P systems can be inspected for thickness.

Wet primers can thin out at pressure points during sleeve application and will not yield the thickness necessary for adequate corrosion protection. s wet systems rely on the epoxy to A adhere the sleeve to the mainline coating and adhesion of epoxy primers to mainline coatings is highly application sensitive, adhesion loss may occur. This can lead to moisture migration under the sleeve system.

p.44 CORROSION & MATERIALS

PROJECT PROFILE

athodic disbondment (CD) C performance is dependant upon the cured thickness of the primer. A key weakness in wet epoxy primer systems is the inconsistency in primer thickness as it is displaced by the shrinking action of the sleeve around the joint. The inconsistent primer thickness can affect CD performance.

Other local factors which influenced coating selection were: Trials demonstrated that a combined epoxy / sleeve coating was faster than a single layer epoxy coating of approximately 1000 microns thickness. he Canusa sleeve over epoxy joint T coating system was selected as it provided the opportunity to test and validate the cured epoxy layer prior to the application of the sleeve.

I n addition, the epoxy material was tested and exhibited the ability to accommodate the circumferential strain that was calculated to occur during the expansion of the QSN3 light wall pipe under hydrotest conditions. There was no alternative epoxy coating available that could surpass the elastic properties of the Canusa HBE-HT product. his was critically important given T the cracking issues experienced with other epoxy products in the field which have caused real alarm in the pipeline industry. The nominal thickness of the epoxy coating was increased from the standard 150 microns to 300 microns in order to provide a standalone corrosion protection coating that was supplemented and protected by the heat shrink sleeve.

The preferred construction plan from an engineering viewpoint was to commence at Wallumbilla and progress the build west to Moomba aiming for

Flooded trench at Gidgealpa.

80% completion in the dry of 2010 and final completion of the works in the dry of 2011. This permitted a number of suitable windows to get across key obstacles such as the Cooper flood plain. The flood plain being around 15km wide during peak flows.

However, securing external project finance dictated a modified build plan be adopted to deliver an improved financial outcome for Epic Energy and its investors.

It would take months of studying the pros and cons of various options and combinations to eventually settle on the new build plan. This planned build would commence at the Western end of the project, at Moomba with 20% project completion in 2010 and the balance in 2011.

Finances were secured and the project was issued a notice to proceed on the 8th December 2009, on the exact same day that the Weather Bureau reported the formation of a low pressure system near Papua New Guinea.

In a matter of days this system would become a category 5 Cyclone called Laurence and along with cyclones Neville, Magda, Olga, and Ului they would dump near record rainfall in the upper catchment of the Cooper system.

Almost the entire length of the 2010 build section was submerged, with the balance of the right of way severely flood impacted.

These flood events dictated a new build plan, similar to the original build plan. Construction would commence at Wallumbilla and build to the west.

The construction objective was 50% project completion in 2010 and the balance in 2011.

May saw first pipe into stockpile and mainline crews followed in July just in time for the arrival of La Nina. In late

Collapsed Trench at Moomba.

July La Nina swung by twice, once more in August and for good measure once more in September.

As the project team left site in 2010, less than 10% of pipe had been laid and morale was low. Production just had to be accelerated rapidly in 2011 to meet the desired practical completion date of 18 December 2011.

The required increase in production rate meant revisiting and automating the joint coating application.

Discussions with Canusa resulted in the introduction of Induction Heating units at the Pipeline Pre-Heat Station and Epoxy-Cure Station which significantly increased productivity and improved the process with more uniform, consistent and controlled joint temperatures being achieved in a faster and safer manner.

The automation of Field Joint Coating resulted in productivity of 315 Joint completions per day which was an unprecedented number. Accordingly despite the incredible number of hurdles faced in completing this project, Practical Completion occurred 9 days ahead of schedule on 9 December 2011.

Any joint coating undertaking of this size requires a highly collaborative approach from the material supplier, owner, constructor and designer to effect successfully and this project highlighted that the alliance type approach adopted by Canusa CPS, Universal Corrosion Coatings Pty Ltd, Epic Energy Pty Ltd, and Nacap Pty Ltd delivered a win-win outcome for all participants despite the difficulties.

David Anderson: Sales and Marketing Manager, Universal Corrosion Coatings Pty Ltd. Nasa Chaabani: Manager Australasia, Canusa-CPS.

Flooded right of way at Wallumbilla.

December 2013  www.corrosion.com.au  p.45

UNIVERSITY PROFILE

University of New South Wales School of Materials Science and Engineering High temperature research group Introduction The School of Materials Science and Engineering at UNSW is a leading Australian academic unit in research and teaching in materials science and engineering. The school is currently composed of 20 teaching and research academic staff, 35 research only staff including one Federation Fellow, five ARC Future Fellows and 12 other ARC supported fellows, 140 higher degree research students, and about 200 undergraduate students. The School’s research activities are extensive, attracting external funding of over $8m in 2010 and $10.9m in 2011. The fields of Materials Engineering and Materials Chemistry at UNSW were scored highly at 4 and 5, respectively, in the recent national research evaluation (http://www.arc.gov.au/pdf/ ERA_s4.pdf).

The High Temperature Group in the School, is internationally recognised for its mixed gas corrosion research, and is the only group in Australia carrying out this nationally significant work. Research on high temperature alloy corrosion has been conducted at UNSW for many decades. The group has graduated over 50 PhD and Masters students in the last 30 years. It has enjoyed successful collaborations with international research institutes, universities and industries. e.g.

Oak Ridge National Lab, USA; CIRIMAT-ENSIACET, France; Haynes International, USA; Max-PlanckInstitute for Iron Research, Germany; Karl-Winnacker-Institute DECHEMA, Germany; State Key Lab for Corrosion and Protection, Institute of Metal Research (IMR), China.

Research facilities The current High Temperature Group laboratory has excellent facilities, and is widely recognised for its capabilities, particularly in the field of corrosion by mixed gases. These facilities include an arc-melting apparatus, 3 sets of thermogramimetric analysers (TGA), and 4 high temperature tubular reactors equipped with mixed gas

p.46 CORROSION & MATERIALS

control systems. These facilities are used for alloy making, processing and reacting with controlled gas mixtures in either isothermal or cyclic conditions. The School provides strong technical support in alloy melting, sample preparation and metallographic analysis. The group’s research is further enhanced by its close collaboration with the Mark Wainwright Analytical Centre at UNSW, which houses XRD, SEM, TEM, EPMA and FIB facilities.

Corrosion researchers Currently there are three researchers in the group, Professor David Young, Dr Jianqiang Zhang, and Dr Thuan Nguyen. Group leader, Emeritus Professor Young, is an internationally recognised researcher in the field of high temperature corrosion. Dr Jianqiang Zhang has been working in the Group on high temperature materials corrosion since he returned from Max-Planck-Institute for Iron Research in 2003. The two have collaborated closely since then, jointly supervising several PhD students, winning research funding, and publishing extensively. Dr Nguyen joined the research group in 2012 as a post-doc research fellow. Currently, there are three PhD and one Master research students in the group.

Research Projects The principal current research projects are Metal dusting, High temperature corrosion of steel in CO2-rich gases, and Heat-resistant Fe-Ni base alloy design - oxygen solubility and diffusivity determination.

Metal dusting project Metal dusting is a corrosion phenomenon which degrades iron, low and high alloy steels and Ni- or Co-based alloys by disintegration of bulk metals and alloys into metal particles dispersed in a coke mass.

It occurs in strongly carburising gas atmospheres (carbon activity ac > 1), at elevated temperatures (400-800°C).

Metal dusting has caused substantial equipment damage in some important

industrial processes, for example steam reforming, direct iron ore reduction and some petrochemical processes. The aim of this research is to determine the effects of gas and alloy compositions and reaction temperature on dusting reaction rate, graphite nucleation and growth, and formation of metal nano-particles.

This investigation is yielding a detailed understanding of metal dusting mechanisms and thereby leading to an ability to control the process: by altering reaction conditions; properly alloying to achieve more protective surface oxide scale properties; or suppressing graphite nucleation by copper alloying.

CO2-rich gas corrosion This project addresses an important problem of handling hot CO2-rich gas corrosion in coal combustion for power generation. A growing difficulty for Australia is the need to reduce CO2 emissions whilst maintaining the economic advantages of coal fired power stations. Technologies for capturing CO2 from these stations are being developed, but inevitably involve the need to handle hot CO2rich gases. These are surprisingly corrosive to the materials of which power stations are constructed, in a way which is not fully understood.

This project aims to achieve this understanding, and to provide the basis for future alloy design.

Heat-resistant Fe-Ni base alloy design - oxygen solubility and diffusivity determination Engineering alloys and coatings designed for high temperature service are usually based on iron, nickel or cobalt, and contain chromium and/ or aluminium to provide protective oxide scales. To form a protective chromia scale, a critical chromium concentration should be achieved. The required value can be calculated from Wagner’s analysis to be related to the concentration of dissolved oxygen and self-diffusion coefficient of oxygen in the alloy. The aim of this project

UNIVERSITY PROFILE

is to determine the oxygen solubility and permeability in Fe-Ni alloys at high temperatures, which will provide sound foundation necessary to design oxidation resistant alloys.

Internal oxidation zone

martensite martensite

internal carburization zone

intergranular carbides

(1) Weight gain (mg/cm2)

40

9Cr

20

Contact Details For more information on research opportunities, collaboration, and consulting with the High Temperature Group in the School of Materials Science and Engineering, UNSW, please contact Professor Young on d.young@unsw.edu.au, or Dr Zhang on j.q.zhang@unsw.edu.au

0.2Si 0.5Si

0

(2) (a)

0.1Si

9Cr 0.1Si 0.2Si 0.5Si

60

50 µm

Consulting In addition to its research activities, the group also provides consulting to local industries and communities through UNSW Global. All this work has been aimed at identifying reasons for corrosion failures, and recommending ways of avoiding them in the future. Examples include advice on corrosion of metals ranging from murder weapons to sheet metal roofing, but mainly involves assistance to process industries with high temperature materials problems.

0 A

40

80

120 160 Time (h)

200

240

Pt Film Professor Young

scale SiO2 alloy B

200 nm

(b) 6

Fe

0 2

Cr

0 0.8

Doctor Zhang

Si

0 1.2

(3)

(c)

SiO2

O

0 A

(Fe, Cr) oxide

Cr2O3

SiO2

alloy

B

Figure. (1) Carburisation of Fe-9Cr in CO2 gas at 818°C; (2) improving effect of Si on corrosion resistance; and (3) TEM cross-section of Fe-9Cr-0.2Si showing the formation of amorphous SiO2 layer underneath the Cr2O3 scale.

December 2013 www.corrosion.com.au p.47

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