The global corrosion control community submitted a near-record amount of nominations for MP’s 2021 Corrosion Innovation of the Year Awards, of which 40 are now finalists. The program provides a forum for Association for Materials Protection and Performance members and customers to showcase their corrosion mitigation technologies and receive recognition for their innovative solutions. Winners will be selected by a panel of corrosion-control experts and announced at the CORROSION 2021 Virtual Conference & Expo.
After 26 years of intensive and continuous research, this group designed a multi-functional material for the surface of stainless steels (SS). It shows ultra-high anticorrosion, anti-coking performances in refinery processes, and it is described as the only large-scale, successful industrialized surface strengthening technology for SS internals in the international petrochemical industry. The product makes contributions to the goal of extending the overhaul period of refining and chemical plants to one repair in five years. The utilization of this technology also benefits the petrochemical industry economically and socially.View Full Description
The innovation is a condition monitoring sensor, named the Belenus, which uses innovative, thin-film ultrasound technology to enable the real-time, in-service monitoring of assets. With its compact size and true flexibility, the Belenus can be fitted to a range of structures including pipes, storage tanks, and pressure vessels, enabling 24/7 asset monitoring. Capable of continuous operation at up to 400 °C, the Belenus is suitable for fixed installation in both extreme and ambient environments.
The Belenus utilizes an ultrasonic pulse-echo to monitor pipe wall thicknesses. It generates an ultrasonic signal into the pipe, and the time taken for a reflection to be detected allows for the calculation and visual display of the pipe wall thickness on a data acquisition unit. A faster arrival time indicates that the pipe wall is thinning. The novel utilization of ultrasonic thin-film material means that the Belenus has no intrinsic Curie temperature, unlike most standard sensors.
CartoPac Cathodic Protection is a next-generation field data collection software used to perform periodic surveys, close-interval surveys, and general troubleshooting. When developing CartoPacCathodic Protection, key objectives were focused on Increasing operational efficiency and maintaining data integrity. Users will see time savings, since this software facilitates performing close interval and periodic surveys. They will also realize cost savings, because it ensures data quality is preserved throughout the data lifecycle, from the point where it is captured to the final database of record. Thus, it reduces the chance of having to resurvey areas due to user errors or errors in data.View Full Description
Cold Fusion Concrete FP250 is a cementitious spray applied fireproofing (SFRM) that contains no Portland cement. According to the developer, it inhibits corrosion as well as or better than galvanizing, intumescent IFRMs, or corrosion-resistant paints and primers. FP250 is also made of industrial waste, which allows it to significantly reduce the carbon footprint of all other SFRMs and IFRMs.View Full Description
Steadily increasing requirements for material properties have led to ongoing research and development of materials in order to resist corrosion. The focus often lies on coatings or modified alloy compositions. Another alternative is the use of application-oriented and qualified material.
With Corrodur 4418 Mod (Super 13 Cr; UNS S41426), Deutsche Edelstahlwerke provides a material solution whose performance exceeds that of conventional chromium steels such as 1.4006 (AISI 410) and 1.4021 (AISI 420). This high-performance steel is characterized by high strength, outstanding toughness, and good resistance to pitting and stress corrosion in a relevant range of temperatures. Material with two different strength levels (min. 95 and min. 110 ksi yield strength, respectively) was qualified according to NORSOK M-650 by setting up a well-controlled manufacturing route. In combination with successful corrosion test results per NACE TM0177 and NACE TM0316 regarding SSC and SCC, this grade was qualified according to NACE MR0175 Annex B.2.3. Deutsche Edelstahlwerke was the first company completing this double qualification, allowing it to guarantee the properties of Corrodur 4418Mod for dimensions ranging from 2" up to 12.25” OD and up to 39’ in length.
The CorTalk RMU1 G4 and INT1 interruption peripheral represents the cathodic protection industry’s first permanently installed, battery powered remote monitoring device that enables GPS synchronized interruption for critical bonds and sacrificial anodes. The RMU1 Generation 4 adds two-way communication, enabling it to receive commands and to control the new INT1 accessory device for GPS-synchronized interruption.
The INT1 automatically pairs with the RMU1, eliminating the need for technicians to install portable interrupters to break bonds or interrupt sacrificial anodes. The RMU1 + INT1 product combination can be installed within minutes inside a standard 3-inch test station, allowing field technicians to greatly expand their remote monitoring and interruption programs to improve their operating efficiency, accuracy of measurements, achieve compliance, and to ultimately improve the safety of field personnel and the public.
Differential Reflectometry Mapping (DRM) is a novel technology that uses electromagnetic reflectometry to assess the state of a coating on buried pipeline networks. This technology allows users to detect, locate, and characterize coating defects, including delaminations. DRM is non-invasive and ideally suited to assess pipelines in cities, under roads or waterways, and in other challenging environments.View Full Description
The DCPro cathodic protection (CP) power supply is a new variation on switch-mode power utilized for the industry. It provides many new and needed features, but in a simplified package that is made to look and “act” like a conventional CP power supply (rectifier). In addition, the DCPro line is a “two sizes fits most” product that can be a solution for 80 percent of the CP industry. The DCPro is stocked and ready to ship, shortening the normal “rectifier” delivery cycle from many weeks to a few days.View Full Description
PPG’s innovation utilizes mobile and cloud-based computing technology to not only collect corrosion and inventory data of assets, but also to apply algorithms to predict future asset conditions. From there, it works to analyze, prioritize, schedule and budget asset management activities. This information can be easily accessed through a user dashboard on an internet connected device.
PPG’s Asset Integrity Management (AIM) program uses a data-driven approach to the corrosion management of assets. PPG AIM incorporates predictive modeling that can forecast future asset conditions by following lifecycle curves. This means at any time, users can fast forward the age of various assets and calculate the likely outcome. Users can compare multiple scenarios based on different inputs and determine what plan meets their overall maintenance needs and budget.
This novel predictive corrosion under insulation (CUI) monitoring system is based on a sensor mounted on the external surface of pipes and vessels. The key technical technology behind the new high-resolution monitoring system from CorrosionRADAR is the Electro-Magnetic Guided Radar (EMGR). This new monitoring system is suitable for wide range of structures and applications, including on large surfaces (such as process vessels and tanks) and complex geometries (e.g. valves and flanges).View Full Description
EVOLUTION is the first fully encapsulated isolation gasket with the highest dielectric strength and highest-pressure capability for an isolation product; the most chemical resistance of any isolation gasket; and the tightest seal of any isolation product, according to the developers. This product isolates flanges to prevent galvanic corrosion and to optimize cathodic protection systems. All previous technology is attacked by chemical additives—by sour gas, steam, and high-pressure. This new design eliminates these problems and specifically addresses several other significant issues that pipeline operators have expressed in recent years, such as fire safety, simple installation, and inventory consolidation.View Full Description
This innovation, the FOAMGLAS Sealed System, is a combination of impermeable, cellular glass insulation used in conjunction with a new joint sealant technology—PITTSEAL Hi-Temp LV RTV Sealant—to completely seal joints and compartmentalize insulated sections to help prevent water from entering a piping system.
By completely sealing the insulation joints, the FOAMGLAS Sealed System creates a moisture barrier, protecting the pipe from various moisture sources such as condensation, precipitation, process leaks, deluge systems, cooling tower drift, sprinklers, and cleaning processes. The system can also be used with other insulating system components, such as jacketing, for additional mechanical protection.
This innovation is a highly specific qPCR assay that allows for the detection and quantification of a gene cluster that is only present in a subset of (methanogenic) microorganisms. These particular microorganisms have been demonstrated by the team to be able to corrode carbon steel at rates of up to 2.4 mm/yr (weight loss-based CR) under conditions that simulate oilfield pipelines. Non-corrosive methanogens are not targeted by this assay, and as such, it has the ability to serve as a binary marker for corrosion caused by this important and abundant group of environmental microorganisms.View Full Description
A new non-magnetic high interstitial (FeCrMnMo(C+N)) austenitic stainless steel has been developed. Outstanding mechanical properties combined with strong corrosion resistance in chloride environments, as well as economically effective production, make the high interstitial (C+N) non-magnetic austenitic stainless steel a promising alloy for oil and gas applications.View Full Description
This new nickel-free, high-strength austenite was developed for additive manufacturing. Investigations show that the new development can be additively processed similar to the reference steel 316L. The mechanical properties of the new development, determined in tensile tests, show mechanical properties (Rp0.2, Rm) that are twice as high when compared to 316L, with simultaneously increased corrosion resistance against chloride ions.View Full Description
This innovation is a cloud-based, mobile digital application designed to help improve installation quality through increased traceability and accountability in both field and office environments. iLINE allows a field crew to remotely access all technical references and instantly update and create quality documentation with GPS coordinates, photos, and final installation approval.View Full Description
The innovation is a systemic method for an economical and safe approach to conducting high-temperature halogen gas corrosion tests on metallic alloys. This eliminates the need for the use of dangerous, flowing halogen gas systems and the attendant safety issues. The test setup consists of a two-compartment ampoule, where a vestibule connects these two compartments. A pre-selected mixture of salts is placed in one compartment to generate a specific partial pressure of halogen gas, while a metallic alloy is placed in the other compartment. The ampoule is then heated to a pre-determined temperature and held at this temperature for the desired time.
A halogen gas of a specific partial pressure is generated from the mixture of salts. Because the ampoule creates a sealed environment, the metallic alloy is under constant halogenation during the pre-determined time period.
CUI (corrosion under insulation) is a dominant cause behind the failure of insulated piping and is triggered by the trapped moisture inside thermal insulation. Any moisture inside the insulation stays trapped, unless allowed to escape via insulation removal or replacement. This can be both a temporary and expensive remedy. Even on pipes with high operating temperatures, the evaporated moisture likely stays on the inside of jacketing and seeps back into the insulation via condensation and pooling at low points. This patented innovation for thermal insulations allows the trapped moisture in the insulated system to escape via low-point drainage and evaporation.View Full Description
Flexitallic's ISOFLEX product range represents a new type of electrically isolating gasket that does not compromise sealing best practices. The ISOFLEX designs are best-in-class in sealing and isolation, according to the developers. Furthermore, the technology addresses the pitfalls and concerns of many existing market offerings that revolve around leak prevention, corrosion mitigation, electrical isolation, and overall asset integrity.View Full Description
LineVision’s innovation is a new field sensor platform that collects and disseminates real-time data on AC power flows and conductor phase arrangements, independent of any involvement by power line companies. The patented technology, known as LineVision PACT, utilizes magnetic and electric field sensors to collect measurements of the Electromagnetic Field(EMF) that power lines generate when AC power is flowing on them. The collected measurements are remotely communicated to servers, where data is processed through proprietary algorithms, and the AC current flowing on the power line is able to be determined.View Full Description
This new cathodic protection (CP) installation setup for a single onshore well casing is associated with the flowline, which saves costs and avoids copper cable theft. By adopting a new setup of installing the CP system, this saves material, efforts, time, and avoids cable theft to the lowest limit.View Full Description
The innovation is an electrical connector where the contacts will not corrode or short out, even when fully immersed and powered in seawater or other corrosive media. This new connector technology does not need to exclude water from the contacts, so it requires no seals or dielectric oil.
Traditional underwater connectors make their electrical contacts from the same materials that they use in air, brass, or copper, and then try to exclude the water from any contacts with seals or oil. NiobiCon makes the contacts from transition metals, such as niobium. These develop highly-insulating passive films in water and other corrosive media, and they can experience relatively high applied voltages without breaking down. The contact-to-contact scraping that occurs during mating removes this film locally, allowing for good electrical contact. Upon de-mating, the film re-forms in milliseconds, thus maintaining the insulation. Therefore, these connectors can be fully powered, while mated or de-mated, without shorting electronics or having the contacts corrode.
The new Non-Intrusive Corrosion application for Emerson’s Plantweb Insight gives customers a superior understanding of the condition of their assets, allowing for better predictive maintenance and plant optimization. Rosemount Wireless Permasense corrosion data is delivered securely to the end-user’s desk through the Plantweb Insight platform, offering real-time advanced analytics to assess the impact of profitability-driven process changes. Users can utilize the retirement planning feature to drive turnaround extensions and avoid unplanned downtime. They can also minimize maintenance costs through better replacement part planning, as well as reduced manpower costs via remote and dangerous location monitoring. Detailed visualizations enable large data sets to be analyzed quickly and effectively.View Full Description
This innovation involves the use of a strong magnet in combination with a conductive epoxy to provide a permanent test lead connection without any heat applied to a pipeline.
The pipeline is prepared for a test lead connection in the normal way, with the coating removed and cleaned for a connection. The two-part conductive epoxy is then mixed and applied to the NotHot saddle, which is then set on the cleaned pipe. The magnet holds the NotHot saddle in place while the conductive epoxy cures. The system can be coated with a standard pipe coating, in accordance with operator requirements. There is an optional extendable pole.
A critical experiment was developed for conducting the world’s first in-core investigation of irradiation-assisted stress-corrosion cracking (IASCC) under cyclic loading and electrochemical control. This is aimed at providing reliable experimental data for examining the validity of various hypotheses, as well as determining the efficacy of something previously untried regarding IASCC.
In these experiments, irradiation assembly and associated remote-sensing instrumentation were designed for in situ and operando monitoring of electrochemically controlled IASCC in cyclically loaded specimens under the influence of high-temperature water (up to 347 °C, 15.5 MPa) and radiation in the U.S. Department of Energy’s High Flux Isotope Reactor (HFIR). This reactor provides one of the highest steady-state neutron fluxes of any research unit in the world.
During the experiment, pre-cracked specimens could be charged with hydrogen at any specific crack growth rate, measured in situ with the world’s highest average crack extension resolution of about 10 nm. In turn, this allows the use of—for the first time in high-temperature water—an experimental method developed for quantitatively defining the extent of hydrogen-induced cracking and stress-assisted dissolution in corrosion fatigue crack growth.
Plasite XHT 400 (Extreme High Temperature) is a heat-resistant lining for the long-term protection of fire tubes. Plasite XHT 400 utilizes a novel new resin system with Supoxy technology (patent pending), a highly cross-linked resin with extreme heat resistance and outstanding chemical resistance.
Supoxy extends heat and chemical resistance beyond current epoxy lining systems, according to the company. This coating is ready for many rigorous tasks associated with corrosion on fire tubes associated with upstream oil and gas process vessels. The impermeable film, reinforced with proprietary ceramics, blocks aggressive vapors and solutions from film penetration and subsequent corrosion. This high cross-link density makes Plasite XHT 400 an exceptional choice for the daily stress associated with coating service for fire tubes.
The new PosiTector DPM L Dew Point Meter Logger makes it easy for inspectors to track and record environmental conditions on the jobsite. It magnetically attaches to steel structures to autonomously measure and record relative humidity, air temperature, surface temperature, dew point temperature, and the difference between dew point and surface temperatures. Using a single battery, it can record readings at user-selected time intervals for up to 200 days.View Full Description
PTFE spacer wrap is an impermeable membrane made from PTFE (ploy tetra fluoroethylene) with dimple shaped protrusions that are aimed to create a 6-mm standoff between thermal insulation and metallic pipe. This is done by eliminating direct contact between thermal insulations and the surface of metallic pipe. The impermeability of PTFE impedes dripping moisture and leaching agents of thermal insulations from contacting a pipe’s surface.
This, in turn, reduces the risk of CUI (corrosion under insulation), SCC (stress corrosion cracking), and corrosion fatigue. In addition to protection from CUI and related damage mechanisms, the thermal insulative nature of PTFE shields heat transfer from pipe to thermal insulations. This insulative ability also reduces the exposure temperature of thermal insulations while increasing the thermal performance of fibrous insulations.
By manipulating the laser flux, its wavelength, and its pulse length, the amount of material that is being removed by a single laser pulse can be controlled with extreme precision. This makes laser cleaning equally suitable for rapid and deep rust removal, since it removes only one thin layer of paint, and without damaging the base coat. The patented software can make 2D-laser patterns, which provide a smoother cleaning result and make operating the handheld machine easier when compared to 1D laser cleaning.View Full Description
REL2310 & REL2310B are normally closed, solid-state relays suitable to interrupt low-voltage rectifier AC secondary signals. The same relay is also suitable for interrupting bond connections using a battery powered RMU. The relay supports short interruption cycles, reduces installation time, and can be installed in smaller areas due to its small footprint. It can interrupt up to 100Vpeak/100A. REL2310 is intended to be line powered, while REL2310B is battery powered. By installing this device on the AC secondary side, it benefits from the surge protection built into rectifiers.View Full Description
The CorTalk RMU1 LITE remote monitoring unit allows pipeline operators to quickly equip cathodic protection (CP) test stations with robust and reliable remote data collection of pipe-to-soil potential measurements. Annual level of protection potential surveys can then be remotely performed from an office environment through a simple web-based control and data platform. Data quality can now be improved by obtaining those same readings at shorter intervals throughout the year, enabling a better understanding of seasonal variations on the CP system.
Offering essential, fit-for-purpose functionality, the RMU1 LITE is an ideal solution to cost-effectively scale IIoT capabilities and gain the benefits that large deployment remote data collection can bring to pipeline operations and maintenance. A unique digital signal-processing algorithm allows for on and instant off potentials to be accurately measured by simply interrupting CP on a structure in a periodic cycling manner for a short period of time.
Sanicro 35 is a unique grade that bridges the performance gap between stainless steels (SS) and higher-cost nickel alloys by offering high performance, strength, and corrosion resistance at a wide range of temperatures. The new alloy features high mechanical yield strength, superior corrosion resistance, and excellent structural stability.
Sanicro 35 provides an alternative to existing duplex and austenitic SS grades and more expensive nickel alloys. It offers a cost-efficient choice for minimizing risk and extending production lifecycles when battling corrosion in demanding environments. Because of its versatile properties, Sanicro 35 can potentially streamline inventories by replacing special grades, including 6Mo, Alloy 825, and Alloy 625. Sanicro 35 has undergone extensive laboratory testing, as well as field testing.
In this innovation, duplex stainless steels (SS) with a pitting resistance equivalent number (PRENw) above 30 have been considered to maintain both cost effectiveness and sufficient corrosion resistance in treated seawater conditions. SM25CRU duplex SS grades, namely, UNS S82551 and S82541 (the latter is a higher-strength version, but same PRENw), have been newly developed for this purpose.
A seawater test program with controlled dissolved oxygen concentrations (DOC), simulating real case conditions, was designed to demonstrate the corrosion performance of UNS S82551/S82541 by replicating water injection service conditions with DOC excursions. Both UNS S82551/S82541 under treated seawater systems with some presence of DOC showed good corrosion resistance. The innovation has been achieved by the combination of fit-for-purpose material design and DOC control technology, bringing important cost savings for Norwegian Continental Shelf wells.
Hexigone brings to market high-performance corrosion inhibitors that are independently proven to protect metal assets for longer, thereby prolonging lifecycles and reducing the strain on natural resources. Known as Intelli-ion, Hexigone's range of products replace toxic chemicals with safer, smarter, and sustainable inhibitors that bring coatings to life by enabling them to react and protect “on demand” against corrosion. This is done by incorporating an active ingredient which has never before been used effectively within coatings.View Full Description
COBALT’s Synthetic Metal Sucker Rod Guide Anodes afford a unique, effective, inexpensive, and simple means of corrosion control caused by electrolysis in oil-well fluids. Currently, there is no method of providing sacrificial anodes in downhole environments. In response, this innovation is the first globally that is cost effective, can be manufactured for all sucker rod sizes and engineered to meet general corrosive solutions, or can be custom designed for complex and/or highly corrosive environments.View Full Description
Apellix has created a tethered aerial robotic system for performing chemical wash using a pressurized high-volume flow of water or chemicals (e.g., NaClO, H3NSO3, Chlor-RidTM, etc.) to clean exterior structures. The system operates at up to 150 feet (~45 meters) and up to 1,450 psi (~100 bar) with 8 gpm (~30 L/min) of water, a chemical agent, or a mix. The system utilizes Apellix’s existing aerial robotic precision flight control autonomous features but remains under the direct supervision and control of a pilot and optional engineer or spotter, who are positioned on the ground and safely out of harm’s way.View Full Description
GPS synchronized current interrupters have been available for some time, but there was still room for improving the field friendliness, safety, and operator convenience. In this product, older LCD screens and keypads were replaced with a touchscreen user interface. Meanwhile, relays were changed to a new bidirectional model that is not sensitive to polarity or orientation, which increases the ease of correct installation.
The firmware now allows for a UTC offset to be programmed so that the CI-TS can be operated in local time. The CI-TS can be programmed to begin the interruption cycle with either the ON or OFF portion of the cycle, allowing the equipment to be seamlessly merged with any other manufacturer/brand of survey equipment. Error checking was incorporated into the firmware to ensure accurate field performance, once deployed. Long-life lithium-ion batteries are utilized to increase standalone run time in the field.
The Tracker CR system consists of a multi-channel remote monitoring unit and a dedicated ground probe assembly. It is designed to continuously measure DC pipe-to-soil potential; DC “coupon disconnect” off potential; free-corroding coupon potential; AC voltage potential; AC current density; DC current density; and AC drain to ground from mitigation equipment. All measurements are stored in internal memory and periodically (based on a user-defined schedule) sent to the web interface. Alarm conditions are sent to the web upon detection.View Full Description
Pumps, valves, and fire hydrants need to be operated slower to prevent cracks, crevice corrosion, and general corrosion due to water hammer. Even so, some water main failures are caused by corrosion alone. A multi-year study of corrosion, water hammer, and water main breaks has proven that water hammer breaks pipes and causes most corrosion failures. Thus, by eliminating water hammer, water main breaks will be nearly eliminated. Simplified estimates to determine these closure speeds for valves, hydrants, and pumps are available (“Water Hammer Breaks Water Mains”, by R. A. Leishear, 2019, ASME Journal of Pressure Vessel Technology).
Prior to this innovative discovery, water main breaks were completely misunderstood, and the understanding of corrosion mechanisms and corrosion control were entirely misguided. A clear understanding of fluid transients and hoop stresses now permits an appropriate understanding of water main cracks and corrosion.
Zerust Inhibitor Fusion (ZIF) Tape is a corrosion inhibiting tape based on silicone elastomers with proprietary Zerust corrosion inhibitor chemistry integrated into the matrix. It combines Zerust’s proven corrosion protection formulation with the specific properties of a self-fusing silicone film, which makes for an easy, ambient application to mitigate corrosion under insulation (CUI).View Full Description