Corrosion Innovation Awards Nominees for 2019

The Corrosion Innovation Awards program provides a forum for NACE International members and customers to showcase their corrosion mitigation technologies and receive recognition for their innovative solutions. Winners from among these finalists will be selected by a panel of corrosion control experts and announced on March 25, 2019, at CORROSION 2019 in Nashville, Tennessee, USA.

Adjustable Atmospheric Corrosion Test Rack

Category: Testing
Nominee: University of Alaska  Anchorage

Modular and adjustable atmospheric corrosion tests were designed and installed on the roof of the University of Alaska’s Engineering Parking Garage. Racks were 46 in by 46 in (1,168.4 mm by 1,168.4 mm) and can be adjusted to three different angles (0°, 30°, 45° to the horizontal), similar to a car hood. The angle of exposure affects the snow/ice retention, and this leads to the formation of varying thicknesses of moisture on metal surface. The angle of exposure also affects the wash off from rain, and this could change the atmospheric corrosion mechanisms. This rack helps in identifying the weather parameters by isolating the corrosion inducing variables and their primary effect on corrosion in extreme cold climates.

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AIMaps - Pipeline Asset Management Platform

Category: Other–Corrosion Database and Analytics Software
Nominee: AIMaps, Inc.

AIMaps is a cloud-based and on-premise corrosion control database and analytical software solution. The solution allows users to monitor all aspects of corrosion, i.e. cathodic protection, internal corrosion monitoring, and atmospheric corrosion, with web-based, desktop, and mobile applications. The product streamlines a corrosion department’s workflow while providing a user-friendly and intuitive software that integrates an easy-to-use control center, navigable and interactive map, project management, and a business intelligence data visualization reporting tool, along with the ability to work offline for those users in remote areas. AIMaps aims to bring the oil and gas corrosion industry into the 21st century.

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Bonded Brackets on Coated Substrates

Category: Other–Secondary steel
Nominee: Muehlhan AG; Fraunhofer  IGP

Welding for subsequent joining of brackets onto fully coated surfaces (for example repair purposes, modification of equipment or subsequent fittings) is not an ideal solution mainly because of the high efforts for preparation and post-processing, as well as the heat load transferred into the surrounding steel as well as to the coating system. In order to decrease costs, time, and effort, and not to compromise the corrosion protection system, an innovative process has been developed using high-performance adhesives. Brackets, and any attachments, are mounted directly to the topcoat without harming the coating or substrate. Part of the procedure is a nondestructive test that confirms the required adhesion to the particular coating system.

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Ceramic Protection for Harsh Environments

Category: Coatings & Linings
Nominee: CIDETEC Surface  Engineering

A cutting-edge technology based on novel ceramic coating protection has been developed for metal components (carbon steel, stainless steel, high and cast alloys), including long and narrow tubes, subjected to industrial extreme conditions. This innovative technology has been developed by CIDETEC side by side with KERACOAT, CIDETEC’s spinoff focused on tailor made ceramic formulations initially for the oil, gas, and power generation sectors. This technological approach gives an efficient and environmental friendly solution, protecting components from critical degradation and keeping the energetic efficiency by avoiding fouling and corrosion phenomena. The whole coating process is completely covered due to associated technological services developed to guarantee industrial needs such as on-site welding and repairs in order to avoid weak areas, where corrosion mechanism could accelerate degradation processes.

The ceramic coating protection is supported by a suitable thickness (±150 μm) and chemical bonding to the metal substrate, with a glassy and smooth surface avoiding ashes, sub-products and liquids fouling and corrosion degradation. Easy to clean properties, high emissivity, chemical resistance to the most common industrial acids and salts products (hot and cold) and thermally resistant up to 800 °C (metal substrate temperature) combined with a high abrasion resistance and hardness (64HRc - 840Hv) are also key properties for this ceramic protection technology.

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Clamp‐On-Ammeter to Measure Current Through Flow Line

Category: Cathodic Protection
Nominee: Saudi Aramco

Cathodic protection usually using a device called the Swain Meter  associated with a 12-in (304.8 mm) ring to measure the current passing  through the flow line. This devices is very expensive and very sensitive, and we face many problems with the cable necking or the device malfunctioning.  Thus, we are suggesting to have another solution to measure the flow line current by the Clamp-On-Ammeter. To do that, we need to install an insulation  flange at the flow line in the wellhead area, or install reinforced  thermoplastic pipe spool and connect a small jumper cable between the two insulated parts of the flow lines and measure the current flowing through the jumper cable by the Clamp-On-Ammeter.

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Connectionless Electrical Pulse Response Analysis (CEPRA) Method

Category: Testing
Nominee: Giatec Scientific

The corrosion rate of rebar in concrete traditionally has been determined using polarization methods such as the potentiostatic, galvanostatic, or potentiodynamic techniques. These techniques are rather slow, and all require having an electrical connection to the rebar, which in turn requires damaging the concrete cover. Therefore, despite the satisfactory accuracy, these techniques have been rarely used for civil engineering structures.

The recently developed Connectionless Electrical Pulse Response Analysis (CEPRA) method eliminates the need to have a rebar connection and allows the determination of corrosion rate in less than 10 seconds per measurement. This enables the user to perform corrosion investigations with minimal disruption to the concrete element and also decreases the time required to inspect large structures. The method is based on using a Wenner array probe (a four-point probe) along the rebar under consideration and monitoring the potential difference between the two inner probes following the application of a step voltage from the outer probes. Using the potential difference between the two inner probes, the characteristics of the system, including the concrete resistivity and the polarization resistance/corrosion rate can be determined using a circuit model. The technique has been commercialized as a hand-held device (iCOR) and has been used in several laboratory and field studies, in which its accuracy has been found to be similar to other well-established methods.

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Controlled and Regulated Power Outputs from a Free Piston Stirling Engine

Category: Cathodic Protection
Nominee: Qnergy

The Qnergy Free Piston Stirling engine technology was initially developed for deep space exploration and tactical military applications, where it performed remarkably well, providing anywhere from just a few hundred watts to more than 5 kW of power. The power control system has since been modified to provide remote power generation solutions specifically for the power needs of the water and wastewater, oil and gas, and marine rectifier requirements. By providing controlled and regulated grid-quality AC power, it can be used on any remote location to provide seamless and uninterrupted power as if it were connected directly to the electrical utility grid.

One specific application where the Qnergy Free Piston Stirling Engine is being widely utilized is for powering AC rectifiers at well sites and pipeline locations. Being that the Stirling engine technology can be installed at a lower cost than competing remote power solutions, there is an appreciable growth of this generating technology at rectifier locations. With automatic power modulation capabilities, these systems can increase power output, as the need for additional current grows without the need to add more expensive hardware. And with a life expectancy of 10 years of continuous operation, the Qnergy Free Piston Stirling engines are a reliable and economic long-term solution for new and existing rectifier applications.

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corTalk RMU1 Remote Monitor

Category: Cathodic Protection
Nominee: Mobiltex Technologies Inc.

The RMU1 is an ideal solution for automated remote monitoring of CP coupon probes and critical bonds terminated in an industry standard 3-in (76.2 mm) test station head. A CP coupon probe emulates a void in a structure’s protective coating; measuring current density and potential parameters on coupons can yield valuable information about the cathodic protection levels on the structure. The RMU1 is equipped with an internal interruption relay and analog measurement channels capable of accurately measuring AC/DC current density and potentials for single coupon, dual coupon, and structure bond applications. Measurement data is remotely accessible through an intuitive Internet web interface called corView, where it can be analyzed using graphical tools.

Prior to the RMU1, corrosion technicians would have to travel to coupon sites to take manual readings or install bulky, power-hungry remote monitoring equipment. Manually reading coupons does not generate data sets with sufficient measurement frequency, and it can also be wrought with errors and measurement method inconsistencies. Prior existing remote monitoring equipment was usually installed in external enclosures next to the test station and required solar panels or some other form of external power supply. Battery operated equipment used volatile battery chemistries that were large and transport limited.

The RMU1 solved these issues with its small innovative package and the use of modern power-efficient electronics. The accuracy of measurement across the rated temperature range is superb, giving reliable data sets. Small standard batteries are used to power the unit beyond 10 years in most configurations and are easily sourced locally when replacements are needed. Its small size allows the unit to be installed directly in the test station head, yielding a simple innocuous-looking installation that does not attract vandalism. The satellite or cellular transceiver and antenna for transporting data to the web service are integral to the unit.

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CP Automated Anode Monitoring System for Vessel Internal

Category: Cathodic Protection
Nominee: Saudi Aramco

Embodiments of systems and methods for providing cathodic protection to a fluid-containing vessel include measuring two distinct voltages at a junction box exterior to the fluid-containing vessel. The first voltage is measured across a shunt in the junction box, such that a current magnitude through the shunt can be determined using Ohm’s Law that is representative of a current output of one or more sacrificial anodes disposed within the fluid-containing vessel. The second voltage is measured by depressing a push button of a momentary switch to open the switch and interrupt current flow through the shunt. The second voltage is representative of a voltage difference between the one or more sacrificial anodes and the wall of the fluid-containing vessel.

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CP Monitoring Using Automated Waveforms

Category: Cathodic Protection
Nominee: Taku Engineering, LLC

Cathodic protection (CP) monitoring data is periodically collected and used to compare against recognized NACE International criteria for adequate cathodic protection. However, techniques widely used for cathodic protection monitoring generally do not allow for the collection of accurate and consistent data. Additionally, unlike most other types of regulatory monitoring, most CP data currently collected is not repeatable, nor does it result in the production of traceable and verifiable documentation. The use of Automated Waveform Analysis during CP surveys produces accurate and repeatable data. It also can be used to produce traceable quality documents for regulatory verification.  Automated waveform evaluation produces data that more accurately accounts for IR (voltage) drop and can serve as a predictor of the true level of polarization afforded a buried structure.

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CUI Monitoring System

Category: Other–Monitoring
Nominee: CorrosionRADAR Ltd.

CorrosionRADAR (CR), a spin-out of Cranfield University (Bedford, United Kingdom), is pioneering a novel distributed sensing approach to corrosion monitoring (patent pending) which is especially suited to the problem of early indication of locations of hidden corrosion such as corrosion under Insulation (CUI). These sensors are in the form factor of a thin, long, and flexible waveguide and are embedded within the insulation near the external surface of a pipe or vessel. The CR sensors have an outermost sacrificial metallic layer which corrode itself in the presence of water, in a similar way to the pipe surface. The CR sensors are activated using microwave guided radar signals along the long sensor, and time-of-flight of wave reflections locate the presence of corrosion and also water near the sensor along the pipe length. It uses industrial internet of things (IIoT) systems to ensure information collected by these sensors are able to be accessed, stored and processed remotely. CR technology enables predictive maintenance to CUI, and the collected data is highly valuable to the risk-based inspection methodologies.

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Derakane Signia Resins for FRP

Category: Materials Design
Nominee: Ashland LLC

Introduced in 1965 to combat corrosion in hot, wet, chlorine environments, Derakane epoxy vinyl ester resins have become the industry standard for corrosion resistance in fiber-reinforced polymer (FRP) equipment. High-performing derivatives have been introduced over the years to allow vinyl ester solutions for expanded chemical environments, high-temperature performance, and areas requiring improved toughness.

Assurance of corrosion performance is critical to users and specifiers of FRP equipment. Since the Derakane Signia polymer backbone is the same compared to previous Derakane products, asset owners and engineers can be assured that all previous Derakane corrosion studies, historical data, and field case histories remain relevant to demonstrate performance for their design requirements. Moreover, Derakane Signia offers the first identifiable resin system. Samples or cutouts of finished FRP articles can be evaluated to validate the materials supplied and delivered were the materials specified on a project.

Today, many FRP fabricators are challenged with finding and retaining qualified, experienced operators to meet current demands. Anticipating these needs, Derakane Signia resins were designed to deliver improved processing characteristics driving faster laminate consolidation, lower foaming, and greatly reduced sanding for application of secondary laminations. These benefits, combined with reduced styrene emissions and less odor in finished parts, lead to the availability of better, more efficiently produced and more environmentally friendly FRP equipment.

Derakane Signia resins provide significant advantages for fabricators, designing engineers, and the owners and end users of corrosion-resistant FRP equipment. Benefits in the FRP shop include low styrene emissions, improved shop efficiency, and longer shelf life, while benefits in the field include an unchanged polymer backbone and an identifiable resin system. With the introduction of Derakane Signia, Ashland has leveraged new production capabilities to modernize resin features including improved environmental performance, better workability, increased workplace conditions, and worker satisfaction. These features help construct higher quality and identifiable FRP piping and vessels for corrosive environments.

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Environmentally Friendly Corrosion Inhibitor

Category: Coatings & Linings
Nominee: Lanotec Australia Pty  Ltd; Lanotec Asia Pacific Pte Ltd

Lanotec Australia Pty Ltd produces a range of high-performance lanolin-based, biodegradable, and environmentally friendly corrosion inhibitors and lubricants, as well as industrial strength degreasers made from a blend of organic solvents and surfactants.

Lanotec Heavy Duty Liquid Lanolin (HD) is extremely versatile and efficient, produced from a renewable source. It is also a major contributor to the reduction of petrochemical consumables and maintenance costs while addressing health, safety, and environmental (HSE) issues. HD contains a barrier (an evaporative paraffin) used to liquefy the lanolin grease for ease of application and penetration. The carrier evaporates in approximately one hour at ambient temperature, leaving behind a microfilm (natural wax) of lanolin for corrosion protection and lubrication.

In June 2018, HD was awarded the prestigious Global Green Tag certification relating to sustainable development and green-certified products.

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Evolution–A New Isolation Method

Category: Cathodic Protection
Nominee: GPT Industries

For over 50 years, pipelines have been isolated for galvanic corrosion and cathodic protection by gaskets made of plastic laminates. As pipeline pressures, temperatures, media types, and H2S content have increased, these laminates were blowing out and being chemically attacked. Evolution has a high-tech coating fully encapsulating a 316SS core with a PTFE internal diameter seal and a backup 718 Inconel C-ring seal. This provides fire safety as well, whereas most prior isolation gaskets were not fire safe. The product is also 1/8’’ (3.2 mm) thick, making installation easier and safer.

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FeCrAL Accident Tolerant Fuel Cladding

Category: Materials Design
Nominee: Oak Ridge National  Laboratory; General Electric/Global Nuclear Fuel

The nuclear incident that occurred at the Fukushima Daiichi Nuclear Power Plant in 2011 showed the world the implications of using Zr-based materials, which rapidly and exothermically oxidize in steam environments, and in the nuclear core during accident scenarios. Since the Fukushima Daiichi incident, a range of material systems have been developed that will not oxidize in the same manner as the Zr-based materials, resulting in enhanced accident tolerance of the global nuclear reactor fleet. Iron-chromium-aluminum (FeCrAl) alloys in initial screening experiments showed potential as a material system to replace Zr-based alloys, but typical commercialized FeCrAL alloys studied at the time (2012) did not have other properties that were acceptable for use in a nuclear fuel environment. The culmination of a multi-year, multi-faceted research, development, and deployment project has led to the production of a FeCrAl cladding deemed acceptable for pilot testing as an accident tolerant fuel (ATF) cladding. The basis of the effort was the optimization of the Cr and Al and solute additions to maintain high-temperature oxidation resistance without significant detriment to other performance factors such as strength, ductility, radiation tolerance, and fabricability, just to name a few. The result of these efforts produced the nuclear-grade FeCrAl ATF cladding, IronClad, which is now available in pre-commercial product forms.

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FlexGel–Corrosion Mitigating Thixotropic Gel

Category: Coatings & Linings
Nominee: Flexlife

The FlexGel range of products are various gels designed to halt the corrosion of carbon steel in subsea flexible and steel risers in the area of an outer sheath/coating damage. They work by displacing the oxygenated seawater from the region of the damage and replacing it with a non-corrosive gel. FlexGel can be used inside I-tubes to eliminate the air-water interface and coat the damaged riser, thus protecting both the outside diameter (OD) of the riser and the inside diameter (ID) of the tube. FlexGel can also be injected into flexible riser repair clamps subsea to form a flexible seal and prevent further corrosion. The thixotropic nature of FlexGel allows it to be pumped easily, yet within 48 hours its viscocity increases significantly to prevent splashing or a loss of gel due to waves and vessel motions. To additionally prevent microbiologically influenced corrosion (MIC), biocides have been suspended in the gel mixture for some applications. The deployment process to install FlexGel is in the annulus between an I-tube and riser.

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Fully Encapsulated Insulation Systems

Category: Materials Design
Nominee: Dragon Jacket

Dragon Jacket is a leader in engineered pre-jacketed insulation systems that provide solutions to the industrial insulation markets while eliminating costly expenses due to insulation failures. Each system is engineered to be installed easily and offers a safer alternative to traditional styles of insulation. This results in significant labor savings and quicker returns to service. Thermal; and operational efficiencies are greatly increased with the static R-value and K-factors that are inherent in the product, which in turn provide a dramatic increase in return on investment (ROI)

Dragon Jacket’s systems eliminate CUI caused from insulation failures by providing insulation that does not allow for moisture to penetrate the outer barrier. The insulation is fully encapsulated, designed for early leak detection while allowing moisture from the pipes to escape without pooling. There are no active conductors in the insulation or jacketing to react with the moisture and piping material.

Dragon Jacket provides multiple industries with modular insulation systems engineered for CUI and thermal management solutions. The superior durability and impermeable barrier to moisture of the outer jacketing allows Dragon Jacket’s systems to withstand the rigorous demands of daily operations and substrate expansion and contraction caused by harsh weather cycles. The re-usability allows for a quicker return to service, as well as drastically reduced overhead from product replacement.

The closed cell foam is fully encapsulated with 100% polyurea to form innovative pre-jacketed insulation systems that increase operational efficiencies, drastically reduces downtime, and lower the overall cost of ownership. All of Dragon Jacket’s systems are engineered to seamlessly integrate from system to system and may also be utilized with existing insulation products.

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Graphene-Based Anticorrosive System

Category: Coatings & Linings
Nominee: Applied Graphene  Materials

Genable 3000 series materials are graphene-based active, non-metallic, anticorrosion additives that have been proven to deliver industry leading performance. The new series has been formulated to enable the full benefit of graphene materials to be accessed by coatings industry formulators seeking step-change anticorrosion performance, particularly under harsher environmental conditions.

Incorporated into the formulation of an industry standard epoxy primer system and tested under representative cyclical salt spray testing (ASTM G-85-94 Prohesion), Genable 3000 series materials have demonstrated to deliver a five-fold extension in coating lifetime.

The properties of the Genable 3000 series make it an ideal tool-box additive for formulators seeking to significantly enhance coating performance in a range of environments. As an additive capable of offering metal-free systems with extended durability it is anticipated that it should find applicability in harsh C4, possibly C5, type environments such as in high humidity industrial, marine, and offshore applications. Once optimized into formulations, Genable 3000 series additives will provide attractive commercial benefits to coating developers and end-users alike, enabling the further optimization of multi-coat systems and providing significant reductions in application, maintenance, and repair costs.

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GPS360

Category: Cathodic Protection
Nominee: American Innovations

The MicroMax GPS360 is American Innovations’ latest addition to its successful current interrupter product line. It retains all the features that may previous models great, such as a built-in keypad and LCD for easy programming; nine fully configurable interruption schedules; weather sealing to survive the harshest environments; and a built-in solid-state relay capable of interrupting 100-V and 100-A CP sources. It also has an internal rechargeable lithium-ion battery delivering a minimum of 50 hours of interruption from a single charge.

Furthermore, the MicroMax GPS360 includes American Innovations’ patented GPS-synchronized Interference mode, which was specifically designed for making interference and influence testing easier than ever. All these new features are included within the same small and light enclosure as previous models, making this model the ultimate tool for current interruption.

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Halar ECTFE Waterborne Coating Systems

Category: Coatings & Linings
Nominee: Solvay

Prior to this waterborne innovation, Halar ECTFE could be applied only by powder coating. The powder coating method limited the use of the material to coating specific components. However, the new waterborne system provides the ability to coat smaller diameter pipe, tanks (vessels), or objects with complex shapes or geometries. The innovation enables the application of the material to coat objects where the powder coating failed to provide good adhesion. This waterborne system allows for the necessary adhesion by application of a two-coating aqueous system that is also environmentally friendly.

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Hazardous Locations Incoplas LED Hybrid

Category: Other–Lighting
Nominee: Shat-R-Shield, Inc.

The Hazardous Locations Incoplas Hybrid was derived from the need for a noncorrosive hazardous and harsh locations luminaire that could withstand exposure to a wide variety of corrosives, dust, vapors, and salt where traditional lighting options made with metallic bodies have failed from the result of corrosion. The main differentiation of the Hybrid Luminaire compared to other traditional aluminum and metal luminaires is that it is the first luminaire to be made completely of engineering plastics and does not have any exposed metal luminaire parts to corrode.

The advantage of traditional aluminum powder-coated luminaires is their excellent ability to dissipate heat and keep the internal electronic components from overheating, thus minimizing the possibility of a shorter life or catastrophic failure. To solve this problem using engineered plastics vs. aluminum was a very challenging effort. The Hybrid Luminaire can offer over 11,000lm, which can generate a significant amount of heat. A specially formulated graphite-infused engineered polymer was used to provide a solution for heat management. Extensive simulations and testing were performed to optimize the plastic’s thermally conductive properties. The rest of the luminaire’s engineered polymer components were also chosen for anticorrosion properties. The Hybrid Luminaire is certified for outdoor and marine applications to withstand rigorous Underwriters Laboratory (UL) safety testing.

Shat-R-Shield’s proprietary blend of thermally conductive engineered polymers provide resilience against a wide range of corrosive elements while optimizing heat management of the light-emitting diodes (LEDs) in an ultra-lightweight package. This multi-purpose light source is functional as an area light, flood light, or wall pack, configured as such with its vast mounting, optic, and lens options. Available in packages of 45 W with up to 5,600 lm and 90 W with up to 11,200 lm, every Hazardous Locations LED Hybrid fixture is built to customer specifications.

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Hexcorder Pro CIPS/DCVG/GPS Survey Instrument

Category: Integrity Assessment
Nominee: Cathodic Technology Ltd.

The Cath-Tech Hexcorder Pro provides state-of-the-art pipe coating condition data (DCVG) &/or pipeline cathodic protection data (CIPS) with GPS coordinates. The Hexcorder may be operated in numerous modes including DCVG only, CIPS only, combined DCVG and CIPS, multi-person DCVG mode, and more.

The Hexcorder Pro utilizes a ruggedized tablet for the display and keypad resulting in an optimal user experience working with the free Android-based Cath-Tech survey app. The operator has the choice of viewing any two of five available survey screens to display survey data. Survey data can be displayed as a graph, numerically, as analogue gauges, birds eye view of the survey team or in real time on maps! Data is exported to a computer as a .csv file via USB connection and may be graphed using Excel or similar spreadsheet programs and is fully PODS compatible, with no special software required. The Hexcorder Pro is also Bluetooth-enabled to pair with Radio Detection and Vivax Metrotech pipe locators to capture the depth of cover data and store it seamlessly correlated into the survey data. Each reading taken during a survey with the Hexcorder Pro is tagged with latitude, longitude, altitude, voltage gradient, PDOP, TR OFF, TR ON, date, time, chainage, and any operator-inserted notes or comments.

The four key features are:

  1. It performs DCVG and CIPS in various combinations simultaneously with all data gathered at the exact same geographic locations at the exact same moment in time under the exact same field conditions, all while seamlessly correlated;
  2. It has rich graphics and data display in real time for maximum operator experience;
  3. No special software is required, since it utilizes standard Microsoft programs and an Android app;
  4. The device is purpose built by corrosion engineers for corrosion engineers, specifically designed to do nothing but pipeline integrity surveys.
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High-Temp CUI Protection

Category: Coatings & Linings
Nominee: Superior Products International II, Inc.

This water-based ceramic filled coating can be sprayed directly to a hot surface at up to 600 °C without a shutdown. The resin system will seal the surface to prevent moisture, chemicals, or air from affecting the surface. The ceramic load is designed to insulate the surface by blocking the loss of heat off of the surface. It therefore holds more of the heat inside the pipe or vessel to reduce the energy needed to maintain the desired heat level. While the system operates more efficiently by saving calculated energy, the resin system prevents CUI development.

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High Tg Internal Pipe Coating System

Category: Coatings & Linings
Nominee: Axalta Coating Systems

Within the environments currently being explored today by oil and gas operators, higher temperatures and concentrations of H2S, CO2, and other gas contaminates may warrant the use of significantly more expensive metal chrome alloys to avoid corrosion and failure. Coatings are a lower-cost alternative that have been used within the industry for years; however, most anticorrosion coatings cannot perform in environments with high temperatures, pressures, and high levels of gas contaminates. This new fusion-bonded epoxy (FBE) coating represents a new generation of more functional high Tg systems. The new system is more flexible, has better adhesion, and is easier to apply than current high Tg FBE systems available today.

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Lanolin Environmental Solutions

Category: Coatings & Linings
Nominee: Lanotec Australia Pty Ltd; Lanotec Asia Pacific Pte Ltd

Lanolin is a natural, renewable product providing protection for a vast array of metals against the effects of corrosion and other effects as the consequence of natural elements such as the sun, water, and friction, as well as acids and hydrogen sulfide (H2S).

It offers effortless application while resisting wash-off, as verified through independent testing. It is biodegradable, non-flammable, and is classified as "Food Grade."

The product is highly effective in harsh corrosive environments, where environmental and HSE requirements are important. These include offshore and onshore mining and drilling, marine asset protection, aviation, and asset storage such as drill pipes.

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Lift Off Rest (LOR)

Category: Materials Design
Nominee: "Lift-Off" Pipe Supports

The Lift Off Pipe Rest (LOR) is a glass-reinforced composite resin pipe support providing a noncorrosive barrier between pipes and beams to eliminate corrosion, designed to meet the thermal and mechanical requirements of load-bearing supports.

This innovative pipe support does not absorb moisture, spreads the pipe load four times greater than existing supports, prevents electrolysis, and is qualified for temperatures as low as -265 °F (-165 °C) and as high as 412 °F (211.1 °C, continuous) and up to 550 °F (287.8 °C, intermittent). The LOR continually maintains position without external support and is designed with grooves for an additional fluid shed and corrosion protection.

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MIC-GUARD Coating & Lining Additive

Category: Other–Coating Additive
Nominee: BTG Products

The MIC-GUARD coating additive is a powder product incorporated into industrial linings, coatings, and molded products to inhibit the growth of mold, mildew, bacteria, and other microorganisms. MIC-GUARD enhanced products create surfaces that neutralize bacteria and inhibit the development of biofilm accumulation. MIC-GUARD utilizes a patented combustion synthesized material to fight microbial growth, even in the harshest conditions. Mix it into industrial coatings and linings to fight microbiologically influenced corrosion (MIC), mold and mildew accumulation, and biofouling.

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Microfluidic MIC Model: Biocide Studies

Category: Chemical Treatment
Nominee: Texas A&M University

Microbiologically influenced corrosion (MIC) occurs by complex interplay between microbial metabolism, corrosive compounds, and metal. MIC has been extensively explored using batch reactors or circulating loop systems or continuous stirred tank reactors (CSTR). Both batch systems and circulating systems can provide confounding results due to nutrient limitation and accumulation of corrosion products and waste products that affect microbial growth and biofilm formation. Further, CSTR requires large volumes of fluids. To overcome these disadvantages, the team developed a novel microfluidic microbiologically influenced corrosion model comprised of carbon steel coated glass slide bonded to a microchannel imprinted inside a transparent polymer, polydimethylsiloxane (PDMS). This flow model is a continuous once-flow-through unit similar to pipelines, where MIC is a major concern.

Microbiologically influenced corrosion (MIC) occurs by complex interplay between microbial metabolism, corrosive compounds, and metal. MIC has been extensively explored using batch reactors or circulating loop systems or continuous stirred tank reactors (CSTR). Both batch systems and circulating systems can provide confounding results due to nutrient limitation and accumulation of corrosion products and waste products that affect microbial growth and biofilm formation. Further, CSTR requires large volumes of fluids. To overcome these disadvantages, the team developed a novel microfluidic microbiologically influenced corrosion model comprised of carbon steel coated glass slide bonded to a microchannel imprinted inside a transparent polymer, polydimethylsiloxane (PDMS). This flow model is a continuous once-flow-through unit similar to pipelines, where MIC is a major concern.   This flow model can be used to establish MIC environment in microchannels using corrosive process fluids or cultures of model organisms in a continuous flow setting while using minimal reagents. This flow model further enables measurements of biofilm viability (instead of planktonic cell viability) using confocal laser scanning microscopy (CLSM) and sessile adenosine triphosphate (ATP) assay and metal surface measurements using scanning electron microscopy (SEM) and optical profilometry. This flow model has been evaluated for its feasibility in the laboratory by conducting biocide efficacy studies using model bacteria associated with MIC. Biofilm viability determined using confocal microscopy was used as an indicator for effectiveness of biocide. Further, this flow model was also tested using produced water to establish biofilm growth and MIC in the microchannels. Biofilm viability determined using fluorescent microscopy and sessile ATP assay were used as indicators for comparing the efficacy of biocides. Hence, this flow model provides an ideal testing and evaluation method with cost and time savings for conducting biocide screening, efficacy, and dosage studies with process fluids for effective MIC mitigation.

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Microfluidic MIC Model: EIS, Microscopy

Category: Testing
Nominee: Texas A&M University

A holistic understanding of microbiologically influenced corrosion (MIC) requires investigation of the underlying microbiological, metallurgical, and electrochemical mechanisms. MIC studies have been conducted largely using batch reactors or large scale continuous circulating loops or continuous stirred tank reactors (CSTR) that require enormous quantities of fluids or have disadvantages with nutrient insufficiency and corrosion product accumulation which disrupt biofilm growth. To effectively comprehend MIC mechanisms while overcoming these drawbacks, the team developed a novel microfluidic microbiologically influenced corrosion model for electrochemical impedance spectroscopy (EIS) and microscopy that is amenable to dynamic and integrated measurements of biofilm physiology and electrochemical impedance. This flow model simulates once-flow-through setup of pipelines and comprises of a two-metal electrode system with carbon steel (corroding electrode) and titanium (non-corroding, counter electrode) deposited on glass and bonded to a transparent polymer, polydimethylsiloxane (PDMS) with imprinted microchannels.

This flow model can be used to establish MIC environment using corrosive process fluids or cultures of model organisms in a continuous flow setting while using minimal reagents. This flow model further enables measurements of biofilm growth dynamics using confocal laser scanning microscopy (CLSM), electrochemical reactions using electrochemical impedance spectroscopy (EIS), and metal surface measurements using scanning electron microscopy (SEM) and optical profilometry. This flow model has been assessed for its feasibility in the laboratory by simultaneously monitoring biofilm biomass and EIS using cultures of bacteria (modified to express fluorescent protein) associated with MIC, and a correlation was observed between these two. Further, the use of equivalent circuit fitting leads to calculation of the corrosion rate through polarization resistance. Hence, the model provides an ideal testing platform with cost and time savings for simultaneously monitoring all the aspects of MIC (corrosion reactions, biological changes, and metal surface variations) for obtaining fundamental understanding of MIC.

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Nano-Clear Industrial Coating Solutions

Category: Coatings & Linings
Nominee: Assero Industrial Coatings; Nanovere Technologies, LLC

Nano-Clear (NCI) is manufactured using proprietary three-dimensional (3-D) nanostructured polymers producing extreme crosslink density. Nano-Clear is a one-component (1K), humidity cured, polyurethane/polyurea hybrid nanocoating that penetrates deep into the pores and voids of new or highly oxidized paint systems to form a hard, protective, clear, topcoat surface.

Nano-Clear protects against corrosion, restores existing colour and gloss, and provides strong resistance to ultraviolet (UV) degradation, extreme weathering, and chemical attack, as well as abrasion, chipping, marring, gouging, impact, and scratching. Nano-Clear also features repellency properties for oil and dirt, water and ice, brake dust, algae, and other environmental and biological contaminants. NCI is a flexible, solvent-based solution with low values of volatile organic compounds (VOCs).

NCI can be applied to 2K epoxies, 2K polyurethanes, powder coatings, polyesters, gel coats, eCoats, latexes, fiberglass, and anodized aluminum (to prevent filiform corrosion). It is engineered to exceed the functional specifications required by industrial, marine, fleet, aerospace, and oil and gas markets.

NCI is designed to protect industrial and commercial equipment such a  rail tank cars, locomotives, fuel tanks, chemical storage tanks, earth moving equipment, ocean going vessels, fleet vehicles and support equipment, painted building structures, light posts, utility enclosures,  emergency response vehicles and equipment, oil and gas platforms, pipelines, shipping containers, military vehicles and support equipment, mass transit vehicles and equipment, and more.

Nano-Clear reduces maintenance frequency, recoating cycles, chemical costs (mixing, repair, cleaning), the length and frequency of repair and maintenance downtime, and the volume of coating material shipped/stored/applied to project surface. In turn, this reduces expenses. Customized "first-to-market" functional additives have also been developed that enhance the multifunctional attributes of NCI to enhanced levels of performance.

Nano-Clear is a reliable, long-term, eco-responsible, industrial solution that extends the surface life of an asset's coating system, and is backed by a 10-year warranty.

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Perforated Offshore Monopile for Corrosion Control and Enhanced Marine Habitats

Category: Cathodic Protection
Nominee: Center for Corrosion and Biofouling, Florida Institute of Technology

Offshore wind energy is a burgeoning industry in the United States, and realizing the benefits will require overcoming critical challenges including corrosion control and supporting stewardship of U.S. waters. This innovation addresses the need to improve on the existing methods for the corrosion control of the monopile interiors used to support the turbines by incorporating a design that also enhances marine habitats and fisheries. Retrofitting monopile interiors with cathodic protection has been attempted on existing wind farms to mitigate corrosion; however, this can cause new problems including water acidification and hydrogen sulfide (H2S) formation. Such chemistry changes can lead to unique localized corrosion concerns. The field experiments presented in this document have demonstrated that a cathodically protected perforated monopile structure while create an environment with more favorable corrosion mitigation, air quality, and water chemistry compared to a sealed structure. Furthermore, a perforated, cathodically protected structure will create a habitat for marine life and recruit a diverse population of settled and mobile organisms.

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Pocket-Sized GPS CP Interrupter

Category: Cathodic Protection
Nominee: Taku Engineering, LLC

The Pocket Interrupter One (PI-1) is a pocket-sized, two-channel, GPS-synchronized cathodic protection (CP) interrupter. This interrupter has a graphical user interface that makes it simple and easy to set up interruption cycles. It incorporates state-of-the-art technology to achieve its small size and 6-day battery life. It also incorporates an incredibly sensitive GPS engine, which allows it to acquire GPS time very quickly and in poor reception areas, such as indoors.

The team is currently working on integrating a high-speed datalogger and Bluetooth to allow continuous waveform capture and analysis during CIS and for telluric nulling. They have developed, patented, and tested a waveform analysis algorithm that can determine accurate instant off readings from highly variable waveforms. This algorithm will run on the PI-1L (waveform logger enabled) and provide the most accurate CP potentials possible.

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Predict-RT: A Software Sensor for Corrosion

Category: Other–Corrosion Prediction and Measurement
Nominee: Honeywell International, Inc.

Predict-RT is a novel, intelligent data analytics framework transforming the oil, gas, and refining industry from traditional, reactive degradation management to real-time, proactive corrosion management through the use of online, real-time corrosion prediction and monitoring. Utilizing extensive corrosion data with real-time process data, Predict-RT functions akin to a real-time corrosion measurement software sensor.

A byproduct of over two decades of Joint Industry Program (JIP) technical research and experimental data development, Predict-RT encapsulates the intelligence of predictive JIP models for critical refinery and oil/gas applications identified by leading operators and JIP sponsors. Predict-RT provides a framework to harness exhaustive laboratory research insights with unique access to real-world process data to deliver compelling analytical framework and provide plant operators real-time visibility into quantified corrosion rates and equipment reliability. The result is predictive models able to forecast corrosion rates with high levels of confidence, along with the ability to correlated predicted data with inspection data and thickness measurements.

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Protecting Imbedded Steel Power Poles

Category: Cathodic Protection
Nominee: Columbia Corrosion Control Co.

Cathodic protection (CP) is used to stop subsurface corrosion on directly imbedded and partially coated transmission and distribution power poles. Coated power poles (and other applications) have sustained numerous corrosion failures due to inadequate coating protection when buried directly in soils. This is a major problem for power utility safely and reliability. However, this simple application of CP solves the problem. Plus, it provides other important spinoffs that increase reliability on the U.S. power system grid networks.

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Remote CP and Corrosion Monitoring

Category: Instrumentation
Nominee: MetriCorr ApS

MetriCorr has developed a new series of dataloggers and remote upload units that are fully compatible with the CP test posts of pipeline operators. Previously, remote monitoring of CP and corrosion date data from ER probes required a dedicated box for installation in the field. However, the new products are waterproof (IP65) and fit directly into standard test posts. Power consumption has been optimized on several levels, and a regular battery pack will provide three years of hourly measurements and weekly uploads to a web-based monitoring solution. Solar panels can be mounted externally on the test post in remote areas for prolonged operation time. The functionality of the system can be varied, ranging from a 1- or 3-channel voltage logger to an interference corrosion logger that gives the operator extensive insight into the effectiveness of a CP system.

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ROCKWOOL WR-TECH

Category: Materials Design
Nominee: ROCKWOOL Technical Insulation

ROCKWOOL has developed the next generation of ProRox mandrel wound stone wool pipe sections that incorporate a hydrophobic additive called WR-Tech, or “Water Repellency Technology.” WR-Tech pipe sections are a best-in-class solution to mitigate the risk of corrosion under Insulation (CUI), resulting in lower total costs of ownership and increased site safety. WR-Tech pipe sections have five-times less water absorption (lower than 0.2 kg/m2) than the best available market standard, fast water dissipation, durability over the entire CUI temperature range, and less than 10 ppm of leachable substances.

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Self-Healing Additives for Corrosion Resistance

Category: Coatings & Linings
Nominee: Autonomic Materials, Inc.

The innovation is in the form of an additive comprised of a microencapsulated healing agent containing an epoxy resin, a polar diluent, corrosion inhibitors, and adhesion promoters. The microcapsules can be formulated into waterborne and solvent-borne liquid epoxy coatings, zinc-rich primers, powder coatings, and fusion-bonded epoxy coatings. Once fully cured, damage to these coatings ruptures the microcapsules releasing the healing agent into the site of damage where it polymerizes, seals the edge of the damage, delays undercutting, and facilitates maintenance of the coating’s adhesion. The improved maintenance of adhesion keeps the coating in service longer, thereby minimizing the extent of recoating and maintenance required and lost productivity due to downtime over the lifetime of the asset. A schematic illustrating the cost savings associated with the lifetime extension of a coating used in a corrosive environment is provided.

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Tellerus HV2 In-Line Static Mixer

Category: Chemical Treatment
Nominee: Tellerus Corp.; Bayswater Exploration & Production; Tomahawk Oil Company, Inc.; Jim Wilson Contract Pumping, Inc.

The Tellerus HV2 static mixing tool is used to deliver a continuous feed multi-function corrosion/scale inhibitor treatment to the casing of several oil wells in central Montana. The operators (Bayswater E&P and Tomahawk Oil Company) both employ electric submersible pumps (ESP) where fluids laden with H2S and CO2 are a significant corrosive factor. In addition, underdeposit scale corrosion is a substantial problem with many producing wells in the oil and gas industry. The HV2 improves the effectiveness of the corrosion/scale inhibitor functions.

The existing chemical treatment is injected into a produced fluid "side stream carrier" taken from each wellhead. The chemical is injected into a port on the head end of the mixing tool and moves through three stages of mixing turbulence before discharging into the well casing, where it drops to the operating fluid level and is drawn into the ESP pump intake.

Initial test installations began in early 2008, with various upgrades and improvements made over time. Prior to the beginning of these field trials, the average ESP pump change interval was running at 36 to 48 months. Since the HV2 installations, the ESP pump change interval has been extended dramatically by up to 126 months for the longest running wells.

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UltraBox Modular Junction Box

Category: Cathodic Protection
Nominee: Dairyland Electrical Industries, Inc.

Historically, industry CP junction boxes, referred to as “anode junction boxes,” “rectifier junction boxes,” and “bond boxes,” are constructed only in one manner. Components such as shunts, resistors, copper header bars, and measurement terminals are mounted to an insulated back panel mounted to the bottom of an enclosure on stand-offs. The screw/nut connections to secure these components, and the copper bus commonly used to join shunts in parallel, are normally on the underside of this panel. Field wiring from a rectifier, anodes, reference cells, or the pipeline enter the enclosure and land on the shunts, resistors, or measurement terminals. The industry has significant problems with this type of construction in the case of loose connections that are inaccessible, or if trying to add another component to the panel, as the hardware on the undersize of the enclosure generally requires the disconnection of all field-wired connections and removal of the back panel from the enclosure and the installation of new components (or tightening of loose connections) on the panel, followed by the reverse procedure to place the unit back in service. This can take a number of hours to perform. On occasion, field wires can even be reversed or placed on the wrong termination, resulting in confusion or in a reversed polarity rectifier connection to the structure and anode bed.

By contrast, in the Dairyland UltraBox, all components such as shunts, resistors, and isolated terminals are designed as modules that snap onto one or more DIN rails mounted inside the box on channels. The DIN rails can be adjusted and positioned anywhere on the channels. Further, any module (shunt module, resistor module, etc.) can readily be added, removed, or repositioned. For any changes, all field wiring can be left in place, and no disassembly of the unit is required. All hardware is accessible, unlike traditional boxes. Where shunts are involved, adjustable and removable link bars are used to connect one to the next, and form a common header. Adding another shunt involves merely adding another header link to connect it to the rest. The modularity and flexibility of this entire approach addresses each of the disadvantages of traditional junction boxes.

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Volumetric Water Repellent Polyurethane Coating

Category: Coatings & Linings
Nominee: Hempel A/S

In the coatings industry, the development of a durable water-repellant or superhydrophobic coating is of high interest to provide greater protection of steel structures from water. This coating would therefore reduce corrosion, especially in severe offshore environments. To that end, Hempel’s new coating actively repels water. The team has demonstrated enhance corrosion protection compared to many conventional three-coat systems used today, when the coating is used as part of a two-coat system comprised of the water-repellent polyurethane with an activated epoxy zinc primer. The water resistance of the polyurethane was evaluated by salt-spray testing on a direct-to-metal (DTM) coating, and the volumetric superhydrophobic effect can be seen by contact angle analyses. The results show a significant improvement in the water resistance, and hence on the corrosion protection compared to standard coatings. The two-coat system was compared to a standard three-coat system in cyclic salt spray/QUV accelerated weathering testing; water condensation testing; and aging resistance testing. The impact resistance and flexibility of the system were also tested. Based on the results, the two-coat system was found to have excellent anticorrosion properties for extended times of exposure and outstanding mechanical performance. This makes it a suitable candidate for areas exposed to aggressive environments, such as offshore platforms.

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Wayfarer Data-Logger

Category: Instrumentation
Nominee: AIMaps, Inc.

Clunky, expensive data loggers can take a hike! The innovative Wayfarer from AIMaps features a built-in Bluetooth voltmeter with integrated GPS and RFID reader atop a lightweight, collapsible cane. Users can take pipe-to-soil potentials and rectifier reads using Wayfarer, and the data is instantly synced with the AIMaps Pipeline Asset Management Platform. With the “smart cane,” a user’s smartphone or tablet becomes a data logger, with Wayfarer taking the reads.

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