The global corrosion control community has submitted a total of 44 nominations for MP’s 2017 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. Winners will be selected by a panel of corrosion-control experts and announced on March 27, 2017 at CORROSION 2017 in New Orleans, Louisiana.
Technical Toolboxes' new AC Mitigation PowerTool has unlimited pipeline and electric transmission tower lines to fully understand, model, and mitigate underground pipeline AC-induced current/corrosion problems. The AC Mitigation PowerTool has been developed to assist the engineer or technician to model and mitigate or modify the design of pipeline cathodic protection systems in order to reduce the AC current density effects to meet the criteria specified either by a client or the NACE International standard. Key performance indicators (KPIs) are used to determine the detrimental effects of AC corrosion using AC current density. This is an enhanced version of the PRCI field-proven and field-tested computational engine that has been designed to work on current and future “cloud” and mobile devices as well as the traditional desktop/laptop.
View Full DescriptionUntil now, single-pack epoxy coatings have been based on epoxy-ester resins, which are not as robust as true amine-cured epoxy coatings, or have been based on epoxy resins and latent hardeners, which require a bake cure and therefore are not practical for most protective and marine coating applications. Amercoat One is a new epoxy coating technology that allows for true epoxy-amine curing in a single-pack product, eliminating certain disadvantages of traditional two-component epoxy technology such as mix-ratio errors, pot life problems, and wasteful packaging, while retaining the performance benefits of a true amine-cured epoxy coating.
View Full DescriptionAmerican Innovations launched the Bullhorn RM4210 remote monitoring unit in October 2015. The RM4210 helps operators identify areas where AC may be a source of corrosion, ensure that AC mitigation systems are working correctly, and quickly know when AC current density conditions change so that mitigation systems can be adjusted. The potential for induced AC corrosion is increasing as more pipelines are being located alongside high-voltage power lines. The RM4210 helps operators mitigate this risk by measuring AC and DC coupon current density, AC and DC pipe-to-soil, native pipe-to-soil, instant off, and AC current drain. These measurements are automatically uploaded via satellite communication to Bullhorn Web, a Web-based asset manager. Bullhorn Web generates detailed reports that make it easy to identify problem areas, see current density trends, and prove that the mitigation systems are working efficiently. Should conditions change, as they often do with high-voltage power lines, the RM4210 will send an immediate alert via email, text message, and/or Bullhorn Web. Other benefits of the RM4210 include:
An unfortunate side effect of the metal recycling process is the inevitable concentration of micro-contaminants that occurs with each generation, particularly in recycled steel. Today’s high-tech coatings don’t fail, surfaces fail.
Rust removers, acid etching, and inhibitors are used—with mixed results—to meet visual cleanliness inspection requirements prior to coating. Finicky dehumidification steps and reblasting are often required to maintain cleanliness long enough to coat large surfaces. Dry or wet abrasive blasting, ultra-high pressure water jetting, rust removers, inhibitors, and acid etch products are not capable of removing non-soluble contaminants, such as iron sulfides, from metal. Water soluble iron salts (chlorides) that form strong ionic bonds with these non-water soluble iron sulfides also remain, creating the "seeds" for corrosion cells. These seeds eventually bloom and cause extensive premature coating failure.
CleanWirx makes rust removers, acid etching, and inhibitors redundant. It not only deep cleans, inhibits rust, removes mill scale and decontaminates surfaces beyond the visual level, but also destroys seeds of corrosion by removing non-water soluble and soluble corrosion generators (reactive sites) to "hold the blast" more effectively (i.e. macroscopic and microscopic levels).
CleanWirx integrates easily into existing corrosion control procedures, and allows them to forego dehumidification, inhibitors, and repeated blasting. Large projects (such as refinery tanks) can be completed in half the time and for drastically reduced cost, because CleanWirx allows surface prep, cleaning, and coating to be performed in uninterrupted progression. Contractors cover around 2,000 ft² of prepared surface per day using CleanWirx.
Field testing and SEM analysis of CleanWirx treated surfaces confirms the product’s proven ability to significantly enhance coating adhesion, remove micro-contaminants, and improve welding sites to achieve a uniformly receptive surface for coating. CleanWirx has been proven to pass metal hygiene inspections the first time—even in extreme-contamination situations where multiple blast attempts and other methods have failed.
View Full DescriptionSewer corrosion is caused by bacteria turning dissolved sulfate in sewage into hydrogen sulfide (H₂S), which is subsequently transferred to sewer air and converted into sulfuric acid (H₂SO₄) at the concrete surfaces. H₂SO₄ is highly corrosive to the concrete pipes and structures used in the majority of sewer networks. As an example, sewer corrosion costs the U.S. economy US$13.75 billion per annum. Cloevis is a low-cost and effective method for prevention of sewer corrosion for water utilities and municipalities.
Since 2002, the sewer research group at the University of Queensland has been carrying out extensive research in the area of sewer odor and corrosion. In 2010, Zhiguo Yuan and Guangming Jiang made a groundbreaking discovery of the effectiveness of free nitrous acid (FNA) in the deactivation and removal of the biofilms that produce H₂S in sewers. It was quickly realized that this breakthrough could produce significant cost savings in the management of sewer corrosion. In addition to direct cost savings, users will also see environment benefits from lower volumes of chemicals needed, reduced greenhouse gas emissions and improved retention of organic carbon necessary for nutrient removal at the downstream wastewater treatment plants.
In 2011, Cloevis was spun-out from the university as a commercial venture led by UniQuest Pty., Ltd., one of Australia's leading university commercialization companies. Cloevis has a strategic partnership with USP Technologies Ltd, to take the technology to the U.S. market. During 2011-2015, full-scale trials and demonstrations of Cloevis technology have been successfully accomplished in both Australia and the USA. To date, Cloevis has been fully developed into a sewer corrosion control technology through removing H₂S producing biofilms. USP Technologies is currently providing the Cloevis biofilm removal service at six sites in the USA with the potential for 20 sites by the end of 2016.
View Full DescriptionThe DFT Smart Bee from Apellix is a software-controlled Unmanned Aerial Vehicle (UAV aka “drone”) system for SSPC-PA2 spot thickness measurement of dry coating thickness (DFT). The DFT Smart Bee consists of 1) a base station with a portable computing device (laptop or tablet or similar), a high-resolution video display (and optional first person view goggles), optional power supply, and optional tether; 2) an aircraft (UAV/drone) with attached sensors, video camera, DFT probe; and 3) specialized software with embedded systems for flight control and communications of the DFT measurements.
The system operator is able to fly the UAV close to a location where the desired DFT reading is to be taken and then, with computer assisted augmentation, fly to the location where the attached wand/probe touches the surface for 2 to 5 seconds and collect a DFT millage thickness measurement. The DFT thickness measurement is recorded (along with the video record if desired). The DFT spot measurement reading/data is in compliance with SSPC-PA2, where three gauge measurements are taken and averaged for each recorded spot measurement. In addition, the raw data from the measurements (and averages) are made available as part of the process (for compliance and audit purposes).
View Full DescriptionCorrosion Djinn™ is easy-to-use software available online and as an App for iOS and Android that helps engineers and designers make sound material choices in design and maintenance by predicting and quantifying galvanic corrosion risk at material interfaces. Galvanic corrosion is the primary corrosion mechanism in multi-material systems such as aircraft, especially Naval aircraft, where 80% of structural failures result from cracks initiated at corrosion pits.
Recent R&D clearly demonstrates that galvanic corrosion rate is determined by corrosion current (kinetics), not by the potential difference, ΔE, between members of the galvanic series. Yet the presently accepted method of estimating galvanic corrosion severity, called out in industry and military specifications, is based on ΔE. We have found that the galvanic potential approach sometimes reverses the expected galvanic corrosion severities, leading engineers to choose the worst galvanic couple rather than the best, even in quite common assemblies. The resulting poor choices of materials, coatings, and sealants create billions of dollars of unnecessary maintenance cost in the Department of Defense alone.
Corrosion Djinn™ calculates self-corrosion and galvanic corrosion current/rate using a new curated, consistent electrochemical database of qualified material polarization curves. It can be used with little or no training, and takes only a minute or two (quicker than looking up ΔE in tables, and orders of magnitude faster than making complex finite element calculations). While galvanic tables contain only generic materials, the Corrosion Djinn™ Electrochemical Database provides data from specific modern alloys, coatings, and surface treatments, and can be readily updated with any specific material or coating that users need.
This is a new paradigm for the industry that will significantly reduce corrosion damage and maintenance cost, while improving system safety and time-on-wing. Although developed for aircraft, it is already being used in general industry, electronics, and automotive.
View Full DescriptionTechnical Toolboxes' new Pipeline Corrosion PowerTool is a steady-state multiphase simulator that integrates corrosion analyses from a comprehensive set of corrosion models together with relevant flow parameters to predict, identify, and assess the locations of highest likely risk or damage. The Pipeline Corrosion PowerTool provides corrosion engineering assessments to design a mitigation and monitoring program. Key performance indicators (KPIs) are used to determine detrimental flow conditions. These indicators include predicted corrosion rates (influenced by sour gas contaminants, oxygen, microbial induced corrosion, iron carbonate scaling, organic acids, temperature, glycol, etc.), remaining pipe life, water accumulation, and erosional velocity. Per NACE methodology, KPIs are assessed by regions that are defined by the user on the basis of relevant pipeline parameters such as the elevation profile, flow pattern, holdup, wall thickness, and predicted corrosion. This assessment enables the engineer to identify the necessary mitigation and monitoring to be taken to reduce and control the likelihood of internal corrosion.
View Full DescriptionMost protective coatings are applied as liquids to sufficiently prepared surfaces either by brush, roller, or spray. This is becoming less acceptable in the industry for safety and environmental reasons; therefore containment of the work area is inevitable.
Using non-crosslinked polymer technology, popularly known as visco-elastics, it has been possible to work on an idea of creating a coating that is applied as foils, therefore eliminating any need for spray or other methods of application. The concept comes from wallpaper application that is also self-adhesive.
View Full DescriptionModumetal is manufacturing and supplying an entirely new class of metals and materials for corrosion control on fasteners, pipes, valves, and pumps among many other applications. This innovative coating is stronger, lighter, more corrosion resistant and durable than conventional steels and comparative conventional coatings. Using a process called nano-lamination, Modumetal produces a coating—think metallic plywood—comprised of layers that are nanometers in thickness. This method, combined with the innovation that allows the ability to control the interface between layers, enables Modumetal to engineer coatings with superior properties using the same basic infrastructure as traditional electroplating. Nanolayering optimizes the structural and corrosion performance of coatings, which offers immediate benefits, such as reduced maintenance, enhanced lifespan, lower risk, and infrastructure reliability and integrity.
View Full DescriptionPipeline operators perform test station surveys on a regular basis. This leads to vast quantities of handwritten field notes that need to be later digitally transcribed into an operating company’s pipeline integrity management database. The Cath-Tech CorrReader was designed to electronically capture test station cathodic protection (CP) survey data, which eliminates the need for handwritten field notes and facilitates electronic records keeping practices. The unit has a user-friendly, intuitive interface allowing nontechnical personnel to gather quality CP data.
The CorrReader has a fully integrated internal GPS to synchronize with GPS current interrupters, allowing the operator to capture the “on” and instant “off” pipe-to-soil potential readings, along with any AC that may be on the structure, and log the data to memory. The CorrReader also stores date, time, GPS coordinates, altitude, etc., along with operator comments for each and every reading. Charge, programming, and download are all via USB.
All data files are in CSV format that can be opened in Excel or readily imported into any pipeline integrity database. Graphs can easily be generated, no special software required. Regulatory compliance documentation at a corporate level is more robust as the pipeline operator can prove precisely what date and time each reading was recorded.
The CorrReader has been on the market since early 2014 and is used by numerous pipeline operators and contractors around the world.
View Full DescriptionThe CorTalk® uDL2 micro data logger is a high-accuracy, two-channel instrument utilized for testing cathodic protection (CP) coupons, test stations, critical bonds, and AC mitigation systems. The device can log the potential and current density effects from varying soil conditions, and the influence from AC transmission lines, telluric events, and stray currents from external sources such as pipeline crossings or electric rail interference. A small physical size of 3.5 by 1.6 by 0.72 in allows the device to easily fit inside most standard CP test stations. An integral current detector with a coupon interruption relay allows direct measurement of coupon AC current and coupon DC protection current. A high impedance reference cell input provides structure-to-cell DC potential, induced AC voltage, and coupon instant-disconnect DC potential measurements. Each measurement channel is lightning and surge protected. Measurement storage capacity of 2,000,000 timestamped readings and an internal rechargeable battery allow the device to capture readings for up to four months. An internal GPS receiver provides an accurate time reference and records the geolocation coordinates of the field test location. A USB connection to a PC provides user configuration control, data uploading, and battery charging. A PC application provides a chart graphical preview of logged data, which can be exported to analytical applications and spreadsheets in a CSV data format.
View Full DescriptionSprinkler pipe corrosion is a serious threat for organizations that rely on wet sprinkler systems to protect their facilities. Internal corrosion, resulting in the formation of localized pinholes, leads not only to costly damage from leaks, but catastrophic losses when compromised sprinkler systems are rendered inoperable during a fire. Under the law of simple physics, air migrates through wet sprinkler piping to the highest points of the system, where it accumulates in pockets under compression due to the water pressure in the system. “Trapped air pockets” are commonplace in wet sprinkler systems due to the complexities of pitching and/or maintaining a proper continuous sprinkler piping slope. Hence, the majority of corrosion in wet sprinkler systems occurs at the oxygen-water interface on the pipe walls of the trapped air pockets.
Prior to the introduction of the DeOx™- DeOxygenation System to the fire protection industry, there had not been a single turn-key solution to address both the oxygen within the trapped air pockets and the dissolved oxygen within the fill water. As part of a simple three-step process, the DeOx™ System pre-purges the sprinkler piping with 99.5% pure nitrogen gas, then fills it with deoxygenated water (1.0 ppm or less dissolved oxygen). Pre-purging the sprinkler piping with nitrogen displaces the oxygen from within the trapped air pockets. And by charging the piping with deoxygenated water, 1.0 ppm or less of dissolved oxygen remains in constant contact with the steel sprinkler piping. 1.0 ppm or less dissolved oxygen within the water is below the threshold of oxygen proven to cause corrosion. It also means that there is a limited amount of dissolved oxygen available to dissipate (outgas) from the water into the trapped nitrogen (formerly air) pockets—protecting the sprinkler piping areas that would have otherwise corroded in the past.
View Full DescriptionImpressed current cathodic protection (ICCP) systems are in widespread use for their effectiveness in protecting steel piling and concrete columns and beams. But in long structures, such as wharves and bridges, limited space and access has mandated that traditional ICCP systems most often be mounted at each end of the structure. This requires a significant cost in copper cabling and associated installation hardware, such as cable trays, which can impact on project cost and sometimes even feasibility.
A new technology developed by Omniflex is allowing such systems to be installed with significant reductions in installation cost while, at the same time, drastically increasing the number of controllable zones of protection and level of control of each zone.
By designing “smart” TR modules with real-time communications built to the core, it has been possible to implement some very large CP systems with unprecedented levels of remote monitoring and control. By placing new smart TRs with multiple independent controllable outputs close to the elements being protected, copper cable has been reduced to a minimum, the number of independently controllable zones of protection increased, and real-time monitoring and control enhanced.
The communication infrastructure extends from each transformer/rectifier zone and reference half-cell right up to the Web services that monitor these systems in real time. This in turn allows full remote monitoring and control of each zone and fully automated CP testing to be implemented in accordance with the international standards, further reducing life cycle costs and increasing assurance of levels of protection. This technology has brought the new “Internet of things” to the world of corrosion protection.
View Full DescriptionCorrosion in the fire sprinkler industry, and the added costs associated with system repair and damage to building contents, has become an ever growing concern for both building owners and fire sprinkler contractors. This added awareness has resulted in the rapid growth of the corrosion management business in the industry, with providers offering a range of potential solutions ranging from chemical corrosion inhibitors to nitrogen-based inerting solutions. As corrosion prevention becomes a more critical component of the fire sprinkler industry, corrosion monitoring is a very important element in a comprehensive corrosion management strategy. An effective corrosion monitoring program should provide evidence that the corrosion control program is working to prevent metal degradation.
The ECS In-Line Corrosion Detector is designed to provide an early warning indication of internal corrosion activity in water-based fire protection systems. A cross-section of the device shows the two key attributes that allow for early detection of corrosion: an externally milled section of the pipe that creates a 35 mil (0.035 in) “thin wall” section and a pressure chamber created by an external sleeve welded over the pipe. The ECS In-Line Corrosion Detector is equipped with a pressure switch to monitor the pressure chamber, so when corrosion penetrates the milled section of the detector, the pressure switch detects system pressure and activates.
The device is designed to be installed where corrosion is most likely to occur: the air/water interface. In wet pipe fire sprinkler systems, this area is generally found on high branch lines where trapped air is present. In dry pipe fire sprinkler systems, this area is generally found on low mains where trapped water is present. The thin wall section of the device will fail before other system components are damaged to the point of needing replacement, allowing corrective action to be taken.
View Full DescriptionFORCE Technology Field Gradient Sensor (FiGS) is a state-of-the-art, non-contact CP inspection tool that performs highly accurate measurements of electric currents in seawater, with a resolution and detection level that surpasses all other sensors available on the market. The sensitivity enables the identification of corrosion problems and the characterization of CP system status on pipelines and subsea structures, even when buried. Accurate field gradient data from FiGS combined with FORCE Technology’s proprietary CP computer modelling expertise will give our clients confirmation of a protected structure. Design codes are usually overly conservative when calculating the steel current density, and using real values in retrofit CP designs have demonstrated typical cost savings of 50%.
Surveys with FiGS are carried out with remotely operated vehicles (ROVs) as the price of oil is dropping, and the push for cost-saving subsea operations is at an all-time high. Subsea vehicles are now moving toward automation with longer, faster subsea surveys, avoiding the heavy vessels and equipment required for ROV operations. FiGS is the only CP tool on the market today that offers non-contact CP inspection suitable for autonomous vehicles.
The FiGS technology has proven substantial cost savings on several levels, from more efficient and quicker inspections, to eliminating the use of divers and excavation of buried or covered structures. The high quality mapping of field gradient data offered by FiGS has opened possibilities, not only to predict the future performance and degradation of a CP system, thereby reducing the frequency of inspections, but also to pinpoint areas of interest offering only necessary and coordinated intervention. Due to the added value and cost saving potential, several customers have now established FiGS as their preferred CP inspection tool, for everything from baseline to standard periodic and life extension surveys.
View Full DescriptionIn this study, two styles of surface topographies were created on stainless steel wires to test their corrosion resistance as simulated implanted biomedical devices. It was found that surfaces with patterns have a relatively higher pitting potential and it takes longer time to initiate stable pitting than the surface without any patterns. No inhibitor or chemicals or coatings were used on the surface and the improved corrosion performance was achieved just by surface design.
View Full DescriptionIntegrity Plugz™ inspection ports are designed to provide safe, repeatable, and reliable alternatives to traditional methods for accessing insulated pipes, tanks, and vessels to perform various types of nondestructive testing (NDT). The Integrity Plugz were designed to help protect against the risk of corrosion under insulation (CUI) and increase the integrity of the insulation system. The key design features are the flexible metal skeleton embedded in the silicone edge trim and the tight precision fit of the cover. These two design elements allow the Integrity Plugz to conform to various shapes and curvatures and still maintain a watertight seal. Integrity Plugz can also withstand significant impacts while still maintaining its seal, thus mitigating water ingress and reducing CUI risks. Other advantages include ease of installation and access (initial installation can take as little as a few minutes, with only hand tools), safe access (once in place, no sharp metal edges are left exposed), and conformability (product can be installed on bends/curved surfaces). Integrity Plugz form an integral part of a CUI mitigation strategy when considering and planning how to perform various types of NDT on insulated systems.
View Full DescriptionThis work aims to develop a nondestructive testing (NDT) device able to characterize the stress corrosion cracking (SCC) in bolts made of stainless AISI 304 steel. This device performs magnetic scans on the bolts and uses Hall effect sensors to identify eventual distortions of the lines of the magnetic field surrounding the screw. This equipment makes it possible to determine the temporal evolution of the SCC phenomenon, which is common in bolts, as well as any associated microstructural alteration.
View Full DescriptionAmerican Innovations, protecting people and the environment with compliance solutions for the oil and gas industry, released the MicroMax GPS350 in March 2015. The new GPS-synchronized current interrupter builds on the capabilities of the GPS300 by integrating a normally closed AC/DC solid-state relay that can interrupt up to 60 amps with on/off cycles of less than 4 seconds, and 80 A with 4 second cycles or longer. Six key benefits of the new MicroMax GPS350 current interrupter:
This environmentally friendly multi-functional surface passivation treatment (MPT) has been developed to provide galvanized steels with outstanding corrosion resistance, surface lubricity for downstream metal forming applications, and other favorable properties. The MPT is applied onto galvanized steel sheets by rolling or spraying to rapidly form a thin hybrid film (~1 μm) that is highly water-resistant to prevent water/dissolved corrosive species from attacking the metal surface during transit or storage. Non-toxic corrosion inhibitors incorporated in the film provide a "self-repairing" characteristic, and water-dispersible polymeric additives provide excellent lubrication property and other favorable properties to the galvanized steel surface. The MPT technology also enables downstream users to achieve a significant cost reduction by eliminating the use of metal forming oils and degreasing chemicals and by minimizing the resulting wastewater treatment cost. The MPT products were launched into the market in 2015.
View Full DescriptionMidstream oil and gas pipelines are wasting millions of dollars each year on traditional internal corrosion programs. Even with a corrosion program in place, these pipelines still suffer from corrosion. U.S. Water’s new approach to pipeline integrity combines innovative multifunctional chemistries, mechanical pigging, and automation in a new way to get and keep the pipeline clean and corrosion essentially eliminated. This process is combined with industry-leading monitoring to ensure integrity is maintained.
View Full DescriptionNew advancements in Fischer’s phase-sensitive eddy current technology have produced a new probe, ESD20-TSA. It was designed specifically for nondestructive measurement of thermal spray aluminum (TSA) directly over nonferrous metals (i.e. stainless steel and aluminum).
TSA is a thick coating over metal used to prevent stress corrosion on offshore construction and other parts exposed to corrosive salt water and harsh environmental conditions. Correct thickness of the TSA coating is critical for its long-term corrosion preventive qualities.
Previously, traditional methods of measuring TSA over stainless steel (SS) were costly and cumbersome. Phase-sensitive eddy current is a unique test method using differences in electrical conductivity of distinct material layers to accurately measure metals applied to metals. The following applications can be done easily and accurately with the PHASCOPE® PMP10 and the new ESD20-TSA probe:
Phase-sensitive eddy current makes it possible to measure TSA coatings on both carbon and non-magnetic SS with a single device. The advantage of phase-sensitive eddy current probes is excellent repeatability. They are able to measure rough coatings, rough substrates, curved parts, and measure lift off. Readings can be taken individually or according to SSPC-PA2 specifications.
The ESD20-TSA probe is available from any Fischer Group location around the world.
View Full DescriptionPhosZero™ cooling water treatment products provide maximum scale and corrosion protection without the use of phosphorus, eliminating phosphorus discharge to the environment and enhancing system sustainability.
View Full DescriptionPneubotics has developed a pneumatically controlled robotic manipulator that is truly mobile due to its being fabricated from lightweight plastic and actuated only with air. To create this new type of robot, we reimagined our approach to automation. Instead of costly motors and drivetrains, we utilize air and high-compliance materials with advanced sensing and control. The Pneubotics tool is constructed out of high-strength plastics and composites that have five times the strength-to-weight ratios of steel. All of this translates into a powerful smart tool that can blast, sand, and paint a surface, yet is light enough to be carried by a single person and mounted onto existing lifts.
View Full DescriptionThe Restorer is a patented hand-held or bench top multi-surface restoration tool that can be used to buff, sand, grind, polish, scrub, or clean any surface while vacuuming up the debris. Redeem the old, restore like new and recreate with the Restorer. The Restorer is able to accomplish a variety of tasks that typically require the use of many different hand tools and power tools, including work done by hand. Its design makes the Restorer very balanced and compact for maneuvering in tight areas and around tough obstacles. The Restorer can be fitted with any type of roller from ScotchBrite—to wire wheel and everything in between. The pistol grip design allows the operator to control the tool with one hand or use the front palm grip to work vertically or overhead. Simply connect a vacuum source to the output of the Restorer to safely and effectively clear away all debris that is being removed from the surface during usage.
View Full DescriptionSurface replicas obtained using Testex™ Tape contain far more information than just peak height as measured by a micrometer. Significant data are available through digital imaging. The patented PosiTector RTR-P uses imaging sensors to measure the peak density (Pd) information contained in replica tape in addition to peak height.
Advanced models are able to generate two-dimensional (2-D) and three-dimensional (3-D) images and a surface data file (SDF) of the replicated surface. Black-and-white 2D and color 3D images are ideal for inclusion into reports and for confirming a consistent blast profile. A high-resolution SDF can be imported into third-party rendering software for further examination at a cost far less than interferometric or confocal profiling devices.
View Full DescriptionCurrently, AD Chemicals, a subdivision of the Dutch AD, International launched a revolutionary new product on the global grit/sand blasting market. This product is called PreCoat F31/20 and is suitable for the treatment of substrate steel. PreCoat Z31/20 treats aluminum and galvanized steel substrates. PreCoat is a chemical treatment applied directly after grit/sand blasting or metallization (also referred to as metal spraying). This product portfolio is the result of an R&D trajectory of more than eight years. PreCoat F31/20 and Z31/20 significantly improve the quality of sandblasted or metallized products. It has two main benefits; by applying the product directly after grit/sand blasting, a conversion layer is created that substantially improves the adhesion of the painting system (suitable for wet painting and powder coating) and significantly enhances the corrosion-protection resistance properties of the paint system as a whole. The application procedure of PreCoat is very easy and can be easily integrated in every business process.
The innovative aspect of these products is that it combines the worlds of grit/sand blasting and chemical pretreatment. A metal surface treatment of grit blasting ensures a uniformly cleaned surface and good paint adhesion but lacks corrosion resistance on the substrate.
PreCoat F31/20 and Z31/20 are based on PreCoat Z31, a product that won the Dutch Innovation Award for surface treatment, ION Borghardt Award 2016.
AD Chemicals is introducing this product on the worldwide market. The first user responses are very promising. A large grit/sand blasting company in The Netherlands stated: “With this product I am able to improve to overall quality of my products and therefore offer my customers more value. It is a tool to distinguish myself in a competitive market place.”
As products are better protected against corrosion, the product lifetime increases and thereby lowers the ecological footprint.
View Full DescriptionCorrosive naphthenic acids and sulfur compounds in crude oils present a major challenge for refineries from a corrosion perspective. According to traditional wisdom, naphthenic acid corrosion does not leave any solid corrosion product on steel surface and some sulfur compounds may form protective iron sulfide (FeS) layers and deter corrosion. However, attempting to correlate the characteristics of FeS scale with its protective properties has not been successful.
In this innovation, it was found that a protective layer composed of iron oxide (Fe₃O₄) was formed in naphthenic acid corrosion due to thermal decomposition of the corrosion product iron naphthenate. A method was established to determine and identify this protective layer against corrosion by crude oils and crude oil fractions. This method identifies naphthenic acids that indirectly provide corrosion protection. A method assessing the potential of these constituents is also disclosed. The method includes exposing metal coupons with fluid of interest at the expected operating temperature of concern. The corrosion potential assessment further analyzes the exposed coupons with transmission electron microscopy and an additional high-temperature exposure that challenges the tenacity of the protection offered by the iron oxide layer.
View Full DescriptionEcoshield 386 is a revolutionary single component waterborne coating that will meet 1,000 h of salt spray performance at 1 mil (25 µm) dry film thickness through the use the innovative use of nano-vpci corrosion inhibitor chemistry combined with non-hazardous contact inhibitors. This new product is low in volatile organic compounds (VOCs), hazardous air pollutants (HAPS) free, fast drying, and can be applied via spray, brush, roll, or dip. It comes standard in a high gloss clear; however, it can be custom color matched to any color.
View Full DescriptionSchlumberger Microbial InstaCheck is a rapid, inexpensive, easy-to-use, portable onsite method for detecting total living aerobic and anaerobic bacteria populations. The method measures living bacteria metabolism that has been calibrated to provide a measure of bacteria populations. The method does not require an incubator or refrigerator. A small airline carry-on size case can carry enough supplies to conduct hundreds of assays. The method has be proven, approved, and used offshore. The method has proven to be highly accurate, compatible with all production, raw water fracking fluids, and chemicals. It can be used to isolate the location of a bacteria population, and assess the effectiveness of treatment or biocide applications. The method has received U.S. Environmental Protection Agency approval for drinking water, and has been tested for accuracy in over 500 unique oil and gas applications. Unlike other methods, standard or known bacteria populations can be run with each test to ensure assay accuracy. Using Microbial InstaCheck biocide can be screened for compatibility and effectiveness in one day. Microbial InstaCheck removes the guess work out of biocide applications and allows the end user to measure the bacteria populations, monitor the effectiveness of a treatment in real time, and control the use of biocides based on their effects on the bacteria populations.
View Full DescriptionThe Luna Sensor Suite for Aircraft Corrosion Monitoring (LS2A) is a wired or wireless sensor node capable of autonomously monitoring environmental and corrosivity parameters to determine the atmospheric severity of difficult-to-access regions within airframes. The technology uses both commercial off-the-shelf and novel sensor elements to monitor a set of parameters and provide an ISO-9223 classification of the environment’s corrosivity. In addition to providing a high-level environmental severity classification, the nodes maintain all raw sensor data with internal storage for future access and engineering analysis. Data from the sensor nodes can be accessed via RS-485 wired or 802.15.4 wireless interfaces.
Corrosion prevention and control plays a major role in maintaining existing military and commercial air fleets. Rising ownership costs of aging aircraft due to corrosion inspection, maintenance, and repair necessitates an efficient means of tracking the severity and cumulative corrosivity that an aircraft experiences. By tracking environmental severity and corrosion within targeted areas of airframes and identifying daily, seasonal, and operational patterns of exposure, maintainers may reduce total cost of ownership, increase aircraft efficiency, and improve overall fleet reliability.
View Full DescriptionThe Elcometer 130 Soluble Salt Profiler (SSP) provides fast and accurate measurement of the level and density of soluble salts on steel surfaces. The SSP allows a Bresle equivalent test to be completed in just over two minutes. The multipoint conductivity sensors enable the Elcometer 130 SSP to accurately display salt concentration, show exactly where the contamination lies, and generate full color salt density maps in two or three dimensions.
In addition to soluble salt levels (cleanliness) or conductivity, the SSP carries out a detailed analysis of the test area—providing an accurate salt density profile map and pinpointing areas of high contamination outside user defined limits.
This new, easy-to-use Elcometer 130 SSP has automatic temperature compensation to ensure accuracy in all climatic conditions. Impure water can be offset for accurate and repeatable readings. The SSP wirelessly transmits readings, statistics, and batches via Bluetooth® or a USB cable directly to an inspection application or into ElcoMaster®, Elcometer’s Mobile App, for instant report generation at a desk or in the field with a mobile device.
A Calibration Verification Tile is available for verifying the accuracy of the gauge in the field. The verification date is recorded for use in reports.
Key features of the Soluble Salt Profiler include:
The innovation consists of three unique aspects:
This innovation (integrated 50-KPI template, online course, and industry benchmark) is effective to indicate status of “corrosion control” in an industry and to improve its performance as well as to educate next-generation corrosion professionals on all aspects of corrosion.
View Full DescriptionOur patent-pending technology provides the capability for scalable and affordable manufacturing of metal-based, super-water-repellent (superhydrophobic) coatings. This technology offers a new paradigm in corrosion protection by preventing water, as one of the main contributors in the corrosion process, from sticking to a surface. The laboratory test results for one of our coating products exhibits corrosion resistance around four times higher when compared to an existing anticorrosion coating made from the same metal. In addition, the large-scale manufacturing of our coatings has an affordable and easy-to-adopt route using widely available electroplating facilities in the industry. Therefore, compared to the existing metal-based coatings, our coatings provide higher corrosion protection in a reasonable range of price and can extend the service life of different operating equipment such as heat exchangers.
View Full DescriptionThe purpose of this experiment is to evaluate the effectiveness of eight different types of coatings in conjunction with 16 different preparation methods. I varied the cleaning of heavily corroded coupons from SSPC-SP2 to SSPC-SP10. I also used commercially available products to remove chlorides as well as prime the surface of the plain carbon steel samples.
View Full DescriptionEffective corrosion protection from a reduced load zinc-rich primer blended with carbon nanotubes and nanoscale carbon such as fullerene and/or graphene applied via a wet-on-wet process.
View Full DescriptionThis nomination presents the Thermoflex® DownHole Pipe (DHP) that was developed and qualified by Polyflow for rehabilitation of corroded carbon steel downhole tubing. Thermoflex DHP is made with polyvinylidene fluoride (PVDF) and aramid fiber reinforcement layers. PVDF is fully compatible with crudes and a wide range of chemicals used in oil field at temperatures up to 100 °C. Aramid fiber reinforcement has high strength-to-weight ratio, creep strength, fatigue resistance, and aging resistance to the downhole conditions. Thermoflex® RTP tubing is fully resistant to corrosion and is capable of handling high CO₂ and H₂S fluids. Couplings and fittings are made with Duplex 2205, a NACE MR0175-listed sour service material.
The method of rehabilitating corroded steel downhole tubing is to run Thermoflex® DHP into the existing steel tubing with packers at the top and bottom. After the DHP reaches the target position, packers are engaged to seal off the corroded portion of existing steel tubing. The Thermoflex® DHP provides the new flow path for bore fluid, and it is capable of containing the full bore pressure without support from existing steel tubing.
Thermoflex® DHP can be spooled and delivered in continuous lengths of up to 2,000 ft, which enables fast field deployment with readily available equipment, such as micro coil tubing units. It can be made into a standard downhole tubing repair kit to enable repair of breached steel tubing quickly. The benefits of minimizing production down time and extending the life of aged wells are drawing more and more attention from operators around the world.
View Full DescriptionThe Tracker LT is a cellular-based remote monitoring device designed specifically for critical bond monitoring applications. It combines compact size with a cellular data packetizing scheme that makes monitoring at bonds and “mid-point” areas on pipelines cost effective.
View Full DescriptionAn Internet of Things device to accurately measure changes in an asset’s wall thickness due to corrosion or erosion using ultrasound and cellular data connectivity.
View Full DescriptionFor years, metal coupons have been used for measuring the level of cathodic protection (CP) of buried or submerged structures such as pipelines, steel pylons, jetties, etc. CP coupons are typically installed near the structure that is being protected and their leads terminated at an aboveground access point often referred to as a test station. In theory, by connecting the coupon to the CP system via the structure, the coupon mimics an exposed area of the structure such as a surface defect or coating holiday. Traditional coupon potential measurements are not always consistent or representative of what the structure is actually experiencing and the reliability of coupon test stations and the data they acquire are often in question. Consequently, proper maintenance planning and risk mitigation objectives are difficult to achieve.
The UT CP Test Station solves this problem by directly measuring the amount of coupon metal loss through the use of ultrasound transducers imbedded inside of metal coupons. The innovation of imbedded thickness measurement transducers augments traditional coupons by providing an increased level of measurement precision while maintaining the ability to provide traditional test station information. Consequently, a direct measure rather than an inferred measured of rate of material loss is provided. Both potential measurements and metal thickness measurements are acquired by the UT CP Test Station. As a result, the UT CP Test Station data are easily incorporated into existing corrosion prevention and control activities. The thickness of the coupon can be measured at any time with a suitable ultrasound pulser/receiver instrument at the test station. There are a number of significant cost and operational advantages inherent in the use of an UT CP Test Station in addition to the significance of data accuracy and measurement precision—all factors that provide significant industry benefits.
View Full DescriptionThe Tracker is a remote test station monitor with data-logging capability designed specifically for monitoring induced alternating current (AC) interference on buried pipelines. It is battery operated, uses cellular or satellite communication, and provides all of the critical data necessary for ongoing monitoring of AC interference and mitigation effectiveness. Measurements include: direct current (DC) voltage potential, AC voltage potential, protected coupon “instant disconnect” potential, unprotected coupon voltage potential, AC current density using a dedicated coupon, DC current density on the protected coupon, and AC drain current from a decoupling device (if used). The Tracker records and stores all values at up to every 15 s (once per hour is the typical application), sends measurements on a periodic schedule (typically weekly), overrides the reporting schedule to alert of any alarm condition upon occurrence, and provides the capability of downloading any or all logged data from the device over the air.
View Full DescriptionRivertop Renewables is simplifying and dramatically improving corrosion inhibition in industrial water treatment with Waterline CI. The product offers an entirely unique set of improvements over existing corrosion inhibition programs: it is high performing, cost-effective, and entirely sustainable.
Rivertop’s product is based on a breakthrough oxidation technology that efficiently converts renewable plant sugars into valuable sugar acids with applications in dozens of industries. Rivertop began full commercial production in 2016 and, for the first time, is producing sugar di-acids at previously unattainable cost levels that can support bulk consumer and industrial market applications. Waterline® CI can be co-formulated with, or entirely replace, corrosion inhibitors that rely on phosphorous and heavy metals, easing the transition away from regulated chemistries that are widely used today.
Waterline CI forms a persistent, passivating film on steel and galvanized surfaces. It provides protection and versatility across a wide array of cooling water conditions and treatment formulations. The product maintains high performance at low and high pH, and in water with both low and high levels of hardness. Phosphorous-based chemistries can be ineffective in high pH and low hardness waters and must be co-formulated with stabilizing polymers to operate effectively in high hardness.
The wide range of operating conditions in which Waterline CI performs enables its use without complex formulation. The unprecedented simplicity of formulations based on Waterline CI creates a performance advantage that also extends to the bottom line by enabling lower total operating costs.
The chemistry behind Rivertop’s Waterline is the first and only corrosion inhibitor to be qualified by the U.S. Environmental Protection Agency (EPA) as safer than traditionally used chemical ingredients and has been placed on the EPA’s Safer Chemical Ingredients List. This designation enables formulators to secure the Safer Choice label for end products sold to industry and consumers.
View Full DescriptionOil and gas companies need to innovate to maintain a competitive edge. The challenges for materials application in Petroleum Development Oman (PDO) move up several degrees owing to a high concentration of hydrogen sulfide (H₂S), extremely high chloride levels, high pressures, and temperatures all the way into uncharted territory. Due to the potential high severity consequences of any loss-of-containment incident, it is vital to ensure that facilities’ designs are in compliance with a “no leak” policy. This “goal zero” target requires a robust design and that represents a challenge for the material selection and corrosion management discipline.
Traditionally, downhole material selection was based on vendor recommendations and limited material performance data. In addition, the primary data inputs used for concept selection of major oil and gas projects were inadequate for accurate downhole material selection and design. Therefore conservatism is applied to the design to ensure equipment integrity and safety resulting in over-specification and over-design with associated cost impact on well completion materials.
An innovative approach was used to conduct comprehensive material compliance evaluation of gas wells across PDO assets. The approach is a well-by-well assessment that reviews material suitability for past, current, and future conditions for all the well related components. A pragmatic approach has been used to define operating envelopes for downhole materials through systematic and comprehensive material performance evaluation. The recommended changes as part of this study showed savings of more than $500 million in capital expenditure (CAPEX) savings over next five years for PDO and the country of Oman.
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