Your hard work and commitment to the development of corrosion mitigation solutions are an important contribution to corrosion control and the protection of vital assets from its damaging effects.
In July 2014, the global corrosion control community submitted a total of 21 nominations for its third annual Corrosion Innovation of the Year
Awards. The program provides a forum for NACE International members and customers to showcase their corrosion mitigation technologies and receive recognition for their innovative solutions.
Corrosion Control Category: Coatings and Linings
Recipient: Hempel Protective R&D Group
Website: www.hempel.com
Organic zinc-rich primers are an established technology used to protect steel from corrosion. In these zinc-rich coating systems, the zinc anode is engineered by using very high levels of zinc dust as a pigment in the coating film. However, because high amounts of zinc are normally necessary to attain good corrosion protection, there is often a negative impact on the mechanical and adhesion properties of the coating. The formulation of organic zinc-rich primers is critical for successful corrosion protection provided by the cathodic protection (CP) of the overall coating system.
Hempel has discovered a novel technique that relies on the combination of zinc dust, hollow glass spheres, and a proprietary activator. The new activated zinc technology was launched in the market in 2014 as part the AvantGuard product series with the ambition of redefining anticorrosion. The activation of the zinc in the organic zinc-rich primers is shown to greatly improve the CP of steel, and the use of hollow glass spheres improves the barrier properties and crack resistance of the film. This technology uses decreased volumes of zinc dust, which enhances the mechanical performance of the coating. Moreover, the glass spheres have an inhibiting effect by acting as a surface for the formation of insoluble complexes of zinc, oxygen, and chloride. Activated zinc-rich organic primers offer a unique corrosion protection product that combines excellent CP with chloride ion inhibition, low water permeability, and improved crack resistance compared to current organic zinc-rich primers.
Corrosion Control Category: Materials Design
Recipients: Michael P. Brady, Yukinori Yamamoto, Bruce A. Pint, Govindarajan Muralidharan, Philip J. Maziasz, Oak Ridge National Laboratory, Materials Science and Technology Division, Oak Ridge, Tennessee, United States
John H. Magee, Samuel J. Kernion, David A. Helmick, Timothy R. Armstrong, Carpenter Technology Corporation, Reading, Pennsylvania, United States
Websites: www.ornl.gov and www.cartech.com
Alumina-forming austenitic (AFA) stainless steels (SS) are a new class of high-temperature alloy family that offers superior high-temperature corrosion resistance in many industrially relevant environments. AFA SS deliver this uniquely superior corrosion resistance with creep strengths in the range of advanced austenitics, and without sacrificing the typical lower cost, formability, and weldability of conventional high-temperature SS. Their outstanding corrosion resistance results from the formation of a protective aluminum oxide (alumina, Al2O3) surface layer, which permits use at higher temperatures and for longer time periods than conventional chromium oxide (chromia, Cr2O3)-forming SS and, in some cases, nickel-base alloys. These unique attributes of AFA SS make them highly desirable for a wide range of energy production, chemical, and process industry applications, where the use of more durable materials capable of withstanding higher temperatures can result in significant cost and energy savings as well as reductions in environmental emissions. The AFA alloy family is based on five U.S. patents (issued from 2010 to 2014) and includes several wrought, carbide-strengthened grades that are now available in pre-commercial product forms from Carpenter Technology Corporation, as well as a new AFA grade designed for cast product forms, and a γ’-Ni3Al strengthened Fe-base superalloy grade.
Corrosion Control Category: Coatings and Linings
Recipients:Tony Collins, Sameer Patel, EonCoat LLC, Pompano Beach, Florida, United States
Website: www.eoncoat.com
EonCoat is a two-part, spray-applied coating that combines acids and bases to form ceramics at room temperature. The technology provides the ultimate in corrosion protection for carbon steel. The coating phosphates the steel in the presence of an alkali and creates an amorphous layer of iron-magnesium phosphate. This iron-magnesium phosphate barrier, which is chemically bonded to the steel, is highly resistant to corrosion, and is permanent. On top of this passive layer, a layer of ceramic made almost entirely of inhibitive pigments is formed. In the unlikely event that both the ceramic and the passive layers are breached, and a corrosion spot occurs, the coating offers a self-healing feature—the ceramic layer will continually leach phosphate onto the surface of the metal. This phosphate will do two things to stop corrosion and prevent further corrosion: 1) it combines with any iron oxide to form iron phosphate that arrests corrosion, and 2) it acts as a catalyst to create the delta form of FeOOH (misawite; feroxyhyte). If a layer of misawite forms on the surface of steel, it creates a barrier that reduces the rate of further corrosion by many orders of magnitude.
Corrosion Control Category: Cathodic Protection
Recipients: Ken Reindel, Dan Huslig, Chris Jones, Randall Sears, American Innovations, Austin, Texas, United States
Website: www.aiworldwide.com/micromax
The MicroMax® GPS300 is American Innovations’ latest generation portable, GPS-synchronized current interrupter, designed specifically for cathodic protection (CP) surveys. Conceived and built on customer input, as well as the success of prior generation MicroMax interrupters, the GPS300—first and foremost—is simple to use. It can be programmed using a straightforward built-in keypad or via USB interface. Using AI’s BAT™ tools, technicians can configure their survey interruption template just once (e.g., in their office, hotel room, or on-site) and BAT™ tools will apply this exact template consistently across all interrupters. Users can store and use up to nine different interruption configurations. This ease-of-use greatly reduces programming errors, as well as preparation and installation time, freeing users to do the real work of surveying assets and collecting data. Additionally, the MicroMax GPS300 is simple—programmable using a built-in keypad or via USB interface; rugged—able to withstand the most extreme treatment and weather conditions; small—fits easily inside rectifiers; reliable—powered from either an AC or DC source, common in rectifiers; flexible—accommodates any interruption schedule, with continuous, daily, dated, and interference modes (our unique interference mode helps operators determine the influence of each CP source on the structure under test, whether their own or another operator’s); smart—built with AC zero crossing interruption synchronization that switches when AC voltage is at zero volts (this lowers stress on rectifiers and interruption switch components, decreasing the possibility of rectifier and solid state relay failure); compatible—works with existing MicroMax interrupters, AI’s RM4010 and RM4150 remote monitors, and other GPS-based interrupters; complementary—seamlessly interacts with our Allegro Field Data Computer, Bullhorn Remote Monitoring System, and Pipeline Compliance System; and compliant—the GPS300’s complex functionality ensures operators comply with U.S. Department of Transportation regulations Title 49 CFR, Parts 192 and 195.
Corrosion Control Category: Integrity Assessment
Recipients: Kamalu Koenig, Ph.D.Structural Integrity Associates, Inc.Centennial, Colorado, United States
Owen Malinowski, Structural Integrity Associates, Inc.State College, Pennsylvania, United States
Brian Carlson and Tyler PowellDiakont, San Diego, California, United States
Websites: www.structint.com and www.diakont.com
Structural Integrity (SI), working with strategic partner Diakont, developed a novel pulsed eddy current sensor (SIPEC™) and integrated this sensor with a robotic inline inspection (R-ILI) tool. This sensor has several advantages including improved spatial resolution and improved signal-to-noise ratio relative to comparable technologies. SIPEC™ also has the ability to acquire data while in motion (dynamic data acquisition). The delivery vehicle for the SIPEC™ is Diakont’s RODIS R-ILI crawler. The RODIS robotic crawler contains dual base tracks for navigation on horizontal surfaces and a single top track that can be extended to push against the inside of the pipe wall for stabilization. This single top track provides the necessary traction for holding the crawler rigidly in place while inspecting difficult pipe geometries. Using this robust traction system, the RODIS robotic crawler can navigate difficult-to-assess applications where conventional ILI tools may not be feasible and direct access to the internal surface of the pipe (including internally corroded and lined piping) is difficult or impossible. The technology is capable of assessing for internal or external corrosion without the sensor making direct contact with the pipeline surface (operating with sensor liftoff of up to 0.625 in [15.8 mm]), making it ideal for inspecting piping with internal liners, significant internal corrosion, or scale buildup.
Corrosion Control Category: Coatings and Linings
Recipients: Anis Rahman, Ph.D., Aunik K. Rahman, Applied Research & Photonics, Inc.Harrisburg, Pennsylvania, United States
Kenneth B. Tator, P.E., KTA-Tator, Inc.Pittsburgh, Pennsylvania, United States
Website: arphotonics.net
The Applied Research & Photonics (ARP) terahertz instrumentation measures corrosion, as well as industrial and commercial coating thickness. A nondestructive, noncontact means of characterizing corrosion beneath a coating and/or coating layers’ thicknesses is accomplished by interrogating a coating system with terahertz radiation (T-ray) and utilizing the interferograms resulting from coherent and diffused reflections from different constituent layers as a function of the delay-time response at specific angle(s) of incidence. The layer-specific thicknesses are deduced by analyzing the interferograms in conjunction with the interference peak positions and some empirical modeling.
Corrosion Control Category: Cathodic Protection
Recipients: Jordan Groody, Jerome Edinger, Bass Engineering, Longview, Texas, United States
Website: www.bass-eng.com/catalog.php?id=200
The TRITON® is the first coupon test station on the market to offer technically sound AC and DC coupons in an independent package that can be easily installed independent of test station location. Every feature, from the heavy duty test switch to the bonded zinc anode terminal, is designed to make the TRITON® durable, easy to install, and easy to use. A clearly labeled faceplate makes field measurement easy. Recessed banana plug terminals prevent accidental contact with an energized pipeline. A heavy duty mil-spec disconnect switch provides a durable connection. A 1-cm2 AC coupon is suitable for accurately determining AC current density. A 100-cm2 test coupon is suitable for measuring “on” and “instant off” potentials. A 100-cm2 native coupon is suitable for measuring true “native” potentials. Custom external markings allow easy field identification. A stationary copper/copper sulfate (Cu/CuSO4) reference electrode incorporated into the design provides measurement of “IR free” coupon potentials. A preinstalled #6 AWG THHN primary pipeline connection and bonding strap allows quick connection of the zinc anode or other AC current drain. A #10 AWG THHN secondary pipeline connection is preinstalled for testing “on” pipeline potentials.
Corrosion Control Category: Other -- Data Acquisition and Monitoring
Recipients: Dan Hughes, Karl Gemperli, Jamey Hilleary, Elecsys Corporation, Olathe, Kansas, United States
Website: www.elecsyscorp.com/solutions/wireless-remote-monitoring/Sentralink-CP.html
The Elecsys Watchdog SentraLink CP monitoring system is a breakthrough concept in remote monitoring for cathodic protection (CP) applications. There are many remote field sites where CP data acquisition is needed along with data typically produced by specialized sensors (pressure, tank levels, strain gauges, corrosion probes, gas detection, etc.). The Watchdog SentraLink CP combines two voltage measurement inputs for measuring CP values (rectifier voltage, rectifier current, structure-to-soil potential), with two sensor/transducer input channels. Each of the sensor/transducer channels may be used with 4 to 20 mA, 0 to 5 V, or 0 to 10 V transducers in two-wire or three-wire configurations. The SentraLink CP provides a 24-V excitation signal to the transducers, and the duration of excitation is programmable in order to accommodate any sensor. Applications for the SentraLink CP include well site monitoring (monitor casing rectifier voltage, rectifier current, and tank levels for storage and waste tanks); gas storage well monitoring (monitor rectifier or pipe-to-soil potential and pressure); and test stations and cased crossings, in particular, where potential measurements and corrosion rate measurements (derived from ER or LRP probes) are used in conjunction with one another for pipeline integrity management.
