The global corrosion control and protective coatings community submitted a record total for MP’s 2025 Corrosion Innovation of the Year Awards program. Of those nominations, up to 10 will be declared winners by a distinguished panel of industry experts.
As of January 2025, here’s a look at award finalists following the first round of judging by our panel. The winners will be publicly announced in April at the 2025 AMPP Annual Conference + Expo in Nashville, Tennessee, USA.
In addition to receiving trophies and public recognition at the conference, winners will be featured editorially throughout 2025 via both the print and digital platforms of MP.
On Monday, April 7, Materials Performance (MP) magazine will honor its new class of winners for its 2025 MP Corrosion Innovation of the Year Awards program. The special ceremony will take place adjacent to the Exhibit Hall entrance and immediately prior to the Exhibit Hall’s Grand Opening.
“The winners of our 2025 MP Corrosion Innovation of the Year Awards will represent some of the most promising technologies in the industry today,” says Rebecca A. Bickham, MP’s Editor-in-Chief.
Since 2014, the MP Corrosion Innovation of the Year Awards program has provided a forum for association members and customers to showcase their corrosion mitigation technologies while receiving recognition for their innovative solutions. Winners are selected by a panel of corrosion control and protective coatings experts spanning a wide range of subject matter expertise from across the industry.
In all, the global corrosion control community submitted approximately 60 nominations for the 2025 awards, representing the most submissions in program history. To be considered an innovation, nominated projects are required show the potential for a significant positive impact in corrosion control. Innovations can be related to coatings and linings, materials, design, equipment, testing, monitoring, integrity assessment, cathodic protection, chemical treatment, or anything else directly related to corrosion prevention and mitigation.
Anyone worldwide involved with corrosion control, including individuals, companies, organizations, and governments, can submit a nomination. There is no fee to enter the program.
Following this cycle, the next edition of the MP Corrosion Innovation of the Year Awards program will be held at the 2027 AMPP Annual Conference + Expo in Columbus, Ohio, USA, with the nominating period beginning the prior year in 2026.
Editor’s note: All of these innovation summaries are from each person’s or organization’s nomination form. While graded and approved by at least one member of our Corrosion Innovation of the Year Awards judging panel, the summary verbiage is from each nominator, not from MP.
These innovations are ordered by an alphabetical ranking of each nominating organization(s). They are not reflective of any grades from the judging panel.
“Smart Mitigation Cell”
Nominating organization(s): 4Z Elektronik Otomasyon ve Kaynak Sistemleri LTD. ŞTİ.
Web site: www.4zelektronik.com
Innovation summary: Cathodic overvoltages caused by direct current (DC) stray currents, especially originating from subway and tram lines are well known all around the world.
They can be very difficult to mitigate by conventional methods. The general approach is to ground the structure over a DC decoupler or by using some sort of metallic (zinc, etc.) grounding. The former method presents an impedance and threshold voltage, which is device specific and changes with the type of grounding material used. The latter method may require too many grounding anodes to be buried, which causes non-uniform cathodic protection (CP) current distribution. This is costly and may not even be possible to apply, at all.
Our new approach utilizes any type of (safe) grounding for mitigation of DC stray current by using a variable resistance technique. The smart mitigation cell (SMC) incorporates a DC decoupler together with a reference electrode monitor and a controlled electronic variable resistor, whose resistance can be between 0.2 ohms to nearly open circuit. The SMC monitors the reference-to-structure potential and adjusts the DC current drain by changing the series resistance. In this way, the reference potential is always at the setpoint, and overvoltage is mitigated.
“SUNBIRD2 SP Test Post Monitor”
Nominating organization(s): Abriox Ltd.
Web site: www.abriox.com
Innovation summary: There are eight key industry-first innovations in the SUNBIRD2 SP, which combine to make this an undisputed “game-changer” in the maintenance of oil pipelines. An extremely clever, perfect alchemy of the best in firmware, software, and power source synergy allows the unit to be always on and always transmitting vital pipeline data. This is unlike other available devices which can only send critical data once a week.
New technologies and innovative design have reduced production costs and therefore the price of the unit, which is passed on to the customer. This makes the SUNBIRD2 SP much more cost effective than competing devices, and it opens up opportunities for pipeline operators to monitor locations where the cost was previously prohibitive. Therefore, it helps ensure legal compliancy and the mitigation of risk and liability.
“El Abrasivo como Principal Fuente Mitigadora de Corrosión”
Nominating organization(s): Acesta
Innovation summary: One of the main corrosion control systems is the material used in cleaning and preparing the surface, in this case the abrasive. After obtaining information, I set out to learn in depth what steel shot is; how it is made; and how to optimize the process so that it can meet quality assurance guidelines and help with production goals.
I found the guidelines for recycled abrasives in the SSPC-AB4 standard. After implementing this process, I was able to reduce abrasive consumption as well as help with a perfect mix. The perfect mix is a set of different sizes of abrasive that are made with a main size after the main size has been consumed. This process, in addition to taking care of abrasive consumption, helps with the adherence of the protective coating, leaving uniformity on the surface.
I think it is novel because I did not find any standard in SSPC or NACE that describes the perfect mix process and the effects that can be caused by not having knowledge of it. It is true that there is a standard that talks about recycled abrasives, but it only mentions the characteristics that the abrasive must have to be considered in good condition for recycling. However, it does not mention anything about the care of the process itself.
As a coating inspector, I have been concerned about quality but also about production itself, implementing processes that help both categories (production, quality) with the knowledge I acquire from AMPP.
“TriFLEX”
Nominating organization(s): Advanced Polymer Coatings
Web site: www.adv-polymer.com
Innovationsummary: TriFLEX is the first exterior coating produced by APC since the inception of MarineLINE and ChemLINE. As anew direct-to-metal (DTM) coating, TriFLEX harnesses Nobel Prize-winning technology to outclass the competition with its groundbreaking benefits.
This innovative solution combines three powerful resin systems, offering unparalleled advantages: superior chemical resistance for maximum protection; enhanced mechanical toughness providing industry leading flexibility and impact resistance; and exceptional UV stability and weather ability to withstand the harshest conditions.
These advanced technologies, seamlessly integrated into a single coating, provide substantial benefits across the industry. TriFLEX is driving transformative improvements in rail applications, including hoppers, tank cars, and various other types of rolling stock. By significantly boosting durability, performance, and efficiency, TriFLEX sets a new benchmark for rail coatings, ensuring unmatched longevity and reliability in every application.
“Hybrid Polymeric Phosphate-Cementitious Coating”
Nominating organization(s): Advanced Polymerics Inc.
Web site: www.permacorr.com
Innovation summary: PERMACORR is a hybrid polymeric phosphate-cementitious coating. The waterborne, single-coat protective coating forms two layers, a protective iron phosphate complex and a cementitious coating.
“Virtual Real-Time Corrosion Sensors”
Nominating organization(s): Aramco
Innovation summary: Aramco continues to uplift its corrosion management through the establishment of regional and international partnerships with technology leaders, under which the company is deploying recent advancements in cutting-edge solutions.
Lately, Aramco—in collaboration with Honeywell—introduced the concept of virtual real-time corrosion sensors to address the limitations of traditional corrosion monitoring techniques such as on-stream inspections, weight loss coupons, and intrusive probes.
Recent advancements in corrosion modeling and prediction have enabled the development of programs to predict the real-time corrosion rate by utilizing online process data, engineering modeling, and computational software. This rate data is used to calculate remaining wall thickness while establishing risk-based inspection and maintenance planning to proactively prevent corrosion failures.
“Horizon Access Fitting”
Nominating organization(s): Axess
Web site: www.axess.energy
Innovation summary: The Horizon Fitting represents a step-change innovation, with its unique design facilitating monitoring from the bottom while accessing a pipe from its side. This resolves issues with ground clearance and minimizes the risk of debris build-up, all without compromising on data accuracy.
The Horizon Fitting can also be utilized for top-of-line monitoring, often reducing the need for scaffolding and fixed platforms. When utilized for sampling, the side-of-line entry ensures clean samples with educed risk of blockages.
Implementing the Horizon Fitting translates to reduced risk sassociated with retrieval tool “pistoning,” as well as wake frequency issues and the requirement of heavy retrieval equipment. Furthermore, the shorter and more manageable device lengths lead to a safer work environment for industry professionals. The human factor should also be considered in terms of manual handling and working at heights.
“Belzona SF6-FIX”
Nominating organization(s): Belzona
Web site: https://www.belzona.com/en/applications/sf6_fix.aspx
Innovation summary: Belzona SF6-FIX is Belzona’s latest solution for the power transmission and distribution industry. This innovative solution can be applied to reduce leaks of the world's most potent greenhouse gas, sulphur hexafluoride, to undetectable levels.
Commonly used in electricity substations, the gas is commonly used in medium and high voltage electrical equipment to insulate live electrical parts and to switch the flow of electrical current on and off. This same equipment, crucial for the efficient functioning of power grids, also plays a pivotal role in connecting the generation and storage of renewable energy. However, this gas is extremely damaging for the environment, with a warming potential 23,500 times more potent than carbon dioxide.
Leaks of this gas are very common, and corrosion of flanges is generally recognized as the main root cause for leakage in outdoor switchgear. Belzona SF6-FIX is an innovative solution that addresses this corrosion-induced leakage. Capable of reducing SF6 leaks to undetectable levels, Belzona SF6-FIX not only tackles the environmental concerns associated with SF6 emissions but also promotes the sustainable and efficient operation of power grids.
“Game Changing De-Coating and Surface Prep”
Nominating organization(s): Best‐Tec Asbestos Abatement, Inc.
Web site: www.best-tec.com
Innovation summary: This innovation consists of advanced media‐free coating removal and surface preparation technology for proactive structural steel corrosion control and zone and spot maintenance application, and it does so in a way that is not feasible using traditional abrasive media blasting.
This novel technique is particularly effective for projects involving the removal of coatings containing lead and other heavy metals. It eliminates the need for complex and costly hazardous dust containment systems; uses no consumable media; creates no hazardous mixed waste; mitigates environmental risks; and enhances worker safety. Surfaces treated with this method are ultra‐clean and ready for an immediate recoating process. Unlike traditional methods, it is a totally unique, new solution to improve bridge maintenance and preservation.
Validated by extensive testing, this technique promises to save time and reduce costs, all while mitigating environmental, health, and safety hazards associated with traditional abrasive media blasting.
“Oil Cooled Hazardous Area Transformer Rectifier Units”
Nominating organization(s): Cathodic Protection Co.Ltd
Web site: www.cathodic.co.uk/transformer-rectifiers/
Innovation summary: The world is changing to be more risk averse, and this is becoming more evident on large industrial sites, including petrochemicals and food processing. Operators and designers are making decisions to classify electrical systems as a hazardous area rather than non-hazardous. This not only provides future proofing for their plants, but it also reduces the possible impact that a lack of maintenance might present in the future. Cathodic Protection Co. Ltd. felt this was a key market sector for product development, particularly with its hazardous-area transformer rectifiers.
“Graphene-Modified Silicon Titanium Nano Heavy Corrosion Coating”
Nominating organization(s): Changsha Tianyuan Empire MaterialsTechnology Co., Ltd.
Web site: www.cstyxw.cn
Innovation summary: Changsha Tianyuan Empire Material Technology Co., Ltd. was settled in the Changsha Economic and Technological Development Zone in September 2019. With a registered capital of 10 million yuan, it is committed to the research, production, application, and promotion services of graphene materials and its heavy anticorrosion and functional materials. The company also invests in research and development pertaining to functional materials and formula technology.
Graphene modified, nano-heavy anticorrosive materials are well received and widely used in industries such as petroleum, chemicals, electric power, marine engineering, smelting, energy, environmental protection, and the military. This project studies the preparation and modification of graphene through physical-chemical methods.
The typical physical methods include a mechanical stripping method, and the typical chemical methods include a redox reduction method, chemical vapor deposition method, silicon carbide crystal growth method, and a solvent thermal method. However, these methods have great defects, such as low yield, high energy consumption, large pollution, large damage of prepared graphene, and high impurity content.
“Portable Plating Shop for On-aircraft Coating Repair”
Nominating organization(s): Corrdesa LLC
Web site: www.corrdesa.com
Innovation summary: Corrdesa has developed a line of robust, non-drip ground support equipment (GSE) that packages a complete plating shop into a single portable unit designed to repair and replace damaged or missing inorganic corrosion-control coatings on fueled aircraft on the flight line or even the carrier deck. More than 100 GSE units have so far been sold for repair of Cd and ZnNi coatings on F-35 aircraft by the United States and partners around the world.
Based on this portable electroplating unit Corrdesa has developed a GSE line that can carry out all the major inorganic chemical and electrochemical coating repair processes—stripping coatings and corrosion, electroplating and passivation, anodizing and sealing, conversion coating, etc. This equipment is non-drip to protect the technician, prevent contamination of the workspace, and carry out large-area repairs on-aircraft, all with minimal preparation and clean-up.
GSE units have been developed and sold for repairing corrosion control coatings on F-35 aircraft around the world and anodizing the entire 22-square-foot leading edge erosion strips and fuselage static ports on P-8 Poseidon submarine-hunting aircraft.
Full plating shop GSE units have been supplied to the USAF for complete inorganic coating remediation on U-2 Surveillance aircraft—to strip corrosion and Cd from fastener heads; repair damaged anodize coatings on the aluminum skin; and replace the chromate-converted Cd coating on fasteners and other steels with modern, better-performing Cr3-passivated ZnNi.
“CR Clarity, Dynamic CUI Risk Analytics Software”
Nominating organization(s): CorrosionRADAR
Web site: www.corrosionradar.com
Innovation summary: Hidden corrosion, such as corrosion under insulation (CUI), is a big issue affecting asset integrity management in industries such as oil and gas and petrochemicals. CorrosionRADAR, a company based in the United Kingdom, has thus developed CR Clarity. This dynamic CUI risk analytics software offers industry-first innovation, which enables predictive corrosion risk management with online data from sensors transformed into live CUI risks.
Designed to transform how energy companies manage asset integrity, CR Clarity provides real-time, predictive risk insights to enable the proactive management of difficult issues, and specifically those connected to CUI.
At the core of CR Clarity is its dynamic risk analytics function, which processes real-time sensing data from moisture and corrosion sensors to detect issues early and predict corrosion risk to assets. By turning raw data from sensors into actionable risk, as well as by correlating asset history, materials, coatings, and thermal profile, CR Clarity allows operators to anticipate actual issues before they escalate. This improves safety, saves costs, and promotes more efficient operations.
CR Clarity is currently being used to predict and reduce CUI risk by early adopters at some of the world’s biggest oil, gas, and petrochemical companies such as Saudi Aramco and Dow. These companies have also invested in the CorrosionRADAR business, highlighting their confidence in the workings and potential of this innovation.
“Closed-Loop Smart Cathodic Protection Technology”
Nominating organization(s): Deakin University Australia
Web site: https://experts.deakin.edu.au/2533-mike-yongjun-tan/about
Innovation summary: This innovation is a patent-pending, closed-loop smart cathodic protection (CP) technology which employs a localized corrosion probe to perform in-situ monitoring of localized corrosion. It then uses corrosion monitoring data to smartly adjust and closed-loop control CP potential/current.
The core component of the technology is a corrosion probe that is designed based on an electrochemically integrated electrode array, which features the unique capability of simulating and monitoring localized corrosion. This technology offers several important capabilities: (i) It automatically adjusts CP potential/current to appropriate levels to count against undesirable environmental condition variations and effects such as stray currents; (ii) It applies more CP currents, when necessary, to generate a high pH environment to control complex forms of localized corrosion, such as corrosion under disbonded coatings on underground pipelines; and (iii) It avoids overprotection that can cause coating damages, such as cathodicdisbondment of coatings on pipelines.
These capabilities are important because localized forms ofcorrosion in complex environments is an unsolved problem and is probably the most significant issue that has not yet been sufficiently addressed in many industries. In the emerging renewable energy age, the control and management of localized forms of corrosion will be even more critical for renewable infrastructures that are often exposed to highly complex environments and are located at remote offshore sites.
Since 2021, a prototype of the technology has been tested on underground gas pipelines affected by coating disbondment and stray currents in Australia. This has confirmed that the technology is able to effectively reduce complex localized corrosion.
“PosiTector DPM L+”
Nominating organization(s): DeFelsko
Web site: www.defelsko.com/DPML
Innovationsummary: The newPosiTector Dew Point Meter (DPM) Logger Plus magnetically attaches to steel structures and is ideal for the unattended logging and remote monitoring of environmental data using WiFi or Bluetooth technology.
Fast response, precision sensors measure and record climatic conditions including relative humidity; air temperature; surface temperature; dew point temperature; the differences between surface and dew point temperatures; and wet bulb temperatures.
“Cathodic Protection Calculator Mobile App”
Nominating organization(s): Ell Engineering LLC
Primary awards contact: Ryan Grant Ell, Corrosion Engineer, ryan@ell-engineering.com
Web site: www.ell-engineering.com
Innovation summary: With both metric and imperialunits, the Cathodic Protection Calculator Mobile App contains over 150+ calculations from Cathodic Protection Tester to Engineer level. This app is currently available in the Apple App Store for Apple devices and the GooglePlay Store for Android devices.
“Application of the Algorithm of Invention (TRIZ)”
Nominating organization(s): Eninco Engineering B.V.
Web site: www.enincoating.com
Innovation summary: Corrosion is perhaps the only professional topic that encompasses three dimensions: science, engineering, and management. Corrosion science primarily relies on electrochemistry. Corrosion engineering involves various treatment methods, including physical methods(e.g., coating), chemical methods (e.g., corrosion inhibitors, biocides), electrical methods (e.g., cathodic/anodic protection), physical methods (e.g.,PIGing), design modification methods, materials selection/upgrade methods, and corrosion prediction methods (e.g., corrosion prediction algorithms/software).
On the other hand, while the key components of corrosion management are still subject to discussion, it can be said that important factors—beyond corrosion engineering elements—include economic and management considerations.
TRIZ, an abbreviation of the Russian term “теория решенияизобретательских задач,” translates to “The Theory of InventiveProblem-Solving.” TRIZ encompasses 40 principles designed to assist inventors in finding innovative solutions.
“Prevent CUI with Fiber Optic Technology”
Nominating organization(s): Fluves
Web site: www.fluves.com
Innovation summary: Fluves provides real-time monitoring and predictive maintenance for critical infrastructure such as pipelines, tanks, cables, furnaces, and reactors. Using innovative fiber optic and IoT technologies, Fluves detects potential issues at an early stage to prevent costly breakdowns and maximize the performance of industrial assets. The different solutions improve operational efficiency, extend asset lifetimes, and support sustainability.
“GC-500X Laser Cleaning System”
Nominating organization(s): G.C. Laser Systems Inc.
Web site: www.gclasers.com
Innovation summary: Pushing the limits of physics, the brand-new GC-500X is the result of 10 years of innovation by G.C. Laser SystemsInc., and it is the most powerful compact 1064nm pulsed laser cleaning systemever made for removing rust, removing coatings, and surface prep.
This record-breaking machine is the only 500W pulsed laser inthe world that can run off of a standard 120V power outlet in the United States, as well as any standard power outlet in the world ranging from 90V-240V AC50/60HZ.
The GC-500X achieves peak powers per pulse of well over 10,000W and offers unmatched tunability and precision. This durable portable unit is smaller than a folding chair, can go into confined spaces, and has enough power to quickly and safely remove rust, coatings, paints, and contaminants from ferrous and non-ferrous metals, as well as other materials.
This versatile system offers unmatched precision, which allows end users to meet the new AMPP laser ablation standards and guidelines: SP21511, GUIDE 21611, and GUIDE 21711. This 500W pulsed laser system is two-to-three-times faster than any other laser of similar output and is designed and made in the United States byG.C. Laser Systems Inc., a woman-owned small business (WOSB) that has brought game-changing laser technology to market for a decade.
This system is an excellent tool to have in the corrosion control toolbox for a variety of industries and Department of Defense (DoD) applications to clean and prepare surfaces for new coatings and linings, welding, and nondestructive testing (NDT) inspections.
“Vapor Pipe Shield”
Nominating organization(s): General Air Products,Inc.
Web site: www.generalairproducts.com/fire-protection-products/vapor-pipe-shield/
Innovation summary: Vapor Pipe Shield is a patented and UL-listedinnovative solution for the prevention of corrosion in dry pipe and pre-actionfire sprinkler systems. Vapor Pipe Shield is a delivery system of a vapor-phasecorrosion inhibitor (VpCI), a technology backed by over 40 years of establishedscience and superior to other corrosion mitigation technologies.
With noelectrical connections, Vapor Pipe Shield is fully mechanical and simply pipeddirectly in-line between the air compressor and the dry pipe valve in a drypipe fire sprinkler system. Vapor Pipe Shield is easy to install, easilymaintained, and makes corrosion mitigation in any dry or pre-action firesprinkler system simple, efficient, and highly cost-effective.
Vapor PipeShield simply takes a time-tested corrosion mitigation technology and adapts itto provide superior corrosion protection in the fire sprinkler industry, whichstruggles with corrosion on a daily basis.
“Iso-Smart Remote Asset Integrity Monitoring System”
Nominating organization(s): GPT Industries
Web site: www.gptindustries.com
Innovation summary: Iso-Smart represents a significant advancement in corrosion prevention and control activities. By providing a comprehensive, automated solution for asset integrity monitoring, it offers substantial cost and time savings, improves inspection and data collection processes, and helps extend the service life of critical assets.
Its ability to integrate with existing systems while providing advanced capabilities positions Iso-Smart as a valuable tool for industries seeking to enhance their corrosion management strategies while meeting the challenges of modern industrial environments.
“HP NanOKoat: Corrosion Mitigation Paint for Oil Refinery”
Nominatingorganization(s): HPCLR&D, Bengaluru
Web site: www.hindustanpetroleum.com/hp-research-and-development
Innovationsummary: HPCL’s research and development (R&D) center has developed an in-house corrosion resistant nanocomposite formulation (i.e., HP-NanOKoat) for the components, such as oil tanks and structures existing in HPCL refineries and its locations. These assets are prone to corrosion due to the salty environment.
The novel in-house coating formulation is a blend of various types of nanoparticles as filler and uses an epoxy resin as a base material. The performance of the in-house developed, corrosion-resistant nanocomposite coating is benchmarked with the currently used refinery coating in terms of bond strength and impedance to corrosive ions.
The coating is also tested in very aggressive salty environment (accelerated degradation)for more than 1000 hours (~42 days) by ASTM B117. The test results indicate that the developed nanocomposite coating is highly corrosion resistant, and this coating can replace the existing three-layer coatings. The in-house formulation is cost-effective with enhanced corrosion resistance.
The nanocomposite coating is applied in feed tanks at HPCL’s Mumbai Refinery for a real-time performance evaluation. It was found that the primer layer (bottom) and top layer (UV protection) was not required with HP-NanOKoat, and hence, the in-house formulation is cost-effective with enhanced corrosion resistance. It is envisaged to increase the operational life of tanks.
“Functionalized Borosilicate-Silica-Epoxy Nanocomposite Superhydrophobic Coating for Corrosion Inhibition under Harsh Environment”
Nominating organization(s): Indian Institute of Technology, Indian School of Mines
Web site: https://www.sciencedirect.com/science/article/abs/pii/S0300944024000560
Innovation summary: A simple and low-cost method for synthesis of corrosion resistant superhydrophobic nanocomposite coating with hierarchical structure was proposed using recycled borosilicate glass particles in combination with epoxy resin.
The micro/nano sized borosilicate glass particles when embedded on epoxy, was observed to bestow appreciable hardness and chemicalinertness. SEM study revealed hierarchical pattern formation of spherical SNPs over microsized borosilicate while maintaining cross-linked network with epoxy resin. 3D AFM topographical images confirmed the surface roughness of coating of Rq = 259 nm, supporting SEM analysis.
Remarkably, the coating maintained superhydrophobicity when subject to 250 abrasion cycles establishing promising durability under mechanical abrasive environment. Coating under acidic and alkaline solution underwent slow interface deterioration signifying limited ion diffusion. The marked corrosion inhibition efficiency of 98.18% under saline condition implied higher impedance of coated surface against ions intrusion.
Overall, this anticorrosive superhydrophobic coating can perform well under heavy applications and is suitable for marine and harsh environments.
“Perma-Clean 100 Single Leg”
Nominating organization(s): Induron
Web site: www.induron.com
Innovation summary: Perma-Clean 100 SL is the first100% solids batch mix product designed to be applied as a potable water tanklining. Perma-Clean 100 SL may be used as a liner for steel or concrete watertanks and may also be specified for immersion service in treatment plants, suchas clarifiers or aeration basins.
“DocuPaint Innovative Quality Control”
Nominating organization(s): Industrial Inspection Group
Web site: www.docupaint.com
Innovation summary: DocuPaint is a quality control/quality assurance software for digital reporting and storage. Written by industry certified professionals in accordance with recognized standards and practices for the paints, coatings, and linings industry, DocuPaint ensures accuracy and compliance by using real-time reporting and geographically stamped documentation.
Files are stored securely in a cloud-based repository for easy retrieval, review, and distribution from a multitude of platforms including mobile, tablet, and desktop. DocuPaint was built by paint people and for paint people.
“Non-Metallic Stand-off Barrier (Mica Spacer)”
Nominatingorganization(s): IntegrityProducts & Supplies Inc.
Web site: https://www.integrity-products.com
Innovationsummary: A patented solution, the Mica Spacer System offers an impermeable and stand-off barrier between thermal insulation and very high-temperature piping. This simultaneously protects against thermal degradation (e.g., binder burn-off) of insulation material, corrosion under insulation (CUI), insulation driven stress cracking (SCC), and thermal losses from high temperature thermally insulated systems.
Backed by peer-reviewed scientific research, the innovation aims to help improve the unaddressed protection and performance issues faced by thermally insulated assets.
“PTFE Spacer Wrap”
Nominating organization(s): Integrity Products & Supplies Inc.
Web site: www.integrity-products.com
Innovation summary: This patented solution—namely, PTFE spacer wrap—offers an impermeable and stand-off barrier between thermal insulation and pipe to simultaneously protect against corrosion under insulation (CUI), insulation-driven stress cracking (SCC), and thermal losses. Backed by peer-reviewed scientific research, the innovation is helping to address the unaddressed protection and performance issues faced by thermally insulated assets.
“Cross-Flo® Metal Jacketing”
Nominating organization(s): Johns Manville
Web site: www.jm.com/en/industrial-insulation/cross-flo-jacketing
Innovation summary: Cross-Flo Metal Jacketing from Johns Manville is a new, innovative, and effective product for removing moisture from an insulation system quickly, helping to reduce the risk of corrosion under insulation. Unlike other jacketing patterns, it provides a pathway between industrial insulation and metal jacketing for water to drain to a low point and through weep holes or drainage ports at the 6:00 position in the jacketing. The pattern promotes cross-directional flow (CDF), a mechanism whereby moisture can travel in any given direction, reducing “dead spots” where moisture can pool throughout a length of pipe. Compared to smooth or stucco embossed jacketing, Cross-Flo allows liquid to drain 45-80% faster.
Part of the maintenance process regarding insulation on industrial piping is the prevention and treatment of corrosion under insulation (CUI). Prevention is the best method to combat CUI because once it occurs, itis costly, time-consuming and expensive to fix. The primary cause of CUI is water getting into—and trapped in—an insulation system. Cross-Flo allows that water to quickly and thoroughly exit the system before it can reach the metal substrate and create CUI or get absorbed into the insulation and degrade thethermal performance.
Cross-Flo cuts, curls, and handles like any other metaljacketing, and it installs quickly. The pattern creates less surface area torub against the underlying substrate, making it easier to maneuver duringinstallation. Unlike corrugated metal sheeting, Cross-Flo can be installed inany orientation. It comes standard with a 3-mil thick polyfilm moisture barrierheat-laminated to its interior. Cross-Flo comes immediately available in .016,.020 and .024 aluminum gauges, and in standard cut and roll sizes and 50- or100-foot rolls. It can also be ordered with or without a safety hem.
Cross-Flo requires no additional tooling or installationmethods to successfully install and can be installed right along otherjacketing patterns. The diamond-shaped pattern allows for an installer to drawstraight lines right onto the jacketing itself without any additional straightedge tools and it also nests into itself when lining up the jacketing around apipe, creating a secure and tight installation.
“Kwiktech Encapsulation for Sandblasting”
Nominating organization(s): Kwiktech
Web site: www.kwiktech.com.au
Innovation summary: Kwiktech’s encapsulation framework offers a cutting-edge, customizable solution for protecting structures and surfaces from corrosion during sandblasting, coating, and rubber lining processes.
The modular design allows for rapid assembly and easy adaptation to varying project needs, empowering coaters to customize the setup themselves.
Kwiktech’s innovative hollow metal connectors ensure a durable, weather-controlled environment, providing optimal conditions for surface preparation and coating applications. This versatile system is the ideal solution for industries requiring flexible, efficient, and effective encapsulation.
“CP Waveform Analysis Tool”
Nominating organization(s): Lake Superior Consulting
Web site: www.lsconsulting.com/technology/field-data-capture/cp-waveform-analysis-tool
Innovation summary: The CP Waveform Analysis Tool isa free web-based tool that allows anyone to use it for the betterment ofcorrosion protection. It improves the analysis and efficiency of processing andinterpreting cathodic protection (CP) direct current time-series structurepotential waveform data.
The tool automatically generates a waveform after uploadingraw data, which provides critical clues on the characteristics of CPinterruption. Readily available to on-site or remote experts, analysis can bequickly performed so that needed repairs are made in the field. This quickly getsthe system to acceptable operating parameters, thereby improving quality andsaving operators time and money.
“CleanTech Industrial Robotic Cell CTIR-6040”
Nominating organization(s): Laser Photonics Corp.
Web site: www.laserphotonics.com/semi-automatic-laser-systems/robotic-cell-enclosure
Innovation summary: The CleanTech Industrial Robotic Cell 6040 (CTIR-6040) is a stationary semi-automatic fiber laser solution for removing corrosion and other contaminants from metallic and other surfaces. Laser Photonics Corp. was the first to combine collaborative robotics and laser cleaning technology inside a safety workcell, thus responding to a rising need for automated surface treatment solutions in industrial applications.
Powered by laser ablation, the cobot in the CTIR-6040 system effectively and repetitively removes corrosion, oils, epoxy, rubber residue, paint, zinc plating, silicate deposits, powder coating, radioactive pollutants, and other contaminants and coatings off a wide variety of surfaces. The tool also conditions the micro-surface of metal, leaving either a textured or polished finish without compromising the integrity of the underlying substrate.
The CTIR-6040 comes with custom-tailored configurations to meet the unique needs of each client, from the enclosure setup to the operating mode and power of the laser. Laser Photonics offers laser systems equipped with pulsed or high-power continuous wave fiber laser technology, providing versatile options for a broad spectrum of applications and industries. The design of the CTIR-6040 workcell, which encompasses the enclosure and the heavy-duty welding table inside, is engineered to cater to each client’s specifications. Custom modifications are made to ensure effective fume filtration, adherence to Class I laser safety standards, and the quick and seamless installation of parts to be treated.
“SentraLink LD Leak Detection Monitoring System”
Nominating organization(s): Lindsay Corp.
Innovation summary: This is a remote monitoring system designed to interface with “passive absorptive sensors.” These sensors detect the presence of liquid hydrocarbons by increasing the sensor resistance as hydrocarbons pass through an absorptive membrane.
The innovation is inventing a monitoring system that can interface with the sensor; detect when an alarm condition indicating a leak occurs; and provide notification to operating personnel for early detection while prompting corrective action.
“Hydrogen Concentration Sensor”
Nominating organization(s): Matergenics Inc.
Web site: www.matergenics.com
Innovation summary: The hydrogen sensor measures several physical variables of the metal and algorithmically converts that to hydrogen concentration. This is compared to the previously determined critical concentration and transmitted wirelessly.
“Zee probe, Graphitization Detection Sensor”
Nominating organization(s): Matergenics, Inc.
Web site: www.matergenics.com/2022/08/04/sweet-success-2
Nomination summary: The “Zee Probe” was designed to overcome the limitations of existing maintenance strategies by introducing a proactive, non-destructive technique for early detection of graphitization. By accurately identifying and assessing the severity of graphitization within critical areas of the water distribution system before catastrophic failures occur, this technology aims to shift the paradigm from reactive to preventive maintenance.
This shift promises not only to enhance the safety and reliability of water supply systems but also to mitigate the economic impacts associated with water main corrosion, thereby safeguarding public health and safety while promoting greater economic stability and resilience within municipal water systems.
“CorTalk RDL1 Remote Datalogger”
Nominating organization(s): Mobiltex Data Ltd.
Web site: https://www.mobiltex.com/solutions/cathodic-protection-remote-monitoring/cortalk-rdl1/
Innovation summary: The RDL1 (Remote Datalogger One) represents a convergence of two classes of technology that have long been cornerstones of the cathodic protection (CP) industry— stationary dataloggers and remote monitoring units. An evolutionary step, the RDL1 is the industry’s most powerful and versatile battery powered remote monitoring device with enhanced fast sample datalogging capabilities.
The RDL1 allows operators to gain visibility into the performance and state of their protection systems while capturing granular data suitable for the identification and diagnosis of fast-occurring events. A versatile tool, the RDL1 can be used in a wide range of applications. These include identifying transient dynamic AC and DC interference from a light rail transit system; datalogging Telluric impacts during a survey; and monitoring a constant potential rectifier.
The RDL1 communicates the data that it has recorded to the CorView.Cloud platform via 4G CATM1 cellular technology and can also be used in local mode as a stationary datalogger. A dual-file structure for data sampling and recording promotes efficiency for battery life and data costs, with battery life exceeding five years—even with one second sampling.
To top it off, the RDL1 pairs with the CorTalk INT1 to provide GPS synchronized interruption for critical bonds and sacrificial anodes, which eliminates the need for technicians to install portable interrupters. Simply put, the RDL1 represents a new generation of remote monitoring capabilities that will dramatically improve how CP systems are operated.
“RMU1-SUB Sub-Grade Remote Monitoring Unit”
Nominating organization(s): Mobiltex Data Ltd.
Web site: www.mobiltex.com
Innovation summary: The RMU1-SUB collects and transmits cathodic protection (CP) performance data and GPS location as frequently as every few hours via satellite or cellular network. This provides technicians with a highly detailed, near-real-time view of the CP system and helps identify short-lived events that may impact CP performance.
When combined with the MOBILTEX CorView web analytics platform, a network of RMU1-SUB devices provides corrosion engineers deep insights into the performance of a CP system. This powerful reporting instantly identifies areas of concern.
The RMU1-SUB installation delivers a unique and intelligently designed solution for the most challenging urban and rural applications. Ultimately, it improves safety, reduces expenditures, and optimizes integrity programs to become proactive, not reactive.
“N’GENIUS 326L35M4N”
Nominating organization(s): N’GENIUS MaterialsTechnology
Web site: www.ngeniusmaterials.com
Innovation summary: N’GENIUS 326L35M4N is a new high-strength austenitic stainless steel grade which possesses vastly improved corrosion resistance compared to cast superaustenitic 6Mo alloys.
Containing less molybdenum and a higher level of nitrogen compared to commonly utilized cast 6Mo grades, including CK3MCuN and CN3MN, the chemical composition of N’GENIUS 326L35M4N has been carefully selected to optimize castability and performance. The result is an alloy that has significantly higher mechanical strength and a far superior resistance to pitting and crevice corrosion.
Furthermore, manufacturing cast 6Mo grades can be problematic in both the manufacturing process and in-service. The materials are difficult to cast in thick sections and they are prone to hot cracking, macro-segregation, micro-segregation, and secondary-phase precipitation. These alloys can also experience grain growth during solution heat treatment, which can significantly affect the performance of the material.
N’GENIUS 326L35M4N has been developed to overcome these issues and has the potential to become a key material of choice for various stainless steel cast components of piping systems including valves, pumps, and filters in major global industries such as oil and gas, defense, and aerospace.
“Internal Corrosion Module (ICM)”
Nominatingorganization(s): OneBridgeSolutions
Web site: https://onebridgesolutions.com/product/corrosion-management
Innovation summary: The Internal Corrosion Module (ICM) adds transparency to an operator's internal corrosion program by integrating and analyzing various data sets to determine a program’s effectiveness. It is designed to provide integration, analysis, and tracking of internal corrosion monitoring and chemical program data and information.
Its value to operations and engineering can be further enhanced when combined with OneBridge’s Cognitive Integrity Management (CIM) Assessment Planning functionality that facilitates correlating ILI data. This provides comprehensive internal corrosion analysis.
“PCMP-PL©: A Comprehensive Approach”
Nominatingorganization(s): PETRONAS
Web site: https://www.mciiassure.petronas.com/PETROLIAM/PCMPPL/Dashboard
Innovation summary: P-CMP for Pipeline (PCMP-PL) is a new way to manage in-service pipeline integrity via risk-based integrity operating window (IOW) development and implementation. This innovation strikes a balance between inspection and control strategies, thus optimizing the corrosion management program (CMP) by focusing on high-risk damage mechanisms while reducing efforts for lower-risk threats.
It includes critical inspections, monitoring, and addresses risk factors, thereby providing a basis for planned CMP activities. The program also sets monitoring limits, or IOWs, and outlines appropriate actions for deviations from these limits.
“Rapid Prep VB 2400 Blast & Recovery System”
Nominating organization(s): Rapid Prep
Web site: www.rapidprep.com/product/vb-2400-blast-recovery-system
Innovation summary: Rapid Prep’s VB 2400 blast andrecovery system is designed for open or contained blasting. The system combinesa high-powered vacuum system, a classification system for grit recycling, andabrasive blasting capabilities to deliver an all-in-one unit fit for a varietyof applications.
The VB 2400 recovers spent abrasive and debris as blastingoccurs, making it ideal for areas where dust control is crucial. The ability toreuse abrasive materials increases efficiency and reduces waste, all whilemaintaining a small jobsite footprint. Since its conception, the classificationand vacuum systems have been improved to increase efficiency and match theneeds of each user.
“Robroy Stainless Hygienic Fittings”
Nominating organization(s): Robroy Industries
Web site: www.robroystainless.com
Innovation summary: Robroy Industries’ industrial fittings are engineered for robust performance in a wide range of industrial applications, including manufacturing, chemical processing, and heavy-duty operations.
Robroy’s stainless food-grade fittings are designed for use in industries where cleanliness and sanitary conditions are paramount, such as those found in food processing, pharmaceuticals, and biotechnology. These fittings are crafted from high-quality stainless steel (304 or 316), which offer excellent resistance to corrosion and are easy to clean.
“CR-Tech (Corrosion Resistant Technology)”
Nominating organization(s): ROCKWOOL TechnicalInsulation
Web site: https://rti.rockwool.com/applications/cr-tech/
Innovation summary: ROCKWOOL Technical Insulation is meeting the challenge of corrosion under insulation (CUI) with the new and innovative CR-Tech (corrosion resistant technology). The proprietary corrosion inhibitor applied to ProRox stone wool mandrel wound pipe insulation helps shield against corrosion in process-critical piping.
The next-generation CR-Tech is embedded into the inner surface of the stone wool, right where the insulation touches the pipe. Upon contact with water, the inhibitor is activated to form a thin, passivating layer that is ready to help neutralize corrosive environments. CR-Tech inhibitor buffers the corrosive environment under the insulation by forming a protective, corrosion-mitigating film on the metal pipe substrate.
ProRox with CR-Tech also includes ROCKWOOL’s WR-Tech (water repellency technology), a low-chloride, water-repellent binder that coats individual insulation fibers to minimize water absorption. This unique combination of water repellency and corrosion inhibition (now in one insulation product) is proven to shield pipes from CUI in multiple industry-standard tests.
In the ASTM G189 test that simulates an accelerated corrosion environment, CR-Tech achieves at least five-times better corrosion mitigation versus alternative, hydrophobic insulation options. In the ASTM C1617 test that measures the relative corrosion rates of steel in contact with solutions that are extracted from the insulation, CR-Tech actively protected the steel, even with the addition of chlorides at concentrations up to 600 ppm.
“AI-Driven MFL-A/C Data Fusion”
Nominating organization(s): ROSEN
Innovation summary: This innovation presents a novel AI-driven magnetic flux leakage (MFL) data fusion model, which works directly on the MFL signal data using machine learning-based (ML) algorithms to overcome the subjectivity in the inspection report.
The ML-driven data fusion process is a series of algorithm enhanced operations. First, it takes the raw measured MFL signals as inputs, and it pre-processes the signals to eliminate the measurement variations. Then, the pre-processed signals are aligned to ensure the signal responses from the same corrosion anomalies are well matched for the final fusion step.
The fusion model is a U-Net structure neural network. It has been trained to take advantage the complementary information from MFL-A and MFL-C signals, and it produces a single output of a high-resolution, three-dimensional (3D) corrosion depth map.
From the produced 3D corrosion depth map, the corrosion anomaly geometry information is generated efficiently and objectively. The fused 3D map provides a detailed morphology of the corrosion anomalies which benefits the calculation of burst pressure and remaining life.
In summary, the testing, application, validation, and generalization of MFL-A and MFL-C inspection fusion are supported with field data. The fusion of complementary information from two MFL inspections decreases the measurement uncertainty, resulting in an accurate max depth prediction and a safe remaining life assessment. Furthermore, the morphology information in the fusion 3D corrosion depth map reduces the inherent conservatism in a conventional box profile, and it leads to a more precise burst pressure calculation.
“Sherplate 600”
Nominating organization(s): Sherwin-Williams
Innovation summary: As a high-solids epoxy phenalkamide lining, the technology is free of restricted solvents and does not contain xylene, toluene, ethylbenzene, or oxsol. This makes it ideal to meet increasingly stringent environmental regulations while still retaining some user-friendly properties.
Approved for potable water use in water tanks, pipes, ductile iron pipes, and water treatment plant assets, the coating’s high film-build and high edge-retention capabilities allow it to be used for stripe coating welds, edges, and corners before completing full lining applications. While epoxy formulations containing solvents have long been preferred for stripe coating, many are no longer permissible under new regulations.
“Heat-Flex® CUI-Mitigation Coatings”
Nominating organization(s): Sherwin-WilliamsProtective & Marine
Innovation summary: Sherwin-Williams Protective & Marine has introduced new ways to mitigate the dangerous condition of corrosion under insulation (CUI) with its new line of Heat-Flex CUI mitigation coatings. The line includes Heat-Flex ACE (advanced CUI epoxy), an ultra-high-solids epoxy novolac featuring a functional chemical enhancement for CUI mitigation.
Representing a new class of CUI mitigation coatings, it performs the best at combating CUI out of any other formulation available. The lineup also includes Heat-Flex 750, Heat-Flex 1200 Plus, and Heat-Flex 650, which feature a high concentration of micaceous iron oxide (MIO) pigment and offer significantly improved CUI-mitigation performance.
Roughly 60% of all insulation in service for more than 10 years will contain corrosion-inducing moisture. This trapped moisture creates a ripe environment for CUI, limiting coating service lives to just five to 13 years. This short time frame significantly raises maintenance costs, as owners will need to frequently shut down processes and rehabilitate insulation systems to gain another short period of protection. The new coatings stave off the corrosion process much longer, all while enhancing safety, reducing downtime, and lowering operational costs.
Heat-Flex ACE is a complete advancement over other similar coatings, outperforming them significantly. The two-component, organic, ultra-high-solids epoxy novolac coating is also solvent free, unlike most other CUI-mitigation epoxies, which typically have between 60-80% volume solids. It reduces the release of VOCs for better environmental stewardship and reduced applicator permitting costs.
Each MIO-enhanced coating features a minimum concentration of 25% MIO pigment by weight in the dried coating film, which helps extend coating life and reduces risk by addressing typical CUI failure mechanisms experienced in service and during shipping and construction.
Heat-Flex CUI mitigation coatings can be used to curb the advancement of corrosion on a wide array of insulated assets, including process piping and vessels, storage tanks, industrial valves and fittings, and other assets.
“Prompt Corrosion Survey and Appraisal During Petrochemical PlantTurnaround”
Nominating organization(s): SINOPEC ResearchInstitute of Safety Engineering Co., Ltd.
Innovation summary: Confronting the challenges of inefficiency and limited data accessibility inherent in traditional corrosion surveys within the refining and chemical industries, we have developed a suite of intelligent, mobile corrosion inspection equipment and software. By harnessing the power of IoT, non-destructive testing (NDT), corrosion assessment algorithms, and cloud services, our solution enhances the collection and utilization of offline equipment condition data.
This innovative solution comprises an explosion-proof smartphone, ultrasonic thickness gauges, and a comprehensive software package including a cloud platform and a mobile application. The thickness gauges interface seamlessly with the smartphone via Bluetooth, transmitting thickness measurements, corrosion defect images, and video footage to the cloud platform.
The software then automatically correlates corrosion data with specific equipment or piping components, processes it through advanced assessment models, and generates critical information such as the corrosion risk level, detailed survey reports, and future inspection plans. This information is promptly disseminated to the relevant personnel and integrated into the upper-level equipment mechanical integrity management systems, thereby establishing a more efficient and data-driven closed-loop corrosion management process.
Since its debut in November 2022, this innovation has been successfully implemented in several big corrosion survey projects. It has demonstrated a significant enhancement in survey efficiency, a reduction in manpower requirements, and the ability to develop scientifically informed inspection and maintenance strategies, leading to substantial cost savings.
“Asset Monitoring Using Magnetostrictive Materials andOptical Fiber Sensors”
Nominating organization(s): University of AlaskaAnchorage
Web site: www.uaa.alaska.edu/academics/college-of-engineering
Innovation summary: Facility piping and flow lines represent the usually most threatened assets. Usually, these pipes are laid above ground and are coated with protective coating and sometimes with a thermal insulation layer. They have relatively small diameters and are rarely equipped with launching and retrieval infrastructure for pipeline inspection gauges (PIGs) that are used for detection of defects on the interior pipe wall. Hence, manned inspections of large networks of facility piping are time consuming, costly, and may also pose a risk to the crews.
We developed a novel monitoring method for detecting degradation of pipe or storage tank walls that is based on the detection of magnetic flux leakage via magnetostrictive materials and fiber optic sensors. The main advantages of the novel method are: (i) it does not require power and will be safe in volatile environments, (ii) does not disturb operation of the pipeline, and (iii) sensing nodes can be deployed over large distances.
The proposed method is based on the idea of monitoring the magnetic flux leaking out of the pipe or tank wall as the wall gets thinner due to corrosion, cracking, or erosion processes. As the wall deteriorates and gets thinner, the magnetic flux will leak out of the pipe wall and pass through the magnetostrictive material, inducing mechanical strain in it. This strain can be measured by a Fiber Bragg Grating (FBG) optical strain sensor. The sensor prototype has been developed and built in the lab and test using carbon steel plates of different thicknesses. We observed approximately linear relationship between the measured strain and the metal thickness.
