corrosion & materials april 2011
DESCRIPTION
Corrosion & Materials April 2011TRANSCRIPT
1
O f f i c i a l P u b l i c a t i o n o f t h e A u s t r a l a s i a n C o r r o s i o n A s s o c i a t i o n • w w w . c o r r o s i o n . c o m . a u
Vol 36 No 2, April 2011ISSN 1326-1932
& M A T E R I A L S
Inside this Issue:ACA Corrosion Challenges Project
List of ACA Certified Technologists and Technicians
Microbially Influenced Corrosion
Project Profile: Re-Lifing a CO2 Absorber Tower Using Welding Robots
Project Profile: Refurbishment of the Vessel One and All
University Profile: University of New South Wales
Research Paper: Probing Corrosion Activities in Difficult-to-Test Media Using the Wire Beam Electrode: Case Studies
Research Paper: Effectiveness of Cathodic Protection System on Constructed Tanks over Bituminous Sand Mix Layer
Vol 36 No 2 April 2011 www.corrosion.com.au 3
Front Cover Photo Weld Procedure Qualification in progress, using a mechanised GMAW system for the Bayu Darwin subsea pipeline project.
Photo Supplied by IWES Pty Ltd
4» President’sMessage
6» ChiefExecutiveOfficer’sMessage
8» News
15» ACABranchNews
16» ACAStandardsUpdate
20» ACACorrosionChallengesProject
25» CoatingsGroupMemberProfile
26» ACATechnicalGroupsUpdate
28» ACACertifiedCorrosionTechnologistsandTechnicians
30» MicrobiallyInfluencedCorrosion
33» ProjectProfile:Re-Lifing a CO2 Absorber Tower Using Welding Robots
36» ProjectProfile:Refurbishment of the Vessel One and All
38» UniversityProfile:University of New South Wales
41» Researchpaper:Probing Corrosion Activities in Difficult-to-Test Media Using the Wire Beam Electrode: Case Studies
50» Researchpaper:Effectiveness of Cathodic Protection System on Constructed Tanks over Bituminous Sand Mix Layer
57» SuppliersandConsultants
The ACA is a founder member of the World Corrosion Organization
ISSN1326-1932Published by the Australasian Corrosion Association Inc. ABN: 66 214 557 257PublicationsDirectorMohammad Ali – GHD, [email protected] Cherry – Monash University, [email protected]: Bruce Hinton – Monash University, [email protected] Practice: Willie Mandeno – Opus International Consultants,
[email protected]: Ian Booth – Australasian Corrosion Association, [email protected] Atrens – University of Queensland Nick Birbilis – Monash University Lex Edmond – Monash University Harvey Flitt – Queensland University of Technology Maria Forsyth – Monash University Rob Francis – Aurecon Australia Warren Green – Vinsi Partners Doug John – Curtin University of Technology Graeme Kelly – Corrotec Services Nick Laycock – STOS Grant McAdam – Defence Science and Technology Organisation David Nicholas – Nicholas Corrosion John Robinson – Mount Townsend Solutions Paul Schweinsburg – Queensland University of Technology Raman Singh – Monash University Graham Sussex – Sussex Material Solutions Tony Trueman – Defence Science and Technology Organisation Geoffrey Will – Queensland University of Technology David Young – University of New South WalesAdvertisingSalesWesley Fawaz - [email protected] Ph: 61 3 9890 4833, Fax: 61 3 9890 7866SubscriptionPrint Version: ISSN 1326-1932 Subscription rates to non members: Within Australia: A$72.60, incl GST, single copies A$16.50, incl GST Outside Australia: A$77, excl GST posted airmail, single copies A$22 incl GST On-Line Version: ISSN 1446-6848 Subscription rates to non members: A$22 incl GSTThe views expressed in Corrosion & Materials are those of the individual authors and are not necessarily those of the ACA. Publication of advertisements does not imply endorsement by the ACA. Copyright of all published materials is retained by the ACA but it may be quoted with due reference.AustralasianCorrosionAssociationIncPO Box 112, Kerrimuir Vic 3129, Australia Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Email: [email protected] Internet: www.corrosion.com.auPresident: Ian MacLeodChief Executive Officer: Ian BoothOperations Chairman: John GrapigliaFinance Director: Paul VinceSenior Vice President: Peter DoveJunior Vice President: Allan SterlingImmediate Past President: Roman DankiwTechnical Director: Graham SussexEducation Director: Geoffrey WillMembership Director: Fred SalomeCommunications Director: Bryan PikePublications Director: Mohammad AliNewcastle Representative: Matthew DafterNew Zealand Representative: John DuncanBranches&DivisionsAuckland Division: Sean Ryder 64 9 261 1400Newcastle: Bill Livingstone 61 2 4954 2329New South Wales: Fred Salome 61 2 9736 3911Queensland: Cathy Sterling 61 7 3821 0202South Australia: Alex Shepherd 61 8 8267 4744Tasmania: Bryan Pike 61 3 6335 4786Taranaki Division: Ron Berry 64 27 671 2278Wellington Division: Alistair MacKenzie 64 4 473 3124Western Australia: Ben Coleman 61 0 433 251 728Victoria: John Tanti 61 3 9885 5305TechnicalGroupsCathodic Protection: Bruce Ackland 61 3 9890 3096Coatings: David Hopkins 61 400 522 944Concrete Structures & Buildings: Frédéric Blin 61 3 9653 8406Mining Industry: Peter Farinha 61 8 9456 0344Refining & Processing Industry: Fikry Barouky 61 402 684 165Research: Nick Birbilis 61 3 9905 4919Research: David Young 61 2 9385 4322Water & Water Teatment: David Mavros 61 419 816 783Welding, Joining & Corrosion: Graham Sussex 61 3 9495 6566Young Corrosion Professionals: Erwin Gamboa 61 8 8303 5473
& M A T E R I A L S
Rebar location needs to be fast and accurate. Profoscope has a unique real-time rebar visualization that allows contractors to actually ‘see’ the location of the rebar beneath the concrete surface.
That may be all that is needed for concrete drilling and sawing contractors but inspectors and engineers need accurate cover measurement and bar diameter assessment.
The Profoscope provides this as well and is a wireless hand held device that slips easily into your pocket.
At last… a Pocket
Rebar Locator
Used by tradesmen for simple location of rebar and conduits … and by engineers for accurate cover measurement.
n Wireless handheld pocket covermeter for site engineers/inspectors.
n Cost effective as personal ‘i-cover’ device.
n Bar, cable and copper pipe locator for tradesmen and building managers.
n Easy to locate the centre of bars for diamond saw cutting or drilling.
n Proceq reliability and after sale care.
Features
n Same accuracy as more expensive logging covermeters (i.e. generally ±2mm).
n Instinctive LED and target graphics for easy bar location.
n Neighbouring bar cover correction.
n Bar diameter estimate.
Sydney n Melbourne n Perth Phone 0408 034 668 www.pcte.com.auPCTEC1102PGX NOW
AT A N
EW LOW
PRICE
Vol 36 No 2 April 2011 www.corrosion.com.au 3
Front Cover Photo Weld Procedure Qualification in progress, using a mechanised GMAW system for the Bayu Darwin subsea pipeline project.
Photo Supplied by IWES Pty Ltd
4» President’sMessage
6» ChiefExecutiveOfficer’sMessage
8» News
15» ACABranchNews
16» ACAStandardsUpdate
20» ACACorrosionChallengesProject
25» CoatingsGroupMemberProfile
26» ACATechnicalGroupsUpdate
28» ACACertifiedCorrosionTechnologistsandTechnicians
30» MicrobiallyInfluencedCorrosion
33» ProjectProfile:Re-Lifing a CO2 Absorber Tower Using Welding Robots
36» ProjectProfile:Refurbishment of the Vessel One and All
38» UniversityProfile:University of New South Wales
41» Researchpaper:Probing Corrosion Activities in Difficult-to-Test Media Using the Wire Beam Electrode: Case Studies
50» Researchpaper:Effectiveness of Cathodic Protection System on Constructed Tanks over Bituminous Sand Mix Layer
57» SuppliersandConsultants
The ACA is a founder member of the World Corrosion Organization
ISSN1326-1932Published by the Australasian Corrosion Association Inc. ABN: 66 214 557 257PublicationsDirectorMohammad Ali – GHD, [email protected] Cherry – Monash University, [email protected]: Bruce Hinton – Monash University, [email protected] Practice: Willie Mandeno – Opus International Consultants,
[email protected]: Ian Booth – Australasian Corrosion Association, [email protected] Atrens – University of Queensland Nick Birbilis – Monash University Lex Edmond – Monash University Harvey Flitt – Queensland University of Technology Maria Forsyth – Monash University Rob Francis – Aurecon Australia Warren Green – Vinsi Partners Doug John – Curtin University of Technology Graeme Kelly – Corrotec Services Nick Laycock – STOS Grant McAdam – Defence Science and Technology Organisation David Nicholas – Nicholas Corrosion John Robinson – Mount Townsend Solutions Paul Schweinsburg – Queensland University of Technology Raman Singh – Monash University Graham Sussex – Sussex Material Solutions Tony Trueman – Defence Science and Technology Organisation Geoffrey Will – Queensland University of Technology David Young – University of New South WalesAdvertisingSalesWesley Fawaz - [email protected] Ph: 61 3 9890 4833, Fax: 61 3 9890 7866SubscriptionPrint Version: ISSN 1326-1932 Subscription rates to non members: Within Australia: A$72.60, incl GST, single copies A$16.50, incl GST Outside Australia: A$77, excl GST posted airmail, single copies A$22 incl GST On-Line Version: ISSN 1446-6848 Subscription rates to non members: A$22 incl GSTThe views expressed in Corrosion & Materials are those of the individual authors and are not necessarily those of the ACA. Publication of advertisements does not imply endorsement by the ACA. Copyright of all published materials is retained by the ACA but it may be quoted with due reference.AustralasianCorrosionAssociationIncPO Box 112, Kerrimuir Vic 3129, Australia Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Email: [email protected] Internet: www.corrosion.com.auPresident: Ian MacLeodChief Executive Officer: Ian BoothOperations Chairman: John GrapigliaFinance Director: Paul VinceSenior Vice President: Peter DoveJunior Vice President: Allan SterlingImmediate Past President: Roman DankiwTechnical Director: Graham SussexEducation Director: Geoffrey WillMembership Director: Fred SalomeCommunications Director: Bryan PikePublications Director: Mohammad AliNewcastle Representative: Matthew DafterNew Zealand Representative: John DuncanBranches&DivisionsAuckland Division: Sean Ryder 64 9 261 1400Newcastle: Bill Livingstone 61 2 4954 2329New South Wales: Fred Salome 61 2 9736 3911Queensland: Cathy Sterling 61 7 3821 0202South Australia: Alex Shepherd 61 8 8267 4744Tasmania: Bryan Pike 61 3 6335 4786Taranaki Division: Ron Berry 64 27 671 2278Wellington Division: Alistair MacKenzie 64 4 473 3124Western Australia: Ben Coleman 61 0 433 251 728Victoria: John Tanti 61 3 9885 5305TechnicalGroupsCathodic Protection: Bruce Ackland 61 3 9890 3096Coatings: David Hopkins 61 400 522 944Concrete Structures & Buildings: Frédéric Blin 61 3 9653 8406Mining Industry: Peter Farinha 61 8 9456 0344Refining & Processing Industry: Fikry Barouky 61 402 684 165Research: Nick Birbilis 61 3 9905 4919Research: David Young 61 2 9385 4322Water & Water Teatment: David Mavros 61 419 816 783Welding, Joining & Corrosion: Graham Sussex 61 3 9495 6566Young Corrosion Professionals: Erwin Gamboa 61 8 8303 5473
& M A T E R I A L S
Rebar location needs to be fast and accurate. Profoscope has a unique real-time rebar visualization that allows contractors to actually ‘see’ the location of the rebar beneath the concrete surface.
That may be all that is needed for concrete drilling and sawing contractors but inspectors and engineers need accurate cover measurement and bar diameter assessment.
The Profoscope provides this as well and is a wireless hand held device that slips easily into your pocket.
At last… a Pocket
Rebar Locator
Used by tradesmen for simple location of rebar and conduits … and by engineers for accurate cover measurement.
n Wireless handheld pocket covermeter for site engineers/inspectors.
n Cost effective as personal ‘i-cover’ device.
n Bar, cable and copper pipe locator for tradesmen and building managers.
n Easy to locate the centre of bars for diamond saw cutting or drilling.
n Proceq reliability and after sale care.
Features
n Same accuracy as more expensive logging covermeters (i.e. generally ±2mm).
n Instinctive LED and target graphics for easy bar location.
n Neighbouring bar cover correction.
n Bar diameter estimate.
Sydney n Melbourne n Perth Phone 0408 034 668 www.pcte.com.auPCTEC1102PGX NOW
AT A N
EW LOW
PRICE
DearMembers
AwalkalongLosAngeles’MalibuBeachonarecentchillymid-springFebruaryday
showedaseriesofsnapshotsfortheworldofcorrosionthatwasfulloflessonsfortheunwary.Despitehavingspentmillionsofdollarsinpurchasingtheirchosenslabsofrealestate,perchedhighabovetherelentlessPacificOcean,theresponseoftheownerswasquitetelling.Somemassivewoodenbeamssupportingtheraftersandupperfloorsofthehouseswereclearlysubjecttolocalisedattackfromwoodboringmolluscswhilethewiseownershadtheintertidalandsplashzoneareasprotectedbywrappedtreatmentsthatmademethink“D***o”!Otherpostshadepoxygroutinginthemforrepairingandconsolidatingthestructuralbeams.Whilesomeownerswerecontenttohavesignificantrustingonthefaceplatesandboltsholdingthetimberstructuresinplaceothersseemedalmostobliviousofthepervasiveyellowbrowntidelineofiron(III)hydroxychloridesweepingfromHsectionsandotherfixtures.ImaginemydelightwhenIcameacrossthesparklingpresenceofahousewheretheownershadreceivedandimplementedthecorrectadvicefromacorrosionconsultant.ThewhitepaintwasnotchalkedandwasclearlyahighbuildcoatingwithaUVresistantouterskin.The
windowframesandgutteringwereamutedblue-greenofcopperhydroxychloridesandtherewasonlythemeresthintofwaterrun-offstaining.
TheselessonsarethereforalltoseeasonewalksalongthebeachandareatimelyreminderthatastheAustraliangovernmentcommitsbillionsofdollarsfortherebuildingofcommunitiesandinfrastructureinthewakeofthedevastatingfloodsandfires,theACAhasavitaladvocacyrole.AllofuswithcontactsinthepoliticalarenaneedtomakesurethattheFederal,StateandLocalGovernmentsareapprisedofourvastwealthofexperiencethatisavailabletoensurethatthesolutionstothepresentdayproblemsdonotbecomeadditionalburdensforourchildrentobearinthecomingyears.IurgeeverymembertogivetheirfullsupporttotheACA’songoingadvocacyprogrammeinthisarea.
Indeedoneofthevitalcomponentsoftheforthcoming18thInternationalCorrosionCongressinPerthwillfocusonthesustainabilityofourpresentdaymethodsoffightingthebattleagainstcorrosionandprematurecollapseofinfrastructure.Itistimetomakeafirmdecisionandbookaheadtoachievethebestdiscountedairfaresthatyoucanfind.Thetechnicalprogrampromisestobebrilliantwithmorethan460abstractsreceivedandreviewedandtheorganisingcommitteeisstrivingtoensurethatallvisitorstoWesternAustraliawillhaveaverypositiveand
enjoyableexperience.TheACAasateamistotallycommittedtoensuringthatyouwillgetexcellentvalueforyourmoneyandthatthe18thICCwillbethebestcorrosioncongressyouhaveeverattended.
OneofthelastingbenefitsofattendinganACAconferenceisthere-exposuretoproductsandservicesthathavemovedonwhileourmindsandexperiencesmighthavebeenmovingataslightlyslowerpace.Physicalisolationcanalsoinducementalstagnationlikewaterstrappedinadryingbillabong.OneofthebenefitsofbeinganobserverinAdelaidewasthatIwasabletodiscernarealchangeintheenergyandcommitmenttoexcellenceofthespeakersandofallthosewholookedaftertheboothsintheTradeShowareas.Takinginabalanceofgoodfood,stimulatingconversationandamazingproductsdevelopedtomakeourworkofpreventingandmitigatingcorrosionontheseas,intheskiesandonthelandareallpartoftheconferenceexperience.AquickbrowseoftheACAwebsiteshowsupavastarrayofcoursesacrossthecountrysonowthereisnoexcuseleft–enrol,participateandexchangeideasandwewillthenallhaveamuchmoresustainablefuture.
YoursinCorrosion
Ian MacLeod President
The traditional and not so common techniques used to mitigate the onset and progress of corrosion are all based on the classic methods: change materials, change the environment, apply a coating or use electrochemical controls. The effectiveness of each method can be observed using a corrosion management plan and measured using a programme such as an inspection survey or more sophisticated corrosion monitoring.
Corrosion monitoring can be defined as any method used to observe, measure and analyse the progress of corrosion. It involves myriad variables – materials, measurement techniques, instrumentation, budgets, standards, logistical support, data analysis, communication and, critically, information management. Real value is gained from corrosion monitoring initiatives when the information gathered over a period is translated into effective corrosion mitigation/control programmes.
Each local seminar programme is available by visiting www.corrosion.com.au or by emailing [email protected]
Register now at www.corrosion.com.au
SEMINAR SERIES:
Sponsored by:Supported by:
CORROSION MITIGATION AND MONITORING
Engineers Australia members can choose to record CPD hours for attendance at this event in their personal CPD logs. Members should refer to Engineers Australia’s CPD Policy for details of requirements and conditions.
LOCATIONS:
DARWIN WEDNESDAY 11Th MAYEngineers Australia, 14 Shepherd St, Darwin
MELBOURNE TUESDAY 17Th MAYEngineering House, 121 Bedford Street, North Melbourne
TASMANIA ThURSDAY 19Th MAYZeps Café, 92–94 High Street, Campbell Town
AUCKLAND TUESDAY 24Th MAYHotel Grand Chancellor Auckland Airport, Ascot Roads, Airport Oaks, Auckland
WELLINGTON ThURSDAY 26Th MAYAbel Tasman Hotel 169 Willis Street, Wellington
ADELAIDE FRIDAY 3RD JUNEMercure Grosvenor Hotel, 125 North Terrace, Adelaide
GLADSTONE TUESDAY 7Th JUNECQUniversity, Bryan Jordan Drive, Gladstone
BRISBANE ThURSDAY 9Th JUNEBrisbane Cricket Ground (GABBA), 411 Vulture Street, East Brisbane
PERTh ThURSDAY 16Th JUNEThe Old Brewery, 173 Mounts Bay Road, Perth
WOLLONGONG TUESDAY 21ST JUNEMedina Executive, 19 Market Street, Wollongong
SYDNEY WEDNESDAY 22ND JUNENorth Ryde RSL, Cnr Magdala & Pittwater Roads, North Ryde
NEWCASTLE ThURSDAY 23RD JUNEEngineers Australia, 122 Parry Street, Newcastle West
DearMembers
AwalkalongLosAngeles’MalibuBeachonarecentchillymid-springFebruaryday
showedaseriesofsnapshotsfortheworldofcorrosionthatwasfulloflessonsfortheunwary.Despitehavingspentmillionsofdollarsinpurchasingtheirchosenslabsofrealestate,perchedhighabovetherelentlessPacificOcean,theresponseoftheownerswasquitetelling.Somemassivewoodenbeamssupportingtheraftersandupperfloorsofthehouseswereclearlysubjecttolocalisedattackfromwoodboringmolluscswhilethewiseownershadtheintertidalandsplashzoneareasprotectedbywrappedtreatmentsthatmademethink“D***o”!Otherpostshadepoxygroutinginthemforrepairingandconsolidatingthestructuralbeams.Whilesomeownerswerecontenttohavesignificantrustingonthefaceplatesandboltsholdingthetimberstructuresinplaceothersseemedalmostobliviousofthepervasiveyellowbrowntidelineofiron(III)hydroxychloridesweepingfromHsectionsandotherfixtures.ImaginemydelightwhenIcameacrossthesparklingpresenceofahousewheretheownershadreceivedandimplementedthecorrectadvicefromacorrosionconsultant.ThewhitepaintwasnotchalkedandwasclearlyahighbuildcoatingwithaUVresistantouterskin.The
windowframesandgutteringwereamutedblue-greenofcopperhydroxychloridesandtherewasonlythemeresthintofwaterrun-offstaining.
TheselessonsarethereforalltoseeasonewalksalongthebeachandareatimelyreminderthatastheAustraliangovernmentcommitsbillionsofdollarsfortherebuildingofcommunitiesandinfrastructureinthewakeofthedevastatingfloodsandfires,theACAhasavitaladvocacyrole.AllofuswithcontactsinthepoliticalarenaneedtomakesurethattheFederal,StateandLocalGovernmentsareapprisedofourvastwealthofexperiencethatisavailabletoensurethatthesolutionstothepresentdayproblemsdonotbecomeadditionalburdensforourchildrentobearinthecomingyears.IurgeeverymembertogivetheirfullsupporttotheACA’songoingadvocacyprogrammeinthisarea.
Indeedoneofthevitalcomponentsoftheforthcoming18thInternationalCorrosionCongressinPerthwillfocusonthesustainabilityofourpresentdaymethodsoffightingthebattleagainstcorrosionandprematurecollapseofinfrastructure.Itistimetomakeafirmdecisionandbookaheadtoachievethebestdiscountedairfaresthatyoucanfind.Thetechnicalprogrampromisestobebrilliantwithmorethan460abstractsreceivedandreviewedandtheorganisingcommitteeisstrivingtoensurethatallvisitorstoWesternAustraliawillhaveaverypositiveand
enjoyableexperience.TheACAasateamistotallycommittedtoensuringthatyouwillgetexcellentvalueforyourmoneyandthatthe18thICCwillbethebestcorrosioncongressyouhaveeverattended.
OneofthelastingbenefitsofattendinganACAconferenceisthere-exposuretoproductsandservicesthathavemovedonwhileourmindsandexperiencesmighthavebeenmovingataslightlyslowerpace.Physicalisolationcanalsoinducementalstagnationlikewaterstrappedinadryingbillabong.OneofthebenefitsofbeinganobserverinAdelaidewasthatIwasabletodiscernarealchangeintheenergyandcommitmenttoexcellenceofthespeakersandofallthosewholookedaftertheboothsintheTradeShowareas.Takinginabalanceofgoodfood,stimulatingconversationandamazingproductsdevelopedtomakeourworkofpreventingandmitigatingcorrosionontheseas,intheskiesandonthelandareallpartoftheconferenceexperience.AquickbrowseoftheACAwebsiteshowsupavastarrayofcoursesacrossthecountrysonowthereisnoexcuseleft–enrol,participateandexchangeideasandwewillthenallhaveamuchmoresustainablefuture.
YoursinCorrosion
Ian MacLeod President
The traditional and not so common techniques used to mitigate the onset and progress of corrosion are all based on the classic methods: change materials, change the environment, apply a coating or use electrochemical controls. The effectiveness of each method can be observed using a corrosion management plan and measured using a programme such as an inspection survey or more sophisticated corrosion monitoring.
Corrosion monitoring can be defined as any method used to observe, measure and analyse the progress of corrosion. It involves myriad variables – materials, measurement techniques, instrumentation, budgets, standards, logistical support, data analysis, communication and, critically, information management. Real value is gained from corrosion monitoring initiatives when the information gathered over a period is translated into effective corrosion mitigation/control programmes.
Each local seminar programme is available by visiting www.corrosion.com.au or by emailing [email protected]
Register now at www.corrosion.com.au
SEMINAR SERIES:
Sponsored by:Supported by:
CORROSION MITIGATION AND MONITORING
Engineers Australia members can choose to record CPD hours for attendance at this event in their personal CPD logs. Members should refer to Engineers Australia’s CPD Policy for details of requirements and conditions.
LOCATIONS:
DARWIN WEDNESDAY 11Th MAYEngineers Australia, 14 Shepherd St, Darwin
MELBOURNE TUESDAY 17Th MAYEngineering House, 121 Bedford Street, North Melbourne
TASMANIA ThURSDAY 19Th MAYZeps Café, 92–94 High Street, Campbell Town
AUCKLAND TUESDAY 24Th MAYHotel Grand Chancellor Auckland Airport, Ascot Roads, Airport Oaks, Auckland
WELLINGTON ThURSDAY 26Th MAYAbel Tasman Hotel 169 Willis Street, Wellington
ADELAIDE FRIDAY 3RD JUNEMercure Grosvenor Hotel, 125 North Terrace, Adelaide
GLADSTONE TUESDAY 7Th JUNECQUniversity, Bryan Jordan Drive, Gladstone
BRISBANE ThURSDAY 9Th JUNEBrisbane Cricket Ground (GABBA), 411 Vulture Street, East Brisbane
PERTh ThURSDAY 16Th JUNEThe Old Brewery, 173 Mounts Bay Road, Perth
WOLLONGONG TUESDAY 21ST JUNEMedina Executive, 19 Market Street, Wollongong
SYDNEY WEDNESDAY 22ND JUNENorth Ryde RSL, Cnr Magdala & Pittwater Roads, North Ryde
NEWCASTLE ThURSDAY 23RD JUNEEngineers Australia, 122 Parry Street, Newcastle West
Vol 36 No 2 April 2011 www.corrosion.com.au 7
ACAhasrecentlyconcludedanagreementwithSSPCfortheintroductiontoAustralasiaofarangeofeducationalprogramsaimedspecificallyatthecontractingsector.DependinguponthesuccessoftheintroductionoftheseprogramsACAwillworkwithSSPCtoexpandontheinitialofferings.
AnotherrecentdevelopmentintheeducationarenaisthepossibilityofajointACAanduniversityaccreditedpostgraduatecorrosionengineeringprogram.Initially,theprogramwillbeaimedatthepostgraduatecertificatelevel.Furtherintegrationintograduatediplomaandmasterslevelsisalsounderconsideration.
Importantforthesuccessofbothoperatorlevelandpostgraduateprogramswillbethemethodofdelivery.
InthecaseofSSPCcourses,ACAwillbeofferingpublicandin-housecourses,dependingontheneedsoftheindustry.Theopportunity
forcontractorstotraintheirownstaffinthedeliveryoftheSSPCprogramswillalsobeavailable.Withthisoption,ACAwillmoderatetheassessmentprocesses.
Theuniversitylevelprogramswhicharebeingproposedwillbeofferedonadistanceeducationplatformwithablockface-to-facecomponent.ThismodeofdeliverywillallowallACAmembersthemaximumopportunitytoparticipateasitisn’tlocationdependant.Itmaybepossibletooffertheface-to-facecomponentinconjunctionwithACAconferencestherebyreducingtravelcosts.Wearealsoexamininghowtheexistingconferencemodelcanbeadaptedtointegratethegraduateprogramintotheconferenceprogram.
SubstantialprogresshasalsobeenmadeonthereviewofACA’sadvancedcathodicprotectioncourse.Oncethereviewofthiscourseiscomplete,theCPintroductionandmonitoringcourseswillbeformallyre-assessed.
Thedemandforin-housetrainingprogramsisontheriseandACAlecturerswillshortlybetravellingtoNewGuineatoofferprograms.ACAisabletoofferstandardormodifiedpackagesin-houseandBarryHodderisavailabletoassistmembersseekingtheseproducts.
Finally,tobetterassistmemberstoplantheirACArelatededucationalrequirements,theACAeducationcalendarforthefirstsixmonthsof2012willbereleasedbyearlyMay2011.Infuture,6monthblockswillbeaddedtothecalendaratleast6monthsinadvanceinordertoallowmembersthemaximumflexibilityinplanning.
INDEPENDENT CORROSION ENGINEERS
AUSTRALASIA • ASIA • UK • USA • AFRICA • MIDDLE EAST
NATA Accredited Inspections • Cathodic Protection Specialists • Investigation & Failure Analysis • Material Selection • Welding Inspections • Training • Protective Coating Specifications • Metallurgy & Materials Consulting • QA/QC Auditing
• Asset Condition Surveys & Maintenance Management
‘Global Corrosion Solutions’
National Toll Free 1300 721 029
International + 61 8 8267 4744
Web www.incospec.com.au
www.maney.co.uk/journals/cst
Corrosion Engineering, Science and Technology
Journal scopeCorrosion Engineering, Science and Technology, an official journal of the EuropeanFederation of Corrosion, provides broad international coverage of research and practicein corrosion processes and corrosion control.Peer-reviewed contributions address all aspects of corrosion engineering and corrosionscience; there is strong emphasis on effectivedesign and materials selection to combat corrosion. CEST’s scope encompasses allmetallic and non-metallic materials and composites.
Featuresn Research papers — peer-reviewed
contributions from research and practicen Critical reviews — in-depth examination of
topics of current interestn Standard news and conference reviewsn Regular topical theme issues
MORE Materials Science & Engineering CollectionThis collection provides instant online access totwenty-eight highly-regarded, peer-reviewed, international materials science publications.
For a 30-day free trial to the MORE Materials Science & Engineering Collecion, visit: www.maney.co.uk/freetrial
Corrosion Engineering,Science and Technology
Vol 46 (2011), 7 issues per year
Print ISSN: 1478-422XOnline ISSN: 1743-2782
UK Editor: Professor S B Lyon, Corrosion and Protection Centre, Manchester, UK
US Editor: Dr S Lillard,Los Alamos National Laboratory,USA
For further information, visit thejournal homepage:www.maney.co.uk/journals/cst
www.iom3.org
CST Advert:Layout 1 23/02/2011 13:21 Page 1
Vol 36 No 2 April 2011 www.corrosion.com.au 7
ACAhasrecentlyconcludedanagreementwithSSPCfortheintroductiontoAustralasiaofarangeofeducationalprogramsaimedspecificallyatthecontractingsector.DependinguponthesuccessoftheintroductionoftheseprogramsACAwillworkwithSSPCtoexpandontheinitialofferings.
AnotherrecentdevelopmentintheeducationarenaisthepossibilityofajointACAanduniversityaccreditedpostgraduatecorrosionengineeringprogram.Initially,theprogramwillbeaimedatthepostgraduatecertificatelevel.Furtherintegrationintograduatediplomaandmasterslevelsisalsounderconsideration.
Importantforthesuccessofbothoperatorlevelandpostgraduateprogramswillbethemethodofdelivery.
InthecaseofSSPCcourses,ACAwillbeofferingpublicandin-housecourses,dependingontheneedsoftheindustry.Theopportunity
forcontractorstotraintheirownstaffinthedeliveryoftheSSPCprogramswillalsobeavailable.Withthisoption,ACAwillmoderatetheassessmentprocesses.
Theuniversitylevelprogramswhicharebeingproposedwillbeofferedonadistanceeducationplatformwithablockface-to-facecomponent.ThismodeofdeliverywillallowallACAmembersthemaximumopportunitytoparticipateasitisn’tlocationdependant.Itmaybepossibletooffertheface-to-facecomponentinconjunctionwithACAconferencestherebyreducingtravelcosts.Wearealsoexamininghowtheexistingconferencemodelcanbeadaptedtointegratethegraduateprogramintotheconferenceprogram.
SubstantialprogresshasalsobeenmadeonthereviewofACA’sadvancedcathodicprotectioncourse.Oncethereviewofthiscourseiscomplete,theCPintroductionandmonitoringcourseswillbeformallyre-assessed.
Thedemandforin-housetrainingprogramsisontheriseandACAlecturerswillshortlybetravellingtoNewGuineatoofferprograms.ACAisabletoofferstandardormodifiedpackagesin-houseandBarryHodderisavailabletoassistmembersseekingtheseproducts.
Finally,tobetterassistmemberstoplantheirACArelatededucationalrequirements,theACAeducationcalendarforthefirstsixmonthsof2012willbereleasedbyearlyMay2011.Infuture,6monthblockswillbeaddedtothecalendaratleast6monthsinadvanceinordertoallowmembersthemaximumflexibilityinplanning.
INDEPENDENT CORROSION ENGINEERS
AUSTRALASIA • ASIA • UK • USA • AFRICA • MIDDLE EAST
NATA Accredited Inspections • Cathodic Protection Specialists • Investigation & Failure Analysis • Material Selection • Welding Inspections • Training • Protective Coating Specifications • Metallurgy & Materials Consulting • QA/QC Auditing
• Asset Condition Surveys & Maintenance Management
‘Global Corrosion Solutions’
National Toll Free 1300 721 029
International + 61 8 8267 4744
Web www.incospec.com.au
www.maney.co.uk/journals/cst
Corrosion Engineering, Science and Technology
Journal scopeCorrosion Engineering, Science and Technology, an official journal of the EuropeanFederation of Corrosion, provides broad international coverage of research and practicein corrosion processes and corrosion control.Peer-reviewed contributions address all aspects of corrosion engineering and corrosionscience; there is strong emphasis on effectivedesign and materials selection to combat corrosion. CEST’s scope encompasses allmetallic and non-metallic materials and composites.
Featuresn Research papers — peer-reviewed
contributions from research and practicen Critical reviews — in-depth examination of
topics of current interestn Standard news and conference reviewsn Regular topical theme issues
MORE Materials Science & Engineering CollectionThis collection provides instant online access totwenty-eight highly-regarded, peer-reviewed, international materials science publications.
For a 30-day free trial to the MORE Materials Science & Engineering Collecion, visit: www.maney.co.uk/freetrial
Corrosion Engineering,Science and Technology
Vol 46 (2011), 7 issues per year
Print ISSN: 1478-422XOnline ISSN: 1743-2782
UK Editor: Professor S B Lyon, Corrosion and Protection Centre, Manchester, UK
US Editor: Dr S Lillard,Los Alamos National Laboratory,USA
For further information, visit thejournal homepage:www.maney.co.uk/journals/cst
www.iom3.org
CST Advert:Layout 1 23/02/2011 13:21 Page 1
Corrosion & Materials8
Submissionofabstractsforthe18thInternationalCorrosionCongressclosed14thFebruary2011with468abstractssubmitted.TechnicalChairLiamHollowayandatechnicalsub-committeethenreviewedeachabstracttoacceptasoral,posterorreject.
Followingthereviewandwithdrawalofsomeabstracts,alistof425acceptedabstractsarepublishedinthepreliminaryprogrammeandregistrationbrochure.307abstractsacceptedasoralpresentationshavebeeninitiallyallocatedwithin19streams.118abstractswereacceptedforapostersession.
Abstractsweresubmittedfrom55countrieswiththefivecountriesmostrepresentedbeingAustralia,China,Japan,KoreaandIndia.
Eachstreamofabstractscanbedownloadedfromthecongresswebsitewww.18iccperth2011.com
Thecongressorganisingcommitteecanalsoconfirmthefollowingplenarylecturersandkeynotespeakersandpapertitles:
PlenaryLecturers:
TimBurstein,UniversityofCambridge,UnitedKingdom
AlisonDavenport,UniversityofBirmingham,UnitedKingdom:SheddingLightonCorrosion
DavidScantlebury,TheUniversityofManchester,UnitedKingdom:UnderprotectionofMildSteelinMarineConditions
HectorVidela,UniversityofLaPlata,Argentina:TheRoleofMicroorganismsontheCorrosionandProtectionofMetals.ACriticalOverview.
KeynoteSpeakers:
MariaForsyth,DeakinUniversity,Australia:MultifunctionalRareEarthCorrosionInhibitorsforSteelandAluminiumAlloys
MadsJuhl,Hempel,Denmark:AdvancesinCorrosionProtectionbyUseofCoatings
IanMacLeod,WesternAustralianMuseum,Australia:ConsumingCorrosion–AJourneyintotheWorldofMaterialsConservation
V.S.Raja,IndianInstituteofTechnologyBombay,India:HighTemperatureCorrosionProblemsinDesigningGradedThermalBarrierCoatings
18th International Corrosion Congress update
Renewing NACE CIP certificationTheACAhasreceivedanumberofenquiriesrecentlyrelatedtohowNACEqualifiedCoatingInspectorsrenewtheirCIPcertification.TheACAhasconfirmedthattorecertifyaninspectormusthavesufficientworkexperiencepointsorotherprofessionaldevelopmentactivity(includingbutnotlimitedtothecompletionofaNACECIP2)torecertify.HowevertheHomeStudyDocumentmentionedontheNACEwebsiteiscurrentlynotrequired.
CoatingInspectorsareassignedworkexperiencepointsaccordingtothetaskstheyperformandthey
musthavesufficientpointsoracombinationofpointsandcourseattendance.
Pointsareawardedpermonthofworkexperienceinthefollowingways:
CoatingInspectionx2pointspermonth
OtherFieldExperience(otherthaninspections)x1.5pointspermonth
Nonfieldexperiencex1pointpermonth
NACEhavealsointroducedanewonlinerenewalprocesswhereCIP
qualifiedInspectorscanlogontotheirprofileontheNACEwebsiteandcompletetheirrenewalapplicationandmakepayment.
If you have any further queries please contact Renata at the ACA on +61 (0)3 9890 4833.
ACA to introduce SSPC application programsACAhasbeenworkingwithSSPCrecentlytointroducearangeofapplicatortrainingandcertificationprograms.Initially,ACAandSSPCwillworktogethertoestablishthefollowing5programs:
Abrasive Blasting Program Thisprogramisdesignedforcontractorpersonnelwhowishtoobtaincertificationorotherswhowishtolearnaboutdryabrasiveblastcleaningofsteel.Itcoversprinciplesofsurfacepreparation,surfacecleanliness,surfaceprofile,dustanddebriscontrol,andabrasives.
Water Jetting Program Thisprogramassessestheskillsofwater-jetterswhohaveaminimumof120hourswater-jettingworkexperienceandpriordocumentedemployer-providedtrainingonthewater-jettingequipmenttheyuseonthejob.Candidatesarecertifiedthroughabriefwritten
examandapracticalhands-onskillassessment.
Airless Spray Basics Thisprogramassessestheskillsofsprayerswhohaveaminimumof800hoursapplyingprotectivecoatingswithairlesssprayinanindustrialormarineenvironment.Candidatesarecertifiedthroughabriefcertificationwrittenexamandapracticalhands-onskillassessment.Thiscourseisdesignedtotrainandcertifymarine/industrialapplicatorstooperateairlesssprayequipment.
Plural Component Basics Thiscourseisdesignedtotrainmarine/industrialapplicatorsintheapplicationofprotectivecoatingsbyairlesssprayusingpluralcomponentsprayequipment.Theprogramfocusisontheapplicationoftwocomponentepoxyandpolyurethaneprotectivecoatingsin
amarine/industrialenvironmentonsteelorconcrete.
Applicator Train-the-Trainer Thecourseisdesignedtotrainowners,supervisorsandotherrepresentativesofindustrialpaintingcontractingcompaniesonthedeliveryoftwolevelsoftheSSPCApplicatorTrainingProgramforsurfacepreparationandcoatingapplication.Itwillalsoprovideyouandyourcraftworkerswithastandardizedcurriculumforapplicatortrainingthatyoucanpresentatyourshoporjobsiteatyourownconvenience.
ACAhavecommencedconsultationswiththecontractingsectortoensuretheprogramsaremodifiedforlocalconditions.Itisanticipatedthattheprogramswillbetrialedonanin-housebasisandthenofferedtothecontractingsectoreitherthroughpublicofferingsoronanin-housebasis.
Simple Solutions
to Complex Problems
INDUSTRIALCOATINGS
AUSTRALIA
MADE IN For information on Wattyl’s extensive product range contactWattyl Customer Service on 132 101 or visit us at www.wattyl.com.auThe above registered trademarks are owned by Wattyl Australia Pty Limited A.B.N. 40 000 035 914
High performance coating systems
Corrosion & Materials8
Submissionofabstractsforthe18thInternationalCorrosionCongressclosed14thFebruary2011with468abstractssubmitted.TechnicalChairLiamHollowayandatechnicalsub-committeethenreviewedeachabstracttoacceptasoral,posterorreject.
Followingthereviewandwithdrawalofsomeabstracts,alistof425acceptedabstractsarepublishedinthepreliminaryprogrammeandregistrationbrochure.307abstractsacceptedasoralpresentationshavebeeninitiallyallocatedwithin19streams.118abstractswereacceptedforapostersession.
Abstractsweresubmittedfrom55countrieswiththefivecountriesmostrepresentedbeingAustralia,China,Japan,KoreaandIndia.
Eachstreamofabstractscanbedownloadedfromthecongresswebsitewww.18iccperth2011.com
Thecongressorganisingcommitteecanalsoconfirmthefollowingplenarylecturersandkeynotespeakersandpapertitles:
PlenaryLecturers:
TimBurstein,UniversityofCambridge,UnitedKingdom
AlisonDavenport,UniversityofBirmingham,UnitedKingdom:SheddingLightonCorrosion
DavidScantlebury,TheUniversityofManchester,UnitedKingdom:UnderprotectionofMildSteelinMarineConditions
HectorVidela,UniversityofLaPlata,Argentina:TheRoleofMicroorganismsontheCorrosionandProtectionofMetals.ACriticalOverview.
KeynoteSpeakers:
MariaForsyth,DeakinUniversity,Australia:MultifunctionalRareEarthCorrosionInhibitorsforSteelandAluminiumAlloys
MadsJuhl,Hempel,Denmark:AdvancesinCorrosionProtectionbyUseofCoatings
IanMacLeod,WesternAustralianMuseum,Australia:ConsumingCorrosion–AJourneyintotheWorldofMaterialsConservation
V.S.Raja,IndianInstituteofTechnologyBombay,India:HighTemperatureCorrosionProblemsinDesigningGradedThermalBarrierCoatings
18th International Corrosion Congress update
Renewing NACE CIP certificationTheACAhasreceivedanumberofenquiriesrecentlyrelatedtohowNACEqualifiedCoatingInspectorsrenewtheirCIPcertification.TheACAhasconfirmedthattorecertifyaninspectormusthavesufficientworkexperiencepointsorotherprofessionaldevelopmentactivity(includingbutnotlimitedtothecompletionofaNACECIP2)torecertify.HowevertheHomeStudyDocumentmentionedontheNACEwebsiteiscurrentlynotrequired.
CoatingInspectorsareassignedworkexperiencepointsaccordingtothetaskstheyperformandthey
musthavesufficientpointsoracombinationofpointsandcourseattendance.
Pointsareawardedpermonthofworkexperienceinthefollowingways:
CoatingInspectionx2pointspermonth
OtherFieldExperience(otherthaninspections)x1.5pointspermonth
Nonfieldexperiencex1pointpermonth
NACEhavealsointroducedanewonlinerenewalprocesswhereCIP
qualifiedInspectorscanlogontotheirprofileontheNACEwebsiteandcompletetheirrenewalapplicationandmakepayment.
If you have any further queries please contact Renata at the ACA on +61 (0)3 9890 4833.
ACA to introduce SSPC application programsACAhasbeenworkingwithSSPCrecentlytointroducearangeofapplicatortrainingandcertificationprograms.Initially,ACAandSSPCwillworktogethertoestablishthefollowing5programs:
Abrasive Blasting Program Thisprogramisdesignedforcontractorpersonnelwhowishtoobtaincertificationorotherswhowishtolearnaboutdryabrasiveblastcleaningofsteel.Itcoversprinciplesofsurfacepreparation,surfacecleanliness,surfaceprofile,dustanddebriscontrol,andabrasives.
Water Jetting Program Thisprogramassessestheskillsofwater-jetterswhohaveaminimumof120hourswater-jettingworkexperienceandpriordocumentedemployer-providedtrainingonthewater-jettingequipmenttheyuseonthejob.Candidatesarecertifiedthroughabriefwritten
examandapracticalhands-onskillassessment.
Airless Spray Basics Thisprogramassessestheskillsofsprayerswhohaveaminimumof800hoursapplyingprotectivecoatingswithairlesssprayinanindustrialormarineenvironment.Candidatesarecertifiedthroughabriefcertificationwrittenexamandapracticalhands-onskillassessment.Thiscourseisdesignedtotrainandcertifymarine/industrialapplicatorstooperateairlesssprayequipment.
Plural Component Basics Thiscourseisdesignedtotrainmarine/industrialapplicatorsintheapplicationofprotectivecoatingsbyairlesssprayusingpluralcomponentsprayequipment.Theprogramfocusisontheapplicationoftwocomponentepoxyandpolyurethaneprotectivecoatingsin
amarine/industrialenvironmentonsteelorconcrete.
Applicator Train-the-Trainer Thecourseisdesignedtotrainowners,supervisorsandotherrepresentativesofindustrialpaintingcontractingcompaniesonthedeliveryoftwolevelsoftheSSPCApplicatorTrainingProgramforsurfacepreparationandcoatingapplication.Itwillalsoprovideyouandyourcraftworkerswithastandardizedcurriculumforapplicatortrainingthatyoucanpresentatyourshoporjobsiteatyourownconvenience.
ACAhavecommencedconsultationswiththecontractingsectortoensuretheprogramsaremodifiedforlocalconditions.Itisanticipatedthattheprogramswillbetrialedonanin-housebasisandthenofferedtothecontractingsectoreitherthroughpublicofferingsoronanin-housebasis.
Simple Solutions
to Complex Problems
INDUSTRIALCOATINGS
AUSTRALIA
MADE IN For information on Wattyl’s extensive product range contactWattyl Customer Service on 132 101 or visit us at www.wattyl.com.auThe above registered trademarks are owned by Wattyl Australia Pty Limited A.B.N. 40 000 035 914
High performance coating systems
Corrosion & Materials10
NEWS
Accreditation course for inspectors to undertake detailed bridge inspections for Main Roads WAInafirstforMainRoadsWA,theirStructuresEngineeringbranchheldatwodaycoursetoprovidetrainingtoappropriatelyqualifiedandexperiencedbridgeengineersandengineeringassociatesinordertobecomeaccreditedtoundertakeDetailedBridgeInspections,knownasLevel2inspections,onsteelandconcretebridgesthroughouttheState.
AccreditationforBridgeInspectorsisrecognisedbothinternationallyandnationallyasanimportantpartofbridgeassetmanagement.Ithelpsprovideconsistencybetweendifferentinspectorsinhowdefectsareassessed,andhowconditionstatesandprioritiesforthemaintenanceworksaredetermined.InadditionthesecourseswillbuildapoolofaccreditedinspectorswhowillbeabletoassistStructuresEngineeringdeliverthisimportantpartoftheassetmanagementprocessintothefuture.
Thenumberswererestrictedtoacorefourteenpeoplefromengineeringconsultancies,MainRoadsWAandotherkeystakeholders.Thecoursecombinedthetheoryofconcrete
andsteelmaterialpropertiesanddeteriorationmechanismswithdetailsoftheon-siteapproachneededtosuccessfullycompleteadetailedinspectioninaccordancewiththein-housedeveloped‘DetailedVisualBridgeInspectionGuidelinesforConcreteandSteelBridges(Level2Inspections)’.Asitevisitwasalsoarrangedaspartofthecourse,providingagreatopportunityfortheattendeestoputthattheorystraightintopractice.
Thecoursewasestablished,organisedandrunbyStructuresEngineeringstaff.Specificlecturesonthecourseincludingdetailsofthecharacteristicsofmaterials,deteriorationmechanismsandrepairmethodswereprovidedbyWarrenGreen,anaccreditedAustralasianCorrosionAssociationlecturer.
EricaSmithofMainRoadsWAsaid“fullaccreditationbyexternalparticipants,throughattendanceonthiscourseandsuccessfulcompletionofacasestudyassignment,isnowarequirementwhenleadingon-siteinspectionsandwhenresponsiblefortheoveralldetailedinspectionreportforMainRoadsWA”.
“ItwasafantasticopportunityforvariousbridgeengineersandtechniciansthroughoutWAtoshareexperiencesandimproveunderstandinginthediagnosisofexistingstructuresandimpactsofcurrentconditiononfutureassetmanagementneeds”saidErica.
Thecoursewaswellreceivedandthereisalreadymuchinterestforasecondcoursetoberunlaterintheyear.
Curtin University launch Graduate Certificate in Corrosion EngineeringThefirstofitskindintheSouthernHemisphere,CurtinUniversitylauncheditsGraduateCertificateinCorrosionEngineeringinthefirstsemesterof2011.
TheGraduateCertificateinCorrosionEngineeringisthefirstinaseriesofpost-graduatecoursesCurtinUniversitywilloffertomeetgrowingindustrydemandforqualifiedcorrosionengineersandqualityresearchinthisfield.ThecourseispartofoilandgascompaniesWoodsideandChevron’ssponsorshipoftheChevron-WoodsideChairinCorrosionEngineering.
TheGraduateCertificateisofferedonlineandistheequivalentofsix-month’sfull-timestudy.Ifyouhaveanundergraduatedegreeinengineeringoranappliedsciencediscipline,thiscourseoffersyouachancetofasttrackyourcareertopracticetheprofessionofCorrosionEngineeringinabroadspectrumofindustries.
AuniqueopportunityforcareerdevelopmentintheEnergyandResourcesIndustryTheonlineGraduateCertificateinCorrosionEngineeringprogramistailoredtoindustryneeds–specificallytheenergyandresourceindustries–andcanbeundertakenwhileworkingastherearenorequirementstoattendclassesattheuniversity.
WhowillbenefitfromtheprogramThecourseisdesignedtodeliverspecificcorrosionengineeringskillsrelevanttotheenergyandresourcesindustries,andissuitableforqualified:
Chemists
MaterialsEngineers
Process/ChemicalEngineers
MechanicalEngineers
Itcanbeappliedinthefollowingindustries:
Oil&Gas
Refining&ChemicalProcessing
Mining&MineralProcessing
PowerGeneration
Defence
HowyouwillbenefitfromtheprogramThroughparticipationinthisprogramyouwillgainexpertiseinthefollowing:
Understandingfundamentalcorrosionandpreventionprinciples
Diagnosingcorrosionproblems
Developingcorrosionmanagementsolutions
Upgradingyourengineeringskillsbyworkingonreal-lifecorrosioncasesandprojects
EntryRequirementsStudentsmustholdarecogniseddegreeinengineeringorsciencewithequivalentoffirstyearChemistry.Ifyoudonothaveanappropriatebachelordegree,youmayberequiredtocompleteadditionalunitswhichwouldextendthedurationofthecourse.
DurationandAvailabilityThisfee-payingcourseisoneyearpart-timestudy.Eachstudentwillbeadvisedoftheirindividualstudyplan,whichwillbesubjecttotheavailabilityandsequencingofunitswithintheprogram.TwointakesareofferedeachyearinMarchandJuly.However,theJulyintakerequiresaminimumofthreesemesterstocompletethecourse.
Forfurtherinformation,pleasecontact:
Professor Rolf Gubner Chevron-WoodsideChairinCorrosionEngineering
ScienceandEngineeringTel:+61892667272Fax:+61892662300Email:[email protected]:www.corrosion.curtin.edu.au
Australian press slam Navy over rust bucketsAreviewofpressreportsoverrecentmonthsdemonstratesthattheAustralianpressisnotaversetoattackingslowmovingtargetswhicharenotabletodefendthemselves.
InOctober2010theHerald Sunwastrumpeting“therustneversleepsonprideofnavyfleet”.InNovemberThe Australianchimedinwith“Rustingwarships…..willsailagainafterrefit:navy”.FebruarysawThe West AustralianoutlineataleofwoefacedbytheresponsibleMinisterchargedwithgovernmentoversightoftheDefenceDepartment.Inthatarticle,thewords“rust”and“corrosion”are
recurringthemeswhichappeartobesetAustralia’snavy.InearlyMarchthisyeartheABC Newsheadlined“Callsforheadstorolloverrust-bucketNavy”.
ACA’sCorrosionChallengesstudies(reportedonelsewhereinthisedition)clearlydemonstratethatmanagementpracticesplayasignificantroleinaddingtounnecessarycostsofcorrosion.
ItisunfortunatethattheeffectsofcorrosiononthepreparednessofAustralia’snavalfleetcametolightduetotheNavy’sinabilitytorespond
toseverenaturaldisasterssuchasCycloneYasi.
ACAhasbeenendeavouringtocommencediscussionswiththeDepartmentofDefenceontherecommendationswhicharisefromtheCorrosionChallengesstudies.Hopefully,asthepoliticalheatdrainsaway,coolerheadsmayprevailandseniorDepartmentalrepresentativeswillaccepttheinvitationfromACAtoworkwithNavyandDefencetoassistthemtoresolvetheircorrosionmanagementproblems.
Concrete Repairs and Reconstruction
• hydro-demolition
• shotcreting
• formwork
• crack injection
• coatings and linings
• carbon fibre wraps
• Cathodic protection
• confined spaces
• industrial rope access
Contact Us:Geoff Adlem
Mob: 419 464 082 Office: 02 9519 8944E-mail: [email protected]
Corrosion & Materials10
NEWS
Accreditation course for inspectors to undertake detailed bridge inspections for Main Roads WAInafirstforMainRoadsWA,theirStructuresEngineeringbranchheldatwodaycoursetoprovidetrainingtoappropriatelyqualifiedandexperiencedbridgeengineersandengineeringassociatesinordertobecomeaccreditedtoundertakeDetailedBridgeInspections,knownasLevel2inspections,onsteelandconcretebridgesthroughouttheState.
AccreditationforBridgeInspectorsisrecognisedbothinternationallyandnationallyasanimportantpartofbridgeassetmanagement.Ithelpsprovideconsistencybetweendifferentinspectorsinhowdefectsareassessed,andhowconditionstatesandprioritiesforthemaintenanceworksaredetermined.InadditionthesecourseswillbuildapoolofaccreditedinspectorswhowillbeabletoassistStructuresEngineeringdeliverthisimportantpartoftheassetmanagementprocessintothefuture.
Thenumberswererestrictedtoacorefourteenpeoplefromengineeringconsultancies,MainRoadsWAandotherkeystakeholders.Thecoursecombinedthetheoryofconcrete
andsteelmaterialpropertiesanddeteriorationmechanismswithdetailsoftheon-siteapproachneededtosuccessfullycompleteadetailedinspectioninaccordancewiththein-housedeveloped‘DetailedVisualBridgeInspectionGuidelinesforConcreteandSteelBridges(Level2Inspections)’.Asitevisitwasalsoarrangedaspartofthecourse,providingagreatopportunityfortheattendeestoputthattheorystraightintopractice.
Thecoursewasestablished,organisedandrunbyStructuresEngineeringstaff.Specificlecturesonthecourseincludingdetailsofthecharacteristicsofmaterials,deteriorationmechanismsandrepairmethodswereprovidedbyWarrenGreen,anaccreditedAustralasianCorrosionAssociationlecturer.
EricaSmithofMainRoadsWAsaid“fullaccreditationbyexternalparticipants,throughattendanceonthiscourseandsuccessfulcompletionofacasestudyassignment,isnowarequirementwhenleadingon-siteinspectionsandwhenresponsiblefortheoveralldetailedinspectionreportforMainRoadsWA”.
“ItwasafantasticopportunityforvariousbridgeengineersandtechniciansthroughoutWAtoshareexperiencesandimproveunderstandinginthediagnosisofexistingstructuresandimpactsofcurrentconditiononfutureassetmanagementneeds”saidErica.
Thecoursewaswellreceivedandthereisalreadymuchinterestforasecondcoursetoberunlaterintheyear.
Curtin University launch Graduate Certificate in Corrosion EngineeringThefirstofitskindintheSouthernHemisphere,CurtinUniversitylauncheditsGraduateCertificateinCorrosionEngineeringinthefirstsemesterof2011.
TheGraduateCertificateinCorrosionEngineeringisthefirstinaseriesofpost-graduatecoursesCurtinUniversitywilloffertomeetgrowingindustrydemandforqualifiedcorrosionengineersandqualityresearchinthisfield.ThecourseispartofoilandgascompaniesWoodsideandChevron’ssponsorshipoftheChevron-WoodsideChairinCorrosionEngineering.
TheGraduateCertificateisofferedonlineandistheequivalentofsix-month’sfull-timestudy.Ifyouhaveanundergraduatedegreeinengineeringoranappliedsciencediscipline,thiscourseoffersyouachancetofasttrackyourcareertopracticetheprofessionofCorrosionEngineeringinabroadspectrumofindustries.
AuniqueopportunityforcareerdevelopmentintheEnergyandResourcesIndustryTheonlineGraduateCertificateinCorrosionEngineeringprogramistailoredtoindustryneeds–specificallytheenergyandresourceindustries–andcanbeundertakenwhileworkingastherearenorequirementstoattendclassesattheuniversity.
WhowillbenefitfromtheprogramThecourseisdesignedtodeliverspecificcorrosionengineeringskillsrelevanttotheenergyandresourcesindustries,andissuitableforqualified:
Chemists
MaterialsEngineers
Process/ChemicalEngineers
MechanicalEngineers
Itcanbeappliedinthefollowingindustries:
Oil&Gas
Refining&ChemicalProcessing
Mining&MineralProcessing
PowerGeneration
Defence
HowyouwillbenefitfromtheprogramThroughparticipationinthisprogramyouwillgainexpertiseinthefollowing:
Understandingfundamentalcorrosionandpreventionprinciples
Diagnosingcorrosionproblems
Developingcorrosionmanagementsolutions
Upgradingyourengineeringskillsbyworkingonreal-lifecorrosioncasesandprojects
EntryRequirementsStudentsmustholdarecogniseddegreeinengineeringorsciencewithequivalentoffirstyearChemistry.Ifyoudonothaveanappropriatebachelordegree,youmayberequiredtocompleteadditionalunitswhichwouldextendthedurationofthecourse.
DurationandAvailabilityThisfee-payingcourseisoneyearpart-timestudy.Eachstudentwillbeadvisedoftheirindividualstudyplan,whichwillbesubjecttotheavailabilityandsequencingofunitswithintheprogram.TwointakesareofferedeachyearinMarchandJuly.However,theJulyintakerequiresaminimumofthreesemesterstocompletethecourse.
Forfurtherinformation,pleasecontact:
Professor Rolf Gubner Chevron-WoodsideChairinCorrosionEngineering
ScienceandEngineeringTel:+61892667272Fax:+61892662300Email:[email protected]:www.corrosion.curtin.edu.au
Australian press slam Navy over rust bucketsAreviewofpressreportsoverrecentmonthsdemonstratesthattheAustralianpressisnotaversetoattackingslowmovingtargetswhicharenotabletodefendthemselves.
InOctober2010theHerald Sunwastrumpeting“therustneversleepsonprideofnavyfleet”.InNovemberThe Australianchimedinwith“Rustingwarships…..willsailagainafterrefit:navy”.FebruarysawThe West AustralianoutlineataleofwoefacedbytheresponsibleMinisterchargedwithgovernmentoversightoftheDefenceDepartment.Inthatarticle,thewords“rust”and“corrosion”are
recurringthemeswhichappeartobesetAustralia’snavy.InearlyMarchthisyeartheABC Newsheadlined“Callsforheadstorolloverrust-bucketNavy”.
ACA’sCorrosionChallengesstudies(reportedonelsewhereinthisedition)clearlydemonstratethatmanagementpracticesplayasignificantroleinaddingtounnecessarycostsofcorrosion.
ItisunfortunatethattheeffectsofcorrosiononthepreparednessofAustralia’snavalfleetcametolightduetotheNavy’sinabilitytorespond
toseverenaturaldisasterssuchasCycloneYasi.
ACAhasbeenendeavouringtocommencediscussionswiththeDepartmentofDefenceontherecommendationswhicharisefromtheCorrosionChallengesstudies.Hopefully,asthepoliticalheatdrainsaway,coolerheadsmayprevailandseniorDepartmentalrepresentativeswillaccepttheinvitationfromACAtoworkwithNavyandDefencetoassistthemtoresolvetheircorrosionmanagementproblems.
Concrete Repairs and Reconstruction
• hydro-demolition
• shotcreting
• formwork
• crack injection
• coatings and linings
• carbon fibre wraps
• Cathodic protection
• confined spaces
• industrial rope access
Contact Us:Geoff Adlem
Mob: 419 464 082 Office: 02 9519 8944E-mail: [email protected]
Vol 36 No 2 April 2011 www.corrosion.com.au 13
NEWS
Coatings market to reach US$98.69 billion by 2015Anewmarketreport‘Coatings:AGlobalStrategicBusinessReport’byresearchfirmGlobalIndustryAnalysts(GIA)forecaststheworldwidecoatingsmarkettobevaluedatUS$98.69billionin2015.
Thereportoutlinesanumberofreasonsattributedtotheexpectedgrowth,includinganincreaseinindustrialisationandariseinthedemandforconstructionandautomotivesectorsindevelopingcountries.ThematuremarketsoftheUSandEuropearealsoexpectedtoincreaseingrowthduetotechnologicalandproductdevelopments,uniqueformulationsandafavourableregulatoryenvironment.
AccordingtoGIA,thecoatingsindustrycanbetermedasmatureinmostregionsoftheworldanditsgrowthisdependantonanumberoffactorssuchaslevelofeconomicactivityandstateoftheconstruction
industry(amajorconsumerofpaintsandcoatings).Industrialgrowthindevelopingeconomiesisalsoamajorgrowthdriverforthecoatingsindustry.TheavailabilityofcheaplabourandanabundanceofresourceshavecompaniesmakingabeelineforAsia-PacificandLatinAmericaandsettingupproductionestablishmentsintheseregions.
GIAreportthatthefuturedevelopmentsincoatingsarelikelytofocusondevelopmentofnewcoatingsystemsasmanufacturersareincreasinglydevelopingcoatingproductsthatwoulddifferentiatethemfromtheircompetitors,creatingnicheproductstogaincustomerconfidence.
Theglobaleconomicdownturnaffectedthepaintandcoatingsindustry,particularlyduringtheturbulentperiodof2008and2009,accordingtothereport.ThedevelopedandmaturewesternmarketsofNorthAmericaandEuropewerethe
worsthitrecordinghighdouble-digitdeclinesduringtheperiod.IntheAsianmarkets,India,VietnamandIndonesiaamongothercountriesweatheredtherecessionandsufferedonlymarginallosses.Chinarecoveredfromtheadverseaffectofthedownturnin2009whendomesticdemandforcoatingsrose,andcoatingsexportsdeclineddrastically,toposthealthygrowthrates.
Thereportpredictstherevivaloftheglobaleconomypost2011-2012tobringthesectorgraduallybackontrack.Asia-Pacific,ledbyadvancesfromhighgrowthmarketsincludingChina,India,Indonesiaandothersstandstallasthelargestregionalmarketingrowth.EuropeandtheUStrailcloselybehindasothersignificantcoatingsmarketsworldwide.TheAsianmarketisalsoforecasttosurgeaheadofotherworldregionsattheoverallfastestcompoundedannualgrowthrateof4.2%through2015.
Project performance of alternative stainless steels gradesFormanyyears,highquality,longserviceanddurabilityhavebeenassociatedwithausteniticstainlesssteelssuchas304and316gradesthataccountformorethan60%oftheAustralasianmarket.Popularityofthesesteelsisduetocombinationofgoodfabricationproperties,reasonablelevelofcorrosionresistanceandlargeexperiencewithdifferentapplications.Inadditiontoabout18%chromium,thesesteelsalsocontainabout8%nickelthatmakesstructureaustenitic.
Inrecentyears,asithasalsobeenthecaseinthepast,priceofnickelhasincreaseddramaticallydirectlyaffectingcostof304and316grades.Historically,eachpeakinnickelpriceshastriggeredresearchintolow-nickelalternativesthatideallywouldbecheaperandnotcompromisewiththequalitiesoftheestablishedausteniticgrades.Typically,thesealternativesarenewferritic,manganesebearingausteniticandduplexstainlesssteelgrades.
Untilnow,therehasnotbeensufficientexperiencewithusingthese
steelgradesintheseverecoastalenvironmentinweldedconditions.HERAincooperationwithNewZealandStainlessSteelDevelopmentAssociation(NZSSDA),localindustriesandinternationalresearchpartnershasbeenconductingacorrosionstudyinvolvinganumberofcorrosiontestsonsteelgrades304,316,430,J4,404GP,445M2andLDX2101inweldedconditionsanddifferentfinishes.
Firsttestresultsthatinclude24-monthatmosphericexposuretestwerepresentedduringtheMetalsIndustryConferenceinWellingtonon14April2011.Furtherresultswillbeavailableatthe18thInternationalCorrosionCongress-Perth2011.
For further details, please contact Dr Michail Karpenko, Manager NZWC at HERA, New Zealand. Email: [email protected] Web: www.hera.org.nz
TestrackwithstainlesssteelsamplesexposedatMuriwaiBeach,Auckland
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Vol 36 No 2 April 2011 www.corrosion.com.au 13
NEWS
Coatings market to reach US$98.69 billion by 2015Anewmarketreport‘Coatings:AGlobalStrategicBusinessReport’byresearchfirmGlobalIndustryAnalysts(GIA)forecaststheworldwidecoatingsmarkettobevaluedatUS$98.69billionin2015.
Thereportoutlinesanumberofreasonsattributedtotheexpectedgrowth,includinganincreaseinindustrialisationandariseinthedemandforconstructionandautomotivesectorsindevelopingcountries.ThematuremarketsoftheUSandEuropearealsoexpectedtoincreaseingrowthduetotechnologicalandproductdevelopments,uniqueformulationsandafavourableregulatoryenvironment.
AccordingtoGIA,thecoatingsindustrycanbetermedasmatureinmostregionsoftheworldanditsgrowthisdependantonanumberoffactorssuchaslevelofeconomicactivityandstateoftheconstruction
industry(amajorconsumerofpaintsandcoatings).Industrialgrowthindevelopingeconomiesisalsoamajorgrowthdriverforthecoatingsindustry.TheavailabilityofcheaplabourandanabundanceofresourceshavecompaniesmakingabeelineforAsia-PacificandLatinAmericaandsettingupproductionestablishmentsintheseregions.
GIAreportthatthefuturedevelopmentsincoatingsarelikelytofocusondevelopmentofnewcoatingsystemsasmanufacturersareincreasinglydevelopingcoatingproductsthatwoulddifferentiatethemfromtheircompetitors,creatingnicheproductstogaincustomerconfidence.
Theglobaleconomicdownturnaffectedthepaintandcoatingsindustry,particularlyduringtheturbulentperiodof2008and2009,accordingtothereport.ThedevelopedandmaturewesternmarketsofNorthAmericaandEuropewerethe
worsthitrecordinghighdouble-digitdeclinesduringtheperiod.IntheAsianmarkets,India,VietnamandIndonesiaamongothercountriesweatheredtherecessionandsufferedonlymarginallosses.Chinarecoveredfromtheadverseaffectofthedownturnin2009whendomesticdemandforcoatingsrose,andcoatingsexportsdeclineddrastically,toposthealthygrowthrates.
Thereportpredictstherevivaloftheglobaleconomypost2011-2012tobringthesectorgraduallybackontrack.Asia-Pacific,ledbyadvancesfromhighgrowthmarketsincludingChina,India,Indonesiaandothersstandstallasthelargestregionalmarketingrowth.EuropeandtheUStrailcloselybehindasothersignificantcoatingsmarketsworldwide.TheAsianmarketisalsoforecasttosurgeaheadofotherworldregionsattheoverallfastestcompoundedannualgrowthrateof4.2%through2015.
Project performance of alternative stainless steels gradesFormanyyears,highquality,longserviceanddurabilityhavebeenassociatedwithausteniticstainlesssteelssuchas304and316gradesthataccountformorethan60%oftheAustralasianmarket.Popularityofthesesteelsisduetocombinationofgoodfabricationproperties,reasonablelevelofcorrosionresistanceandlargeexperiencewithdifferentapplications.Inadditiontoabout18%chromium,thesesteelsalsocontainabout8%nickelthatmakesstructureaustenitic.
Inrecentyears,asithasalsobeenthecaseinthepast,priceofnickelhasincreaseddramaticallydirectlyaffectingcostof304and316grades.Historically,eachpeakinnickelpriceshastriggeredresearchintolow-nickelalternativesthatideallywouldbecheaperandnotcompromisewiththequalitiesoftheestablishedausteniticgrades.Typically,thesealternativesarenewferritic,manganesebearingausteniticandduplexstainlesssteelgrades.
Untilnow,therehasnotbeensufficientexperiencewithusingthese
steelgradesintheseverecoastalenvironmentinweldedconditions.HERAincooperationwithNewZealandStainlessSteelDevelopmentAssociation(NZSSDA),localindustriesandinternationalresearchpartnershasbeenconductingacorrosionstudyinvolvinganumberofcorrosiontestsonsteelgrades304,316,430,J4,404GP,445M2andLDX2101inweldedconditionsanddifferentfinishes.
Firsttestresultsthatinclude24-monthatmosphericexposuretestwerepresentedduringtheMetalsIndustryConferenceinWellingtonon14April2011.Furtherresultswillbeavailableatthe18thInternationalCorrosionCongress-Perth2011.
For further details, please contact Dr Michail Karpenko, Manager NZWC at HERA, New Zealand. Email: [email protected] Web: www.hera.org.nz
TestrackwithstainlesssteelsamplesexposedatMuriwaiBeach,Auckland
Carboline has been global leader in the High Performance Coatings industry for over 63 yrs.
Specify Carboline - Coatings that deliver:SPEED, COMPLIANCE, PERFORMANCE
1800-RentDH (736 834) Melbourne Sydney Adelaide Perth Brisbanewww.rentdh.com [email protected] 24 hours a day / 7 days a week on-call service
Battling with Excessive Humidity?We have the solution.Dehumidification Technologies offers rental & sales of desiccant and refrigerant dehumidifiers. We have a wide range of dehumidification, cooling and heating equipment available to create any environment for our customer. Our innovative techniques, a wealth of knowledge and experience, and dependable service help customers achieve a successful project – on time and under budget.
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au14 15
NEWS
ACA welcomes new membersCorporateMembersTranspowerNZ(www.transpower.co.nz)TranspoweristheStateOwnedEnterprisethatplans,builds,maintainsandoperatesNewZealand’shighvoltageelectricitytransmissionnetwork–theNationalGrid–whichlinksgeneratorstodistributioncompaniesandmajorindustrialusers.
InternationalCorrosionServices(www.internationalcs.com.au)InternationalCorrosionServices(ICS)inbasedinHendersonWAandprovidesservicesinthreecoreareasofpostweldtreatmentofstainlesssteel,on-siteoperationalstainlesssteelcorrosionmaintenanceaswellasstainlessrelatedpiggingandflushingsolutions.ICSmobilisesstaffandequipmentforonsiteworkaswellasofferingalargeindustrialpicklingandpassivationbathconformingtoASTMA380-06&ASTMA967-05e2.
CityWestWater(www.citywestwater.com.au)AsoneofthreeVictorianGovernment-ownedretailwaterbusinessesinmetropolitanMelbourne,CityWestWaterprovidesdrinkingwater,sewerage,tradewasteandrecycledwaterservicestoresidentialandbusinesscustomersinMelbourne’scentralbusinessdistrict,innerandwesternsuburbs.Thecompanymanages3,909kilometresofsewerpipesandover4,000kilometresofwatermains–someofwhichdatebacktothe1850s.
IndividualMembersJayneArthurofAPAGroup
PeterBeckfordofApacheEnergy
DineshBankarofCoatingInspectionServices(India)
GarryBonadioofG&SPaintingServices
NeilBrodieofContractResources
EmilyWaiLynChanofWoodsideEnergy
MartinDonelanofACORBuildingConsultants
ColinEdgerton
MatthewEdmondsofEdmondsIndustrial
StephenHoltofShellRefining
CoreyHopeofParchemConstructionSupplies
DavidIrelandofBureauVeritas
GarryLuskanofWoodsideEnergy
BobbyMathanofJamesCookUniversity
DavidMorganofGoodline
DaleO'TooleofSavillsAustralia
KeithPerryofTenix
MichaelReynoldsofJeneilfen
AroonchaiRungvichaniwadofJBPInternationalPaint
PatrickStevensofMondelphous
PeerapongSueasukofJBPInternationalPaint
AlastairTawnsofWoodGroup
DonaldThomasofWACorrosionControl
JohnTomlinsonofTomlinsonHoldings
NicholasVanStyn
BrianWalshofFIB
BrentonWattsofLloyd'sRegisterAsia
StudentMembersAmaliaYunitaHalimofCurtinUniversity
VedapriyaPandarinathanofCurtinUniversity
GMA Garnet Group Level 18, Exchange Plaza, The Esplanade, Perth, WA 6000
For more information, contact us at 08 9287 3250 or email [email protected]
Quality range of blasting grades for your blast cleaning requirements.
www.garnetsales.com
GMA NewSteelTM
New steel, surface with light rust & thin coatings
GMA SpeedBlastTM
General purpose abrasive
GMA PremiumBlastTM
Maintenance grade for tough jobs
Wellington Division February Meeting
Auckland Division February Meeting
TheWellingtonDivisionFebruaryMeetinginvolvedtwopresentationsonaspectsofaluminiumcorrosion–oneintheairandoneincontactwiththeground.
RozJulianofQuestReliabilityspokeaboutaluminiumconductorssteel-reinforced(ACSR)whichcarrythehighvoltageelectricityaroundthecountry.Thesecanbesubjecttoalmostallpossibletypesofcorrosion–mostsevereisinternalattackonthealuminiumbytheenvironment,whichinmanyareasofNZismarine,andleadstopittingcorrosionandenhancedcrevicecorrosion.Therecanbemossanddepositswhichleadtolossofsurfacepassivity,whichinturnleadstoexternalsurfaceattack.Butbiggerproblemsseemtocomefromgalvaniccorrosionbetweenthealuminiumandthesteelcoreandoccasionallyfromfrettingasthealuminiumstrandsrubagainsteachother.Historicallythecoresteelfibresarecoatedwithzinc,whichcorrodespreferentiallytoboththesteelandthealuminium,untilitisgone,atwhichstagethealuminiumcorrodespreferentiallytothesteel.Thesteelcorecanhavegreaseappliedtoit–butthisgreaseapplicationcanbeintermittent,sothatthere
arepocketsofno-grease(withtheconsequentdifferentialenvironmentcellabletobeestablished).Thegreasecanalsodegradewithrisingtemperatureandcanreactwiththealuminiumcorrosionproductstoloseitsflexibilityandalsocreatedifferentialenvironmentproblems.
Theissuesareunderstoodwellenoughthatthefailurepointscanbepredictedforexamplewhenbulgesareobservedsincethecorrosionproductshavethreetimesthevolumeoftheinitialaluminium.Suchbulgescanbevisiblefromthegroundininspections,andremanentlifepredictionscanbemadefromsuchinspectionsorfromon-linemeasurementsofzincintegrity(lossofzincsignallingrapidcorrosionofaluminium),bulgingoraluminiumarealoss.
JonathanMorrisofOPUSspokeaboutcorrosioninanaluminiumculvertliningunderamajorroad.Pittingwasobservedduringaninspectionin2006oftheculvert(builtin1987),andatfurtherinspectionsin2008and2010itwasseentohavebecomemorenoticeable.Thereneededtobeanextensiveinvestigationinsitutosolvewhytheproblemsofperforating
corrosionseemedtobeonlyintheupperhalfofthelining.Eventuallythecausewastrackedtotheclay-likefillthathadbeenusedtobackfilltheconstruction(eventhoughthestandardspecificationatthetimeofconstructionin1987hadbeentouseagradedfree-drainingbackfill–butthelocalauthorityspecificationforthisjobhadnotreproducedthisrequirement).Thishadresultedinsignificantattackstartingonthesoilsideofthealuminium.Arehabilitationmethodologyhasbeendevised,whichwillallowtheworktobedonewithoutclosingtheroad.
Thefirstmeetingof2011forACAAucklandDivisionwasheldatTheLandinghotelon23rdFebruary.ThespeakerwasAaronDavey,DirectorofMarine&CivilSolutionsLtdwhoaddressedthetopic“CorrosioninMarineEnvironments–APerspectivefromAboveandBelowtheWaterline”.Thetalkcommencedwithanoverviewoftheissuesinvolvedinassessingamarineassetforcorrosiondamageinthemarineenvironment.Themainfactorstoconsiderwereseawatervariations,riskassessment,accessibilityfordivinginspections,tidesandtheweather.Aaronthen
describedthetypesofcorrosionthatareoftenencounteredonmarinestructures(usuallysteel)requiringrepairsincludinggalvanic,pittingcorrosionandmicrobialcorrosion(MIC)suchasacceleratedlowwatercorrosion(ALWC).
Aaronthendescribedandillustratedtheremediationofcorrodingmarineassetssuchasshiphulls,apontoon,anoiltransferplatform,shipseachests,ALWConsheetpiling,andsteelpilesunderwharves.Theremediationmethodofteninvolvedapplicationofpetrolatumtape
wrappingsafterthemarinestructurehasbeenappropriatelycleaned.Paintcoatingsandapplicationofanodes(CP)wereanotherremedialoption.Theremediationprocedureemployeddependedupontheexpectedlongevityandthemaintenancerequirementsoftheassetowner.
Aaron’spresentationwasfollowedbyanextensiveQ&Asessioninwhichmanyinterestingaspectsofmarinecorrosionwerediscussedwiththeaudiencepresent.
RozJulianofQuestReliability
JonathanMorrisofOPUS
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au14 15
NEWS
ACA welcomes new membersCorporateMembersTranspowerNZ(www.transpower.co.nz)TranspoweristheStateOwnedEnterprisethatplans,builds,maintainsandoperatesNewZealand’shighvoltageelectricitytransmissionnetwork–theNationalGrid–whichlinksgeneratorstodistributioncompaniesandmajorindustrialusers.
InternationalCorrosionServices(www.internationalcs.com.au)InternationalCorrosionServices(ICS)inbasedinHendersonWAandprovidesservicesinthreecoreareasofpostweldtreatmentofstainlesssteel,on-siteoperationalstainlesssteelcorrosionmaintenanceaswellasstainlessrelatedpiggingandflushingsolutions.ICSmobilisesstaffandequipmentforonsiteworkaswellasofferingalargeindustrialpicklingandpassivationbathconformingtoASTMA380-06&ASTMA967-05e2.
CityWestWater(www.citywestwater.com.au)AsoneofthreeVictorianGovernment-ownedretailwaterbusinessesinmetropolitanMelbourne,CityWestWaterprovidesdrinkingwater,sewerage,tradewasteandrecycledwaterservicestoresidentialandbusinesscustomersinMelbourne’scentralbusinessdistrict,innerandwesternsuburbs.Thecompanymanages3,909kilometresofsewerpipesandover4,000kilometresofwatermains–someofwhichdatebacktothe1850s.
IndividualMembersJayneArthurofAPAGroup
PeterBeckfordofApacheEnergy
DineshBankarofCoatingInspectionServices(India)
GarryBonadioofG&SPaintingServices
NeilBrodieofContractResources
EmilyWaiLynChanofWoodsideEnergy
MartinDonelanofACORBuildingConsultants
ColinEdgerton
MatthewEdmondsofEdmondsIndustrial
StephenHoltofShellRefining
CoreyHopeofParchemConstructionSupplies
DavidIrelandofBureauVeritas
GarryLuskanofWoodsideEnergy
BobbyMathanofJamesCookUniversity
DavidMorganofGoodline
DaleO'TooleofSavillsAustralia
KeithPerryofTenix
MichaelReynoldsofJeneilfen
AroonchaiRungvichaniwadofJBPInternationalPaint
PatrickStevensofMondelphous
PeerapongSueasukofJBPInternationalPaint
AlastairTawnsofWoodGroup
DonaldThomasofWACorrosionControl
JohnTomlinsonofTomlinsonHoldings
NicholasVanStyn
BrianWalshofFIB
BrentonWattsofLloyd'sRegisterAsia
StudentMembersAmaliaYunitaHalimofCurtinUniversity
VedapriyaPandarinathanofCurtinUniversity
GMA Garnet Group Level 18, Exchange Plaza, The Esplanade, Perth, WA 6000
For more information, contact us at 08 9287 3250 or email [email protected]
Quality range of blasting grades for your blast cleaning requirements.
www.garnetsales.com
GMA NewSteelTM
New steel, surface with light rust & thin coatings
GMA SpeedBlastTM
General purpose abrasive
GMA PremiumBlastTM
Maintenance grade for tough jobs
Wellington Division February Meeting
Auckland Division February Meeting
TheWellingtonDivisionFebruaryMeetinginvolvedtwopresentationsonaspectsofaluminiumcorrosion–oneintheairandoneincontactwiththeground.
RozJulianofQuestReliabilityspokeaboutaluminiumconductorssteel-reinforced(ACSR)whichcarrythehighvoltageelectricityaroundthecountry.Thesecanbesubjecttoalmostallpossibletypesofcorrosion–mostsevereisinternalattackonthealuminiumbytheenvironment,whichinmanyareasofNZismarine,andleadstopittingcorrosionandenhancedcrevicecorrosion.Therecanbemossanddepositswhichleadtolossofsurfacepassivity,whichinturnleadstoexternalsurfaceattack.Butbiggerproblemsseemtocomefromgalvaniccorrosionbetweenthealuminiumandthesteelcoreandoccasionallyfromfrettingasthealuminiumstrandsrubagainsteachother.Historicallythecoresteelfibresarecoatedwithzinc,whichcorrodespreferentiallytoboththesteelandthealuminium,untilitisgone,atwhichstagethealuminiumcorrodespreferentiallytothesteel.Thesteelcorecanhavegreaseappliedtoit–butthisgreaseapplicationcanbeintermittent,sothatthere
arepocketsofno-grease(withtheconsequentdifferentialenvironmentcellabletobeestablished).Thegreasecanalsodegradewithrisingtemperatureandcanreactwiththealuminiumcorrosionproductstoloseitsflexibilityandalsocreatedifferentialenvironmentproblems.
Theissuesareunderstoodwellenoughthatthefailurepointscanbepredictedforexamplewhenbulgesareobservedsincethecorrosionproductshavethreetimesthevolumeoftheinitialaluminium.Suchbulgescanbevisiblefromthegroundininspections,andremanentlifepredictionscanbemadefromsuchinspectionsorfromon-linemeasurementsofzincintegrity(lossofzincsignallingrapidcorrosionofaluminium),bulgingoraluminiumarealoss.
JonathanMorrisofOPUSspokeaboutcorrosioninanaluminiumculvertliningunderamajorroad.Pittingwasobservedduringaninspectionin2006oftheculvert(builtin1987),andatfurtherinspectionsin2008and2010itwasseentohavebecomemorenoticeable.Thereneededtobeanextensiveinvestigationinsitutosolvewhytheproblemsofperforating
corrosionseemedtobeonlyintheupperhalfofthelining.Eventuallythecausewastrackedtotheclay-likefillthathadbeenusedtobackfilltheconstruction(eventhoughthestandardspecificationatthetimeofconstructionin1987hadbeentouseagradedfree-drainingbackfill–butthelocalauthorityspecificationforthisjobhadnotreproducedthisrequirement).Thishadresultedinsignificantattackstartingonthesoilsideofthealuminium.Arehabilitationmethodologyhasbeendevised,whichwillallowtheworktobedonewithoutclosingtheroad.
Thefirstmeetingof2011forACAAucklandDivisionwasheldatTheLandinghotelon23rdFebruary.ThespeakerwasAaronDavey,DirectorofMarine&CivilSolutionsLtdwhoaddressedthetopic“CorrosioninMarineEnvironments–APerspectivefromAboveandBelowtheWaterline”.Thetalkcommencedwithanoverviewoftheissuesinvolvedinassessingamarineassetforcorrosiondamageinthemarineenvironment.Themainfactorstoconsiderwereseawatervariations,riskassessment,accessibilityfordivinginspections,tidesandtheweather.Aaronthen
describedthetypesofcorrosionthatareoftenencounteredonmarinestructures(usuallysteel)requiringrepairsincludinggalvanic,pittingcorrosionandmicrobialcorrosion(MIC)suchasacceleratedlowwatercorrosion(ALWC).
Aaronthendescribedandillustratedtheremediationofcorrodingmarineassetssuchasshiphulls,apontoon,anoiltransferplatform,shipseachests,ALWConsheetpiling,andsteelpilesunderwharves.Theremediationmethodofteninvolvedapplicationofpetrolatumtape
wrappingsafterthemarinestructurehasbeenappropriatelycleaned.Paintcoatingsandapplicationofanodes(CP)wereanotherremedialoption.Theremediationprocedureemployeddependedupontheexpectedlongevityandthemaintenancerequirementsoftheassetowner.
Aaron’spresentationwasfollowedbyanextensiveQ&Asessioninwhichmanyinterestingaspectsofmarinecorrosionwerediscussedwiththeaudiencepresent.
RozJulianofQuestReliability
JonathanMorrisofOPUS
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au16 17
ReportonSAIGLOBALPublicationsathttps://infostore.saiglobal.com/store,forallcurrentpublicationsandstandardsrelatingto“coatingsandcorrosion”forthe“Coatings”TechnicalGroup
Atotalof620Publicationsfoundfrom35PublishersaslistedinTable1below.
Table1ListofPublishersandnumberofpublicationsforeach
AmericanArchitecturalManufacturersAssociation(1) AmericanSocietyforTestingandMaterials(8)
AmericanWeldingSociety(1) AsociacionEspanoladeNormalizacion(25)
AssociationFrancaisedeNormalisation(32) BelgianStandards(22)
BrazilianStandards(7) BritishStandardsInstitution(37)
BureauofIndianStandard(4) ComitéEuropéendeNormalisation(27)
DetNorskVeritas(1) FordMotorCompany(73)
GermanInstituteforStandardisation(DeutschesInstitutfürNormung)(40)
GermanischerLloyd(1)
InternationalOrganizationforStandardization(16) Interstandard(Russia)(38)
ItalianStandards(29) JapaneseStandardsAssociation(7)
ACAStandardsOfficerArthurAustinhaspreparedascheduleofthelateststandardsdevelopments.
Thestandardsreportingfor2011isscheduledagainstTechnicalGroups(TG)asindicatedbelow:
Issue2011
StandardssearchforTGinterests
Feb ConcreteStructures&Buildings
April Coatings
June Refining&Processing
August CathodicProtection
October MiningIndustry
December Water&WasteWaterandWelding,Joining&Corrosion
IssueonewastheConcreteStructuresandBuildingsTG;thisissueisfortheCoatingsTG.
Asinthepast,thisreportisintwostages,namely:
1.Aglobalstandardsandpublicationfocus,searchingthroughSAIGLOBALPublicationsathttps://infostore.saiglobal.com/store,forallcurrentpublicationsandstandardsrelatingtooneofthe
ACATGs,withthisedition'sgroupfocusbeingthe“Coatings”TG.
2.ASAIGlobalsearch,aspreviously,athttp://www.saiglobal.com/online/fornewstandards,amendmentsordraftsforAS,AS/NZS,EN,ANSI,ASTM,BSI,DIN,ETSI,JSA,NSAIandstandardsandamendmentsforISO&IECpublishedfrom2Januaryto23March2011,usingthekeywordsandkeywordgroups:
‘durability’.
‘corrosion’or‘corrosivity’or‘corrosive’;butnot‘anodizing’or‘anodize(d)’.
'paint’or‘coating’;butnot‘anodizing’or‘anodize(d)’.
'galvanize'or‘galvanized’orgalvanizing’.
'electrochemical'or‘electrolysis’or‘electroplated’.
‘cathode’or'cathodic'.
‘anode’or‘anodic’.
'corrosion'and'concrete'or‘concrete’and‘coatings’.
Summary1.ThroughSAIGLOBALPublications
athttps://infostore.saiglobal.com/storetherewere620Publicationsfoundfrom35PublishersaslistedinTable1belowagainstasearchfor“coatingsandcorrosion”with18ASAS/NZSpublicationslisted.ThepublicationslistedbySubjectareinTable2below.
2.AcrossSAIGLOBALonlineStandardsPublicationstherewasatotalof47listingsofnewstandards,DraftsandAmendments,foundissuedfromto2Januaryto23March2011.TherewasoneASdraft(DRAS/NZS3566.2Self-drillingscrewsforthebuildingandconstructionindustries-Part2:Corrosionresistancerequirementsandrequirementsfornon-conductiveseals)andoneASAmendment(AS2841-2005/Amdt1-2011Galvanizedsteelwirestrand.
3.Therewasonestandardrelatingtothere-alkalizationofconcrete(DDCEN/TS14038-2:2011electrochemicalre-alkalizationandchlorideextractiontreatmentsforreinforcedconcrete.Chlorideextraction)thatmaybeofinterest.
Seetheattachedtablesfordetails.
NACEInternational(5) NationalStandardsAuthorityofIreland(27)
NederlandsNormalisatieInstituut(26) NorwegianStandards(NorgesStandardiseringsforbund)(29)
OsterreichischesNormungsinstitut(31) PolishCommitteeforStandardization(34)
SocietyofAutomotiveEngineers(3) SouthAfricanBureauofStandards(4)
Standardiserings-KommissionenISverige(31) StandardizationAdministrationofChina(5)
StandardsAustralia(18) SwissStandards(29)
SSPC–TheSocietyforProtectiveCoatings(1) UnionInternationaledesCheminsdeFer(1)
USMilitarySpecs/Standards/Handbooks(4) VerlagStahleisenGmbH(1)
WirtschaftsundVerlagsgesellschaftGasundWasser(2)
PublicationsbySubjectarelistedinTable2below:
Table2Listofpublicationsbysubject
Manufacturingengineering(339)-Surfacetreatmentandcoating(339)-Industrialautomationsystems(1)
Paintandcolourindustries(86)-Paintsandvarnishes(50)-Paintcoatingprocesses(37)
Constructionmaterialsandbuilding(73)-Structuresofbuildings(58)-Constructionmaterials(12)-Installationsinbuildings(2)-Elementsofbuildings(1)-Protectionofandinbuildings(1)
Metallurgy(29)-Corrosionofmetals(28)-Ironandsteelproducts(1)
Fluidsystemsandcomponentsforgeneraluse(19)-Pipelinecomponentsandpipelines(19)
Generalities.Terminology.Standardization.Documentation(18)-Vocabularies(18)
Aircraftandspacevehicleengineering(14)-Fastenersforaerospaceconstruction(12)-Coatingsandrelatedprocessesusedinaerospaceindustry(2)
Precisionmechanics.Jewellery(8)-Jewellery(8)
Testing(4)-Environmentaltesting(3)-Mechanicaltesting(1)
Chemicaltechnology(2)-Analyticalchemistry(2)
Mechanicalsystemsandcomponentsforgeneraluse(2)-Fasteners(2)
Electronics(1)-Electroniccomponentsingeneral(1)
Environment.Healthprotection.Safety(1)-Environmentalprotection(1)
Roadvehiclesengineering(1)-Roadvehiclesystems(1)
Toaccessthesepublications,gotohttps://infostore.saiglobal.com/storeandtype‘coatingsandcorrosion’intothesearchboxandexaminethesearchresults.
STANDARDSFORAS,AS/NZS,EN,ANSI,ASTM,BSI,DIN,ETSI,JSA,NSAIANDSTANDARDSANDAMENDMENTSFORISO&IECPUBLISHEDfrom2Januaryto23March2011for:
Newstandards,amendmentsordraftsforAS,AS/NZS,EN,ANSI,ASTM,BSI,DIN,ETSI,JSA,NSAIandStandardsorAmendmentsforISO&IECPUBLISHEDbetween2Januaryto23March2011
Keywordsearchon‘durability’.-1BSENcitationsfoundrelatingtosolidbiofueldurability
BSEN15210-2:2010 Solidbiofuels.Determinationofmechanicaldurabilityofpelletsandbriquettes.Briquettes
Keywordsearchon‘corrosion’or‘corrosivity’or‘corrosive’;butnot‘anodizing’or‘anodize(d)’-18citationsinall–1AS/NZSDraftcitations;
DRAS/NZS3566.2 Self-drillingscrewsforthebuildingandconstructionindustries-Part2:Corrosionresistancerequirementsandrequirementsfornon-conductiveseals
ISO5952:2011 Continuouslyhot-rolledsteelsheetofstructuralqualitywithimprovedatmosphericcorrosionresistance
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au16 17
ReportonSAIGLOBALPublicationsathttps://infostore.saiglobal.com/store,forallcurrentpublicationsandstandardsrelatingto“coatingsandcorrosion”forthe“Coatings”TechnicalGroup
Atotalof620Publicationsfoundfrom35PublishersaslistedinTable1below.
Table1ListofPublishersandnumberofpublicationsforeach
AmericanArchitecturalManufacturersAssociation(1) AmericanSocietyforTestingandMaterials(8)
AmericanWeldingSociety(1) AsociacionEspanoladeNormalizacion(25)
AssociationFrancaisedeNormalisation(32) BelgianStandards(22)
BrazilianStandards(7) BritishStandardsInstitution(37)
BureauofIndianStandard(4) ComitéEuropéendeNormalisation(27)
DetNorskVeritas(1) FordMotorCompany(73)
GermanInstituteforStandardisation(DeutschesInstitutfürNormung)(40)
GermanischerLloyd(1)
InternationalOrganizationforStandardization(16) Interstandard(Russia)(38)
ItalianStandards(29) JapaneseStandardsAssociation(7)
ACAStandardsOfficerArthurAustinhaspreparedascheduleofthelateststandardsdevelopments.
Thestandardsreportingfor2011isscheduledagainstTechnicalGroups(TG)asindicatedbelow:
Issue2011
StandardssearchforTGinterests
Feb ConcreteStructures&Buildings
April Coatings
June Refining&Processing
August CathodicProtection
October MiningIndustry
December Water&WasteWaterandWelding,Joining&Corrosion
IssueonewastheConcreteStructuresandBuildingsTG;thisissueisfortheCoatingsTG.
Asinthepast,thisreportisintwostages,namely:
1.Aglobalstandardsandpublicationfocus,searchingthroughSAIGLOBALPublicationsathttps://infostore.saiglobal.com/store,forallcurrentpublicationsandstandardsrelatingtooneofthe
ACATGs,withthisedition'sgroupfocusbeingthe“Coatings”TG.
2.ASAIGlobalsearch,aspreviously,athttp://www.saiglobal.com/online/fornewstandards,amendmentsordraftsforAS,AS/NZS,EN,ANSI,ASTM,BSI,DIN,ETSI,JSA,NSAIandstandardsandamendmentsforISO&IECpublishedfrom2Januaryto23March2011,usingthekeywordsandkeywordgroups:
‘durability’.
‘corrosion’or‘corrosivity’or‘corrosive’;butnot‘anodizing’or‘anodize(d)’.
'paint’or‘coating’;butnot‘anodizing’or‘anodize(d)’.
'galvanize'or‘galvanized’orgalvanizing’.
'electrochemical'or‘electrolysis’or‘electroplated’.
‘cathode’or'cathodic'.
‘anode’or‘anodic’.
'corrosion'and'concrete'or‘concrete’and‘coatings’.
Summary1.ThroughSAIGLOBALPublications
athttps://infostore.saiglobal.com/storetherewere620Publicationsfoundfrom35PublishersaslistedinTable1belowagainstasearchfor“coatingsandcorrosion”with18ASAS/NZSpublicationslisted.ThepublicationslistedbySubjectareinTable2below.
2.AcrossSAIGLOBALonlineStandardsPublicationstherewasatotalof47listingsofnewstandards,DraftsandAmendments,foundissuedfromto2Januaryto23March2011.TherewasoneASdraft(DRAS/NZS3566.2Self-drillingscrewsforthebuildingandconstructionindustries-Part2:Corrosionresistancerequirementsandrequirementsfornon-conductiveseals)andoneASAmendment(AS2841-2005/Amdt1-2011Galvanizedsteelwirestrand.
3.Therewasonestandardrelatingtothere-alkalizationofconcrete(DDCEN/TS14038-2:2011electrochemicalre-alkalizationandchlorideextractiontreatmentsforreinforcedconcrete.Chlorideextraction)thatmaybeofinterest.
Seetheattachedtablesfordetails.
NACEInternational(5) NationalStandardsAuthorityofIreland(27)
NederlandsNormalisatieInstituut(26) NorwegianStandards(NorgesStandardiseringsforbund)(29)
OsterreichischesNormungsinstitut(31) PolishCommitteeforStandardization(34)
SocietyofAutomotiveEngineers(3) SouthAfricanBureauofStandards(4)
Standardiserings-KommissionenISverige(31) StandardizationAdministrationofChina(5)
StandardsAustralia(18) SwissStandards(29)
SSPC–TheSocietyforProtectiveCoatings(1) UnionInternationaledesCheminsdeFer(1)
USMilitarySpecs/Standards/Handbooks(4) VerlagStahleisenGmbH(1)
WirtschaftsundVerlagsgesellschaftGasundWasser(2)
PublicationsbySubjectarelistedinTable2below:
Table2Listofpublicationsbysubject
Manufacturingengineering(339)-Surfacetreatmentandcoating(339)-Industrialautomationsystems(1)
Paintandcolourindustries(86)-Paintsandvarnishes(50)-Paintcoatingprocesses(37)
Constructionmaterialsandbuilding(73)-Structuresofbuildings(58)-Constructionmaterials(12)-Installationsinbuildings(2)-Elementsofbuildings(1)-Protectionofandinbuildings(1)
Metallurgy(29)-Corrosionofmetals(28)-Ironandsteelproducts(1)
Fluidsystemsandcomponentsforgeneraluse(19)-Pipelinecomponentsandpipelines(19)
Generalities.Terminology.Standardization.Documentation(18)-Vocabularies(18)
Aircraftandspacevehicleengineering(14)-Fastenersforaerospaceconstruction(12)-Coatingsandrelatedprocessesusedinaerospaceindustry(2)
Precisionmechanics.Jewellery(8)-Jewellery(8)
Testing(4)-Environmentaltesting(3)-Mechanicaltesting(1)
Chemicaltechnology(2)-Analyticalchemistry(2)
Mechanicalsystemsandcomponentsforgeneraluse(2)-Fasteners(2)
Electronics(1)-Electroniccomponentsingeneral(1)
Environment.Healthprotection.Safety(1)-Environmentalprotection(1)
Roadvehiclesengineering(1)-Roadvehiclesystems(1)
Toaccessthesepublications,gotohttps://infostore.saiglobal.com/storeandtype‘coatingsandcorrosion’intothesearchboxandexaminethesearchresults.
STANDARDSFORAS,AS/NZS,EN,ANSI,ASTM,BSI,DIN,ETSI,JSA,NSAIANDSTANDARDSANDAMENDMENTSFORISO&IECPUBLISHEDfrom2Januaryto23March2011for:
Newstandards,amendmentsordraftsforAS,AS/NZS,EN,ANSI,ASTM,BSI,DIN,ETSI,JSA,NSAIandStandardsorAmendmentsforISO&IECPUBLISHEDbetween2Januaryto23March2011
Keywordsearchon‘durability’.-1BSENcitationsfoundrelatingtosolidbiofueldurability
BSEN15210-2:2010 Solidbiofuels.Determinationofmechanicaldurabilityofpelletsandbriquettes.Briquettes
Keywordsearchon‘corrosion’or‘corrosivity’or‘corrosive’;butnot‘anodizing’or‘anodize(d)’-18citationsinall–1AS/NZSDraftcitations;
DRAS/NZS3566.2 Self-drillingscrewsforthebuildingandconstructionindustries-Part2:Corrosionresistancerequirementsandrequirementsfornon-conductiveseals
ISO5952:2011 Continuouslyhot-rolledsteelsheetofstructuralqualitywithimprovedatmosphericcorrosionresistance
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au18 19
StandardsUpdate
ISO8994:2011 Anodizingofaluminiumanditsalloys-Ratingsystemfortheevaluationofpittingcorrosion-Gridmethod
ISO/DIS11997-2 Paintsandvarnishes-Determinationofresistancetocycliccorrosionconditions-Part2:Wet(saltfog)/dry/humidity/UVlight
ISO/DIS14802 Corrosionofmetalsandalloys-Guidelinesforapplyingstatisticstoanalysisofcorrosiondata
ISO/DIS17752 Corrosionofmetalsandalloys-Procedurestodetermineandestimaterunoffratesofmetalsfrommaterialsasaresultofatmosphericcorrosion
I.S.ENISO4404-2:2010 PetroleumandRelatedProducts-DeterminationoftheCorrosionResistanceofFire-resistantHydraulicFluids-Part2:Non-aqueousFluids
11/30204373DCBSISO17752
Corrosionofmetalsandalloys.Procedurestodetermineandestimaterunoffratesofmetalsfrommaterialsasaresultofatmosphericcorrosion
11/30215346DCBSISO14802
Corrosionofmetalsandalloys.Guidelinesforapplyingstatisticstoanalysisofcorrosiondata
11/30241787DCBSEN62321-7-1
Determinationofcertainsubstancesinelectrotechnicalproducts.Part7-1.Determinationofthepresenceofhexavalentchromium(Cr(VI))incolourlessandcolouredcorrosion-protectedcoatingsonmetalsbythecolourimetricmethod
BSEN2596:2006 Aerospaceseries.Washers,lock,withradialserrationsincorrosionresistingsteel,cadmiumplatedforflightcontrolrods.Dimensions
BSENISO4404-2:2010 Petroleumandrelatedproducts.Determinationofthecorrosionresistanceoffire-resistanthydraulicfluids.Non-aqueousfluids
BSISO5952:2011 Continuouslyhot-rolledsteelsheetofstructuralqualitywithimprovedatmosphericcorrosionresistance
JISG0596:2010 Methodofcorrosiontestforstainlesssteeltubefittings
DINEN4538-003(2011-02)
Aerospaceseries-Bearings,sphericalplain,incorrosionresistingsteelwithself-lubricatinglinerelevatedloadunderlowoscillations-Narrowseries-Dimensionsandloads-Part003:Inchserieswithlowfrictioncoefficient;GermanandEnglishversionEN4538-003:2010
DIN65307(2011-03) Aerospaceseries-Insertsforcompositematerials,withMJthread,closedtype,lightweight,screw-locking,corrosion-resistingsteel;TextinGermanandEnglish
DIN65308(2011-03) Aerospace-Insertsforcompositematerials,withMJthread,opentype,screw-locking,corrosion-resistingsteel;TextinGermanandEnglish
DINEN4539-003(2011-02)
Aerospaceseries-Bearings,sphericalplain,incorrosionresistingsteelwithself-lubricatinglinerelevatedloadunderlowoscillations-Wideseries-Dimensionsandloads-Part003:Inchserieswithlowfrictioncoefficient;GermanandEnglishversionEN4539-003:2010
Keywordsearchon'paint’andor‘coating’;butnot‘anodizing’or‘anodize(d)’orcorrosion–27Publicationsfound;3Drafts;nopublicationsfromAS/NZS;
ISO1519:2011 Paintsandvarnishes-Bendtest(cylindricalmandrel)
ISO2811-1:2011 Paintsandvarnishes-Determinationofdensity-Part1:Pyknometermethod
ISO2811-2:2011 Paintsandvarnishes-Determinationofdensity-Part2:Immersedbody(plummet)method
ISO2811-3:2011 Paintsandvarnishes-Determinationofdensity-Part3:Oscillationmethod
ISO2811-4:2011 Paintsandvarnishes-Determinationofdensity-Part4:Pressurecupmethod
ISO/DIS11997-2 Paintsandvarnishes-Determinationofresistancetocycliccorrosionconditions-Part2:Wet(saltfog)/dry/humidity/UVlight
ISO/DIS15091 Paintsandvarnishes-Determinationoftheelectricalconductivityandthespecificelectricalresistivity
I.S.ENISO1519:2011 PaintsandVarnishes-BendTest(cylindricalMandrel)
I.S.ENISO2811-1:2011 PaintsandVarnishes-DeterminationofDensity-Part1:PyknometerMethod
I.S.ENISO2811-2:2011 PaintsandVarnishes-DeterminationofDensity-Part2:ImmersedBody(plummet)Method
I.S.ENISO2811-3:2011 PaintsandVarnishes-DeterminationofDensity-Part3:OscillationMethod
I.S.ENISO2811-4:2011 PaintsandVarnishes-DeterminationofDensity-Part4:PressurecupMethod
11/30217717DCBSENISO15091
Paintsandvarnishes.Determinationoftheelectricalconductivityandthespecificelectricalresistivity
11/30233262DC BSEN1871.Roadmarkingmaterials.Paint,thermoplasticandcoldplasticmaterials.Specifications
BSENISO1519:2011 Paintsandvarnishes.Bendtest(cylindricalmandrel)
ISO26945:2011 Metallicandotherinorganiccoatings-Electrodepositedcoatingsoftin-cobaltalloy
I.S.ENISO12690:2010 MetallicandOtherInorganicCoatings-ThermalSprayCoordination-TasksandResponsibilities
I.S.ENISO14921:2010 ThermalSpraying-ProceduresfortheApplicationofThermallySprayedCoatingsforEngineeringComponents
I.S.ENISO26945:2011 MetallicandOtherInorganicCoatings-ElectrodepositedCoatingsofTin-cobaltAlloy
I.S.ENISO3613:2010 MetallicandOtherInorganicCoatings-ChromateConversionCoatingsonZinc,Cadmium,Aluminium-zincAlloysandZinc-aluminiumAlloys-TestMethods
11/30237910DCBSEN927-3
Paintsandvarnishes.Coatingmaterialsandcoatingsystemsforexteriorwood.Part3.Naturalweatheringtest
11/30241787DCBSEN62321-7-1
Determinationofcertainsubstancesinelectrotechnicalproducts.Part7-1.Determinationofthepresenceofhexavalentchromium(Cr(VI))incolourlessandcolouredcorrosion-protectedcoatingsonmetalsbythecolourimetricmethod
BSENISO12690:2010 Metallicandotherinorganiccoatings.Thermalspraycoordination.Tasksandresponsibilities
BSENISO14921:2010 Thermalspraying.Proceduresfortheapplicationofthermallysprayedcoatingsforengineeringcomponents
BSENISO26945:2011 Metallicandotherinorganiccoatings.Electrodepositedcoatingsoftin-cobaltalloy
BSENISO3613:2010 Metallicandotherinorganiccoatings.Chromateconversioncoatingsonzinc,cadmium,aluminium-zincalloysandzinc-aluminiumalloys.Testmethods
BSISO9717:2010 Metallicandotherinorganiccoatings.Phosphateconversioncoatingofmetals
Keywordsearchon'galvanize'or‘galvanized’or'galvanizing’–1ASAmendmentStandardPublicationsfound;
AS2841-2005/Amdt1-2011
Galvanizedsteelwirestrand
Keywordsearchon'corrosion'and'concrete'or‘concrete’and‘coatings’-0StandardPublicationsfound.
Keywordsearchon‘cathode’or'cathodic'-0corrosionrelatedStandardPublicationsfound
Keywordsearchon'anode'or‘anodes’or‘anodic’–3StandardPublicationsfound–NonefromAS/ANZS
ISO2106:2011 Anodizingofaluminiumanditsalloys-Determinationofmassperunitarea(surfacedensity)ofanodicoxidationcoatings-Gravimetricmethod
ISO8251:2011 Anodizingofaluminiumanditsalloys-Measurementofabrasionresistanceofanodicoxidationcoatings
ISO8994:2011 Anodizingofaluminiumanditsalloys-Ratingsystemfortheevaluationofpittingcorrosion-Gridmethod
KeywordSearchon'electrochemical'or‘electrolysis’or‘electroplated’-
DDCEN/TS14038-2:2011
Electrochemicalre-alkalizationandchlorideextractiontreatmentsforreinforcedconcrete.Chlorideextraction
KeywordSearchon'anodize'or‘anodized’-0Publicationsfound
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au18 19
StandardsUpdate
ISO8994:2011 Anodizingofaluminiumanditsalloys-Ratingsystemfortheevaluationofpittingcorrosion-Gridmethod
ISO/DIS11997-2 Paintsandvarnishes-Determinationofresistancetocycliccorrosionconditions-Part2:Wet(saltfog)/dry/humidity/UVlight
ISO/DIS14802 Corrosionofmetalsandalloys-Guidelinesforapplyingstatisticstoanalysisofcorrosiondata
ISO/DIS17752 Corrosionofmetalsandalloys-Procedurestodetermineandestimaterunoffratesofmetalsfrommaterialsasaresultofatmosphericcorrosion
I.S.ENISO4404-2:2010 PetroleumandRelatedProducts-DeterminationoftheCorrosionResistanceofFire-resistantHydraulicFluids-Part2:Non-aqueousFluids
11/30204373DCBSISO17752
Corrosionofmetalsandalloys.Procedurestodetermineandestimaterunoffratesofmetalsfrommaterialsasaresultofatmosphericcorrosion
11/30215346DCBSISO14802
Corrosionofmetalsandalloys.Guidelinesforapplyingstatisticstoanalysisofcorrosiondata
11/30241787DCBSEN62321-7-1
Determinationofcertainsubstancesinelectrotechnicalproducts.Part7-1.Determinationofthepresenceofhexavalentchromium(Cr(VI))incolourlessandcolouredcorrosion-protectedcoatingsonmetalsbythecolourimetricmethod
BSEN2596:2006 Aerospaceseries.Washers,lock,withradialserrationsincorrosionresistingsteel,cadmiumplatedforflightcontrolrods.Dimensions
BSENISO4404-2:2010 Petroleumandrelatedproducts.Determinationofthecorrosionresistanceoffire-resistanthydraulicfluids.Non-aqueousfluids
BSISO5952:2011 Continuouslyhot-rolledsteelsheetofstructuralqualitywithimprovedatmosphericcorrosionresistance
JISG0596:2010 Methodofcorrosiontestforstainlesssteeltubefittings
DINEN4538-003(2011-02)
Aerospaceseries-Bearings,sphericalplain,incorrosionresistingsteelwithself-lubricatinglinerelevatedloadunderlowoscillations-Narrowseries-Dimensionsandloads-Part003:Inchserieswithlowfrictioncoefficient;GermanandEnglishversionEN4538-003:2010
DIN65307(2011-03) Aerospaceseries-Insertsforcompositematerials,withMJthread,closedtype,lightweight,screw-locking,corrosion-resistingsteel;TextinGermanandEnglish
DIN65308(2011-03) Aerospace-Insertsforcompositematerials,withMJthread,opentype,screw-locking,corrosion-resistingsteel;TextinGermanandEnglish
DINEN4539-003(2011-02)
Aerospaceseries-Bearings,sphericalplain,incorrosionresistingsteelwithself-lubricatinglinerelevatedloadunderlowoscillations-Wideseries-Dimensionsandloads-Part003:Inchserieswithlowfrictioncoefficient;GermanandEnglishversionEN4539-003:2010
Keywordsearchon'paint’andor‘coating’;butnot‘anodizing’or‘anodize(d)’orcorrosion–27Publicationsfound;3Drafts;nopublicationsfromAS/NZS;
ISO1519:2011 Paintsandvarnishes-Bendtest(cylindricalmandrel)
ISO2811-1:2011 Paintsandvarnishes-Determinationofdensity-Part1:Pyknometermethod
ISO2811-2:2011 Paintsandvarnishes-Determinationofdensity-Part2:Immersedbody(plummet)method
ISO2811-3:2011 Paintsandvarnishes-Determinationofdensity-Part3:Oscillationmethod
ISO2811-4:2011 Paintsandvarnishes-Determinationofdensity-Part4:Pressurecupmethod
ISO/DIS11997-2 Paintsandvarnishes-Determinationofresistancetocycliccorrosionconditions-Part2:Wet(saltfog)/dry/humidity/UVlight
ISO/DIS15091 Paintsandvarnishes-Determinationoftheelectricalconductivityandthespecificelectricalresistivity
I.S.ENISO1519:2011 PaintsandVarnishes-BendTest(cylindricalMandrel)
I.S.ENISO2811-1:2011 PaintsandVarnishes-DeterminationofDensity-Part1:PyknometerMethod
I.S.ENISO2811-2:2011 PaintsandVarnishes-DeterminationofDensity-Part2:ImmersedBody(plummet)Method
I.S.ENISO2811-3:2011 PaintsandVarnishes-DeterminationofDensity-Part3:OscillationMethod
I.S.ENISO2811-4:2011 PaintsandVarnishes-DeterminationofDensity-Part4:PressurecupMethod
11/30217717DCBSENISO15091
Paintsandvarnishes.Determinationoftheelectricalconductivityandthespecificelectricalresistivity
11/30233262DC BSEN1871.Roadmarkingmaterials.Paint,thermoplasticandcoldplasticmaterials.Specifications
BSENISO1519:2011 Paintsandvarnishes.Bendtest(cylindricalmandrel)
ISO26945:2011 Metallicandotherinorganiccoatings-Electrodepositedcoatingsoftin-cobaltalloy
I.S.ENISO12690:2010 MetallicandOtherInorganicCoatings-ThermalSprayCoordination-TasksandResponsibilities
I.S.ENISO14921:2010 ThermalSpraying-ProceduresfortheApplicationofThermallySprayedCoatingsforEngineeringComponents
I.S.ENISO26945:2011 MetallicandOtherInorganicCoatings-ElectrodepositedCoatingsofTin-cobaltAlloy
I.S.ENISO3613:2010 MetallicandOtherInorganicCoatings-ChromateConversionCoatingsonZinc,Cadmium,Aluminium-zincAlloysandZinc-aluminiumAlloys-TestMethods
11/30237910DCBSEN927-3
Paintsandvarnishes.Coatingmaterialsandcoatingsystemsforexteriorwood.Part3.Naturalweatheringtest
11/30241787DCBSEN62321-7-1
Determinationofcertainsubstancesinelectrotechnicalproducts.Part7-1.Determinationofthepresenceofhexavalentchromium(Cr(VI))incolourlessandcolouredcorrosion-protectedcoatingsonmetalsbythecolourimetricmethod
BSENISO12690:2010 Metallicandotherinorganiccoatings.Thermalspraycoordination.Tasksandresponsibilities
BSENISO14921:2010 Thermalspraying.Proceduresfortheapplicationofthermallysprayedcoatingsforengineeringcomponents
BSENISO26945:2011 Metallicandotherinorganiccoatings.Electrodepositedcoatingsoftin-cobaltalloy
BSENISO3613:2010 Metallicandotherinorganiccoatings.Chromateconversioncoatingsonzinc,cadmium,aluminium-zincalloysandzinc-aluminiumalloys.Testmethods
BSISO9717:2010 Metallicandotherinorganiccoatings.Phosphateconversioncoatingofmetals
Keywordsearchon'galvanize'or‘galvanized’or'galvanizing’–1ASAmendmentStandardPublicationsfound;
AS2841-2005/Amdt1-2011
Galvanizedsteelwirestrand
Keywordsearchon'corrosion'and'concrete'or‘concrete’and‘coatings’-0StandardPublicationsfound.
Keywordsearchon‘cathode’or'cathodic'-0corrosionrelatedStandardPublicationsfound
Keywordsearchon'anode'or‘anodes’or‘anodic’–3StandardPublicationsfound–NonefromAS/ANZS
ISO2106:2011 Anodizingofaluminiumanditsalloys-Determinationofmassperunitarea(surfacedensity)ofanodicoxidationcoatings-Gravimetricmethod
ISO8251:2011 Anodizingofaluminiumanditsalloys-Measurementofabrasionresistanceofanodicoxidationcoatings
ISO8994:2011 Anodizingofaluminiumanditsalloys-Ratingsystemfortheevaluationofpittingcorrosion-Gridmethod
KeywordSearchon'electrochemical'or‘electrolysis’or‘electroplated’-
DDCEN/TS14038-2:2011
Electrochemicalre-alkalizationandchlorideextractiontreatmentsforreinforcedconcrete.Chlorideextraction
KeywordSearchon'anodize'or‘anodized’-0Publicationsfound
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au20 21
A report on the impact of failure of infrastructure assets through corrosion as a result of current practices and skilling in the Australian mainland urban water and Naval defence sectors.
IntroductionNumerousstudieshavebeenundertakenacrosstheglobetodeterminetheeconomicimpactofcorrosionandit’sdegradationofinfrastructureandassets.Throughthesestudies,anevaluationofthecostofcorrosiontoafirstworldeconomyhasbeenestimatedas3%to5%ofGDP.InAustralasianterms,thisrepresentsanannualcosttotheAustralianeconomyofbetween$36Band$60Bperyear.FortheNewZealandeconomy,theestimateliesbetween$5.5Band$9.2Bannually.Whatisnotclearisthesizeandimpactoftherolemanagementandinappropriatetechnologyapplicationscontributetocorrosioncosts,andwhatopportunitiesareavailabletoreducesuchcosts.
ObjectiveTheobjectiveofthisProjectwastoexamine,identifyandestimatecorrosionfailurecostsattributabletoindustrypractices,industryskillingandregulatoryframeworks,andestimatepotentialcorrosionfailurecostreductionsbyimplementingavoidable/preventablestrategies.TheNavaldefenceandmainlandAustraliadomesticwaterindustrieswerechosenastestcases,basedontheavailabilityofindustryprofessionalsandaccesstodata.
ItisexpectedthatakeyoutcomewillbetoexpandandimprovetheACA’strainingprogrammeandgeneraleducationactivities.Byachievingtheseobjectives,theACAisfulfillingitsmandateandservingtheinterestsofitsMembershipthoughthisleadershipinitiativeoncorrosioninAustralasia.
BriefingPaperThefollowingbriefingpaperwasdrawnfromthecombinedreportontheAustralianmainlandurbanwaterandNavaldefencesectors.Thefullreportmaybeaccessedatwww.corrosion.com.au
There is a pressing need to address the present and growing cost of corrosion and improve the economic sustainability of Australia’s infrastructure
CorrosionpreventionisafundamentalcomponentofeconomicsustainabilityforAustralia’sinfrastructureassetsandeconomy.
Corrosioncreatesasignificanteconomicdragthatlimitsgrowthandprofitability.
ThecostofcorrosionincreasesasAustraliadevelopsandthepopulationgrows.
Internationallyitiswellrecognisedthatcorrosioncosts,onaverage,betweenthreeandfivepercentofGDPannually.
TheABS4613.0reportedthatduring2008-09Australia’stotalchainvolumeGDPwasAUS$1.194trillion.AroughextrapolationofthethreetofivepercentrulewouldputthecostofcorrosionforAustralia’seconomyatbetweenAUS$35billionandAUS$60billionduring2008-09.
Improvedcorrosionpreventioncandeliversubstantialgainsinproductivityandcostsavingstoindustry,governmentandthecommunity.
Thebenefitsofearlyinterventionaresignificantandcanbeachievedthroughimproveddesignandmaintenance,educationandtraining.
Asexamples,thefollowingsummarisesthefindingsofinvestigationsintothecauses,costandopportunitiestoaddresscorrosioninAustralia’swaterianddefenceiisectors.
The financial burden of corrosion is significant
IntheurbanWaterUtilitysector
Theannualcostofcorrosiontothe52urbanWaterUtilitiesservicingapproximately75%ofAustralia’spopulationisestimatedat$982M±30%:
AggregatedcorrosioncoststotheAustralianurbanWaterIndustry
Annualcost$m
Waterlossfrompipelineleakage(at$1.53perkL)
120.0
Waterlossfrompipelinefailures(at$1.53perkL)
4.3
Intangiblecostsassociatedwithwaterandsewerpipefailuresandreplacements
91.2
Waterpipelinecorrosionrepairs 118.7
Sewerpipelinecorrosionrepairs 39.0
Sewagetreatmentcostsduetoinfiltration 38.0
Capitalcostforwaterandsewerpipelinereplacements
298.7
Maintenance&repairwatertreatmentplants
52.0
Maintenanceandrepairofotherassets(tanks,pumpstationsetc)
42.4
Maintenance&repairsewagetreatmentplants
176.8
Totalcost 981.1
Whereextensiveinternalcorrosionofwatermainsoccurs,tasteandaestheticqualitiesarecompromised(knownasredwater)whichinvariablyleadstowaterqualitycomplaints.
IntheUnitedStatesNavy(USN)
USNiiicasestudiesofthreevesselgroupsshowedthatdeferringcorrosionmaintenanceandrepairsforonlyfouryearsresultedinanexponentialincreaseincosts–fromUS$4.8milliontoUS$36.5million.
IntheRoyalAustralianNavy(RAN)
RANcasestudiesexaminedbothagedamphibiousvesselsandrelativelynew,MilitaryOffTheShelf(MOTS),SurfaceForcevessels.
ThefindingsoftheRANcasestudiessuggestthatacostbenefitratioofbetween7:1and10:1isachievablethroughcorrosionpreventativemaintenanceforagedvesselsconstructedtoMerchantruleswithahighdamagetolerance.
ForMOTS,vesselsbuilttonavalruleswithlessdamagetolerancethecostbenefitrationwouldreasonablyexceed10:1.
ThecurrentfocusonmaintenanceinplaceofcorrosionpreventionintheRANresultsin:
significantlyhigherrepairandreplacementcosts,
unnecessarilyhighermaintenanceexpenditure,and
delaystoidentifyingcorrosionpreventionworks.
TheRANcasestudiesshowedthateffectiveandtimelycorrosionpreventionwouldsignificantlyreduceavoidablelabourcosts,comprisingupto89%ofrepaircosts.
The incidence and cost of repairs, and maintenance attributable to corrosion is unacceptably high
IntheurbanWaterUtilitysector
During2008-09,oneminorormajorpressurepipebreakorfailureoccurredevery20minutes.
Forthe139,000kmofexistingmainspipeline,approximately26,700minorandmajorbreaksorfailuresoccurredduring2008/2009.
Forevery100kmofpressuredwaterandsewerpipes,anaverageof19failuresoccurseachyear.
Thepercentageofbreaksattributedtocorrosionisapproximately79%.
Theaveragerepaircostforreticulationwatermainsofupto300mmnominaldiameter(DN)isaround$4550.
ThemostsignificantrepairstolargermainsgreaterthanDN300cancostupto$1.0million.
TheconsequencesoffailureinAustralia’s260watertreatmentplantsaregenerallynotasseriousaspipelinefailurebutcanbesignificantandrequireongoingrepairandmaintenance.
Hydrogensulphideby-products,ofteninconjunctionwithmarineatmosphericenvironments,causeahighnumberofcorrosionissuesinthe442wastewatertreatmentplantsthattreatrawsewage.Concretesewerpipesarealsosusceptibletointernalcorrosionfromhydrogensulphide.
Asignificantpercentageofmaintenanceandrepairinthelargenumberofwaterstoragetanks,reservoirsandassociatedpumpstationscanbeattributedtocorrosion.
IntheRAN
Thecasestudiesfoundthatthecostofroutineonboardmaintenance(ship’shusbandry)toremoveaccumulateddebris,orsetupandconductpreservationandrepairissignificantlycheaperthansteelworkrenewal.
Casestudiesfoundthatbyimplementingexpenditureof$0.19Mto$0.27Mincorrosionpreventionmaintenance,around$1.9millioninadditionalexpenditurecouldhavebeenavoided.
Inonecasestudy,inadditiontolostexpenditureofinstallingandremovingearlierrepairs,avoidablefinalrepaircostswere$377,000or650%higherthantheoriginalrepairbudgetof$58,000.
Current asset management practices leave significant opportunity for improvement
IntheurbanWaterUtilitysector,maintenanceandmanagementofwatersupplyandseweragepipelinenetworksinvolves:
RetrofittingofCathodicProtection(CP)systemstopipelineswhereeconomical–usuallyinvolvingcontinuouslyweldedsteel,cementmortarlinedpipes.
Conditionassessmentsofcriticalmains(withinthelimitationsofexistingtechnology).
ACA corrosion challenges project
ACA Report
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au20 21
A report on the impact of failure of infrastructure assets through corrosion as a result of current practices and skilling in the Australian mainland urban water and Naval defence sectors.
IntroductionNumerousstudieshavebeenundertakenacrosstheglobetodeterminetheeconomicimpactofcorrosionandit’sdegradationofinfrastructureandassets.Throughthesestudies,anevaluationofthecostofcorrosiontoafirstworldeconomyhasbeenestimatedas3%to5%ofGDP.InAustralasianterms,thisrepresentsanannualcosttotheAustralianeconomyofbetween$36Band$60Bperyear.FortheNewZealandeconomy,theestimateliesbetween$5.5Band$9.2Bannually.Whatisnotclearisthesizeandimpactoftherolemanagementandinappropriatetechnologyapplicationscontributetocorrosioncosts,andwhatopportunitiesareavailabletoreducesuchcosts.
ObjectiveTheobjectiveofthisProjectwastoexamine,identifyandestimatecorrosionfailurecostsattributabletoindustrypractices,industryskillingandregulatoryframeworks,andestimatepotentialcorrosionfailurecostreductionsbyimplementingavoidable/preventablestrategies.TheNavaldefenceandmainlandAustraliadomesticwaterindustrieswerechosenastestcases,basedontheavailabilityofindustryprofessionalsandaccesstodata.
ItisexpectedthatakeyoutcomewillbetoexpandandimprovetheACA’strainingprogrammeandgeneraleducationactivities.Byachievingtheseobjectives,theACAisfulfillingitsmandateandservingtheinterestsofitsMembershipthoughthisleadershipinitiativeoncorrosioninAustralasia.
BriefingPaperThefollowingbriefingpaperwasdrawnfromthecombinedreportontheAustralianmainlandurbanwaterandNavaldefencesectors.Thefullreportmaybeaccessedatwww.corrosion.com.au
There is a pressing need to address the present and growing cost of corrosion and improve the economic sustainability of Australia’s infrastructure
CorrosionpreventionisafundamentalcomponentofeconomicsustainabilityforAustralia’sinfrastructureassetsandeconomy.
Corrosioncreatesasignificanteconomicdragthatlimitsgrowthandprofitability.
ThecostofcorrosionincreasesasAustraliadevelopsandthepopulationgrows.
Internationallyitiswellrecognisedthatcorrosioncosts,onaverage,betweenthreeandfivepercentofGDPannually.
TheABS4613.0reportedthatduring2008-09Australia’stotalchainvolumeGDPwasAUS$1.194trillion.AroughextrapolationofthethreetofivepercentrulewouldputthecostofcorrosionforAustralia’seconomyatbetweenAUS$35billionandAUS$60billionduring2008-09.
Improvedcorrosionpreventioncandeliversubstantialgainsinproductivityandcostsavingstoindustry,governmentandthecommunity.
Thebenefitsofearlyinterventionaresignificantandcanbeachievedthroughimproveddesignandmaintenance,educationandtraining.
Asexamples,thefollowingsummarisesthefindingsofinvestigationsintothecauses,costandopportunitiestoaddresscorrosioninAustralia’swaterianddefenceiisectors.
The financial burden of corrosion is significant
IntheurbanWaterUtilitysector
Theannualcostofcorrosiontothe52urbanWaterUtilitiesservicingapproximately75%ofAustralia’spopulationisestimatedat$982M±30%:
AggregatedcorrosioncoststotheAustralianurbanWaterIndustry
Annualcost$m
Waterlossfrompipelineleakage(at$1.53perkL)
120.0
Waterlossfrompipelinefailures(at$1.53perkL)
4.3
Intangiblecostsassociatedwithwaterandsewerpipefailuresandreplacements
91.2
Waterpipelinecorrosionrepairs 118.7
Sewerpipelinecorrosionrepairs 39.0
Sewagetreatmentcostsduetoinfiltration 38.0
Capitalcostforwaterandsewerpipelinereplacements
298.7
Maintenance&repairwatertreatmentplants
52.0
Maintenanceandrepairofotherassets(tanks,pumpstationsetc)
42.4
Maintenance&repairsewagetreatmentplants
176.8
Totalcost 981.1
Whereextensiveinternalcorrosionofwatermainsoccurs,tasteandaestheticqualitiesarecompromised(knownasredwater)whichinvariablyleadstowaterqualitycomplaints.
IntheUnitedStatesNavy(USN)
USNiiicasestudiesofthreevesselgroupsshowedthatdeferringcorrosionmaintenanceandrepairsforonlyfouryearsresultedinanexponentialincreaseincosts–fromUS$4.8milliontoUS$36.5million.
IntheRoyalAustralianNavy(RAN)
RANcasestudiesexaminedbothagedamphibiousvesselsandrelativelynew,MilitaryOffTheShelf(MOTS),SurfaceForcevessels.
ThefindingsoftheRANcasestudiessuggestthatacostbenefitratioofbetween7:1and10:1isachievablethroughcorrosionpreventativemaintenanceforagedvesselsconstructedtoMerchantruleswithahighdamagetolerance.
ForMOTS,vesselsbuilttonavalruleswithlessdamagetolerancethecostbenefitrationwouldreasonablyexceed10:1.
ThecurrentfocusonmaintenanceinplaceofcorrosionpreventionintheRANresultsin:
significantlyhigherrepairandreplacementcosts,
unnecessarilyhighermaintenanceexpenditure,and
delaystoidentifyingcorrosionpreventionworks.
TheRANcasestudiesshowedthateffectiveandtimelycorrosionpreventionwouldsignificantlyreduceavoidablelabourcosts,comprisingupto89%ofrepaircosts.
The incidence and cost of repairs, and maintenance attributable to corrosion is unacceptably high
IntheurbanWaterUtilitysector
During2008-09,oneminorormajorpressurepipebreakorfailureoccurredevery20minutes.
Forthe139,000kmofexistingmainspipeline,approximately26,700minorandmajorbreaksorfailuresoccurredduring2008/2009.
Forevery100kmofpressuredwaterandsewerpipes,anaverageof19failuresoccurseachyear.
Thepercentageofbreaksattributedtocorrosionisapproximately79%.
Theaveragerepaircostforreticulationwatermainsofupto300mmnominaldiameter(DN)isaround$4550.
ThemostsignificantrepairstolargermainsgreaterthanDN300cancostupto$1.0million.
TheconsequencesoffailureinAustralia’s260watertreatmentplantsaregenerallynotasseriousaspipelinefailurebutcanbesignificantandrequireongoingrepairandmaintenance.
Hydrogensulphideby-products,ofteninconjunctionwithmarineatmosphericenvironments,causeahighnumberofcorrosionissuesinthe442wastewatertreatmentplantsthattreatrawsewage.Concretesewerpipesarealsosusceptibletointernalcorrosionfromhydrogensulphide.
Asignificantpercentageofmaintenanceandrepairinthelargenumberofwaterstoragetanks,reservoirsandassociatedpumpstationscanbeattributedtocorrosion.
IntheRAN
Thecasestudiesfoundthatthecostofroutineonboardmaintenance(ship’shusbandry)toremoveaccumulateddebris,orsetupandconductpreservationandrepairissignificantlycheaperthansteelworkrenewal.
Casestudiesfoundthatbyimplementingexpenditureof$0.19Mto$0.27Mincorrosionpreventionmaintenance,around$1.9millioninadditionalexpenditurecouldhavebeenavoided.
Inonecasestudy,inadditiontolostexpenditureofinstallingandremovingearlierrepairs,avoidablefinalrepaircostswere$377,000or650%higherthantheoriginalrepairbudgetof$58,000.
Current asset management practices leave significant opportunity for improvement
IntheurbanWaterUtilitysector,maintenanceandmanagementofwatersupplyandseweragepipelinenetworksinvolves:
RetrofittingofCathodicProtection(CP)systemstopipelineswhereeconomical–usuallyinvolvingcontinuouslyweldedsteel,cementmortarlinedpipes.
Conditionassessmentsofcriticalmains(withinthelimitationsofexistingtechnology).
ACA corrosion challenges project
ACA Report
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au22 23
Applicationofstructuralorsemi-structuralliningstoextendthelifeofcriticalpressurewatermains.
Wherestraycurrentcorrosionfromtractionsystemsislikely,Utilitiescarryoutactiveelectrolysistestingandcorrosionmitigation.
CCTVinspectionprogramsofnon-pressuresewerpipesareactivelyundertakentodeterminethepipeconditionandtoenableinternalrepairstobecarriedoutbeforecorrosioncancauseamajorcollapse.
Leakdetectionprogrammes.
However
WhilethereisconsiderableapplicationofCP,itislikelythatagreateruseofthistechnologycouldbemadetomitigateexternalcorrosionofsteelmains.
TheuseofCPonothermetallicpipesuchascastironorductileiron(sleevedorun-sleeved),isnotaviableapplicationofthistechnology.
Greycastironandasbestoscementpipesmakeupthelargestproportionofreticulationpipes.Manyofthesearereachingatimewherereplacementwillberequired.
Therearealsonospecificrequirementstotreatdomesticdrinkingwaterpipeswithcorrosioninhibitors.
IntheRAN,considerableeffortandexpenditureisundertakenonship’smaintenance:
MaintenanceforRANvesselsissubjecttotworegimes:conductedonboardbyRANpersonnel;andmaintenancebyRANpersonnelandcontractorsduringscheduledmaintenanceperiods.
MaintainingNavalcertification(ClassificationSocietycertificationor‘Class’)requiresastructuredsurveyregime,incorporatingasystemofimposed“ConditionsofClass”,whensurveyeditemsarefoundtobebelowtheminimum‘Condition’requirement,andidentifiedforcorrectiveactionwithinanagreedtimeframe.
TheConditionitselfresultsinadditionalexpensetotheVesselOwnerfortheClassSociety’scostsassociatedwithIndependentValidationandVerificationtoensuretheOwner’srepairactionscomplywithapplicablestandards.
However
ClassConditionsarealwayscorrectiveratherthanpreventative,andleadtomissedopportunitiesinpreventativemaintenancethatcouldsignificantlyreducecostsandrepairs.
Thecasestudiesshowedthatadditionalcostsandthenecessityforcorrectivemaintenancecausedbycorrosioncouldbeavoidedby:
conductingcorrosionpreventionmaintenanceatanappropriatetime,
replacingandrepairingareasofcorrosionwhenidentified,
buildingtodesignspecifications,and
employingappropriateship’shusbandryregimes.
Data collection fails to adequately recognise and account for the cost of corrosion, nor does it inform optimum return-on-investment decisions.
IntheurbanWaterUtilitysector
DatacollectionisanimportantandrecognisedaspectofallwaterutilityAssetManagementpractices.
However
Mostcorrosionexpertiserestswithspecialistgroupsinsomewaterutilities.ProgramstodisseminatethisknowledgeacrosstheUtilitieswouldbeofbenefit.
CollectionofreliabledataasaimedforintheNationalWaterMainsFailureDataBase(7.1.3)1isreliantontheinterpretationofpipelinefailuresbyoperationsstaffthatdonothavespecifictrainingincorrosionmanagement.
IntheRAN
Thecostofoperatingavesselonadailybasisisknown,anddataiscollectedthroughtheClassSocietysurveyregimeandRANinspectionprocesses.
However
Thereisnodetailedbreakdownofrepaircosts.Limitationsofdatarecordsmakeitdifficulttoisolateandanalysecorrosioncostsamongstotherrepairactivities.
Datacollectionoccursintheabsenceofamethodologytopredicttime,effortandresourcesrequiredforcorrectivemaintenance,impactingupontheabilitytoascertainvalueformoney.
Thecostofoperatingavesselisnotarticulatedinsuchawaythatlostdaysofoperationismeasuredindollartermsagainstthecostofcorrosionpreventionorcorrectivemaintenance.
Codes and regulations do not adequately recognise or address the principle of corrosion prevention
IntheurbanWaterUtilitysector
TheWaterSupplyCodeofAustraliaandSewerageCodeofAustraliacoverthedesignandconstructionofwaterandseweragenetworkinfrastructure,andcoverlimitedaspectsofmaterialsandcorrosionprevention.
TheWaterServicesAssociationofAustraliahasrecentlyimplementedaDesignAssuranceScheme,focusedonensuringcompetencyusingtheSewerageCodeofAustraliaandtheWaterSupplyCodeofAustralia.
Therearenospecificregulationsorlegislationthatcouldbedirectlylinkedtofactorsthatmayexacerbatecorrosionorhinderanymeasures,whichmaybeimplementedtomitigatecorrosion.
However
WhiletheAustralianCodescoveraspectsofmaterialsandcorrosion,thefocusisoncivildesignandconstruction;althoughspecificationsandstandardsforindividualitemsoftenaddressmaterialdurabilityissuesincludingcorrosion.
Someregulationcanexacerbatecorrosion.Forexample,inresponsetoodourcomplaints,localauthoritiesmaycloseoffsewerventpipesorenclosetreatmentfacilitiestopreventtheescapeofhydrogensulphidegases;gaseswhichaccelerateconcretecorrosionandcausesignificantdamagetoinfrastructure.
IntheRAN
AustralianDefenceNavalAssetsaresubjecttoanextensiveregulatoryregime,asarticulatedintheNavalTechnicalRegulationsManual(NTRM)iv.
CompliancewithNTRMisaddressedbyanextensivecertificationregimewithacombinationofIndependentThirdPartyorNavalcertification.
However
Existingengineeringpolicycouldbeadaptedtoprovidegreaterassuranceoftechnicalintegrityinconjunctionwithsoundeconomicjudgement.
ApplicationofNavalTechnicalRegulatoryrequirementsappearsinconsistentwithitsintent.
StaffwithinNavalsustainmentorganisationsdonotunderstandthecostbenefitofpreventativemaintenanceasthisisnotrequiredtomaintainClassificationSocietycertificationbutisattheVesselOwner’sdiscretion.
Classconditionandrepaircertificationalwaysdetailscorrectiveactionratherthanpreventativemeasuressothecauseofthecorrosionisnotbeingidentifiedoraddressedearly.
Processestoengagecontractedlabourresultina‘reportandforget’approachwithlimitedornofollowthroughorreviewonceaworkrequesthasbeensentfromtheship.
Alackofconsiderationforcontingentrequirementsinvariablyresultsincostandscheduleblowoutsandsafetyimpactssuchaslowrisksafetyissueselevatingtoahigherrisk.
Education and training programs do not place sufficient focus on corrosion prevention
IntheurbanWaterUtilitysector
Extensivetrainingisavailableforwaterandwastewateroperations(GovernmentSkillsAustralia,NWP07WaterTrainingPackage)whichincludealargenumberofcompetencyrequirementsbutonlyalimitedfocusoncorrosiontheory.
RequirementsfordesignersanddesignauditorstoshowcompetencyinusingtheWaterSupplyandSewerageCodesofAustraliaarebeingintroduced.
However
Moredetailedinformation/trainingandspecificaccreditationoncorrosionpreventionisrequiredaspartof,orasaseparaterequirementto,theWaterServicesAssociationofAustralia’sDesignAssuranceScheme.
Specificcorrosioncoursesaimedatthewaterindustryandcompetencytraininginvolvingaunitspecificallyrelatingtocorrosionarerequired.
CorrosiontrainingcoursesthataresupportiveandcomplementarytotheinitiativesoftheNationalWaterMainsFailureDataBasewouldaidinmoreeffectivedatacollection.
IntheRAN
ConsiderableresourcesareappliedtotheeducationofNavalEngineeringpersonnel,MarineEngineeringOfficers(ME)andMarineTechnician(MT)Sailors.
WithintheMarineTechnicianbranchtherearecoursemodulesonwelding,fabrication,ship’sstabilityandconstruction.
Bosun’sMate(BM)CorrosionControlincludesacourseoncorrosioncontrol,andwillshortlybetheonlyoneofitskind.
ACACorrosionChallengesProject
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au22 23
Applicationofstructuralorsemi-structuralliningstoextendthelifeofcriticalpressurewatermains.
Wherestraycurrentcorrosionfromtractionsystemsislikely,Utilitiescarryoutactiveelectrolysistestingandcorrosionmitigation.
CCTVinspectionprogramsofnon-pressuresewerpipesareactivelyundertakentodeterminethepipeconditionandtoenableinternalrepairstobecarriedoutbeforecorrosioncancauseamajorcollapse.
Leakdetectionprogrammes.
However
WhilethereisconsiderableapplicationofCP,itislikelythatagreateruseofthistechnologycouldbemadetomitigateexternalcorrosionofsteelmains.
TheuseofCPonothermetallicpipesuchascastironorductileiron(sleevedorun-sleeved),isnotaviableapplicationofthistechnology.
Greycastironandasbestoscementpipesmakeupthelargestproportionofreticulationpipes.Manyofthesearereachingatimewherereplacementwillberequired.
Therearealsonospecificrequirementstotreatdomesticdrinkingwaterpipeswithcorrosioninhibitors.
IntheRAN,considerableeffortandexpenditureisundertakenonship’smaintenance:
MaintenanceforRANvesselsissubjecttotworegimes:conductedonboardbyRANpersonnel;andmaintenancebyRANpersonnelandcontractorsduringscheduledmaintenanceperiods.
MaintainingNavalcertification(ClassificationSocietycertificationor‘Class’)requiresastructuredsurveyregime,incorporatingasystemofimposed“ConditionsofClass”,whensurveyeditemsarefoundtobebelowtheminimum‘Condition’requirement,andidentifiedforcorrectiveactionwithinanagreedtimeframe.
TheConditionitselfresultsinadditionalexpensetotheVesselOwnerfortheClassSociety’scostsassociatedwithIndependentValidationandVerificationtoensuretheOwner’srepairactionscomplywithapplicablestandards.
However
ClassConditionsarealwayscorrectiveratherthanpreventative,andleadtomissedopportunitiesinpreventativemaintenancethatcouldsignificantlyreducecostsandrepairs.
Thecasestudiesshowedthatadditionalcostsandthenecessityforcorrectivemaintenancecausedbycorrosioncouldbeavoidedby:
conductingcorrosionpreventionmaintenanceatanappropriatetime,
replacingandrepairingareasofcorrosionwhenidentified,
buildingtodesignspecifications,and
employingappropriateship’shusbandryregimes.
Data collection fails to adequately recognise and account for the cost of corrosion, nor does it inform optimum return-on-investment decisions.
IntheurbanWaterUtilitysector
DatacollectionisanimportantandrecognisedaspectofallwaterutilityAssetManagementpractices.
However
Mostcorrosionexpertiserestswithspecialistgroupsinsomewaterutilities.ProgramstodisseminatethisknowledgeacrosstheUtilitieswouldbeofbenefit.
CollectionofreliabledataasaimedforintheNationalWaterMainsFailureDataBase(7.1.3)1isreliantontheinterpretationofpipelinefailuresbyoperationsstaffthatdonothavespecifictrainingincorrosionmanagement.
IntheRAN
Thecostofoperatingavesselonadailybasisisknown,anddataiscollectedthroughtheClassSocietysurveyregimeandRANinspectionprocesses.
However
Thereisnodetailedbreakdownofrepaircosts.Limitationsofdatarecordsmakeitdifficulttoisolateandanalysecorrosioncostsamongstotherrepairactivities.
Datacollectionoccursintheabsenceofamethodologytopredicttime,effortandresourcesrequiredforcorrectivemaintenance,impactingupontheabilitytoascertainvalueformoney.
Thecostofoperatingavesselisnotarticulatedinsuchawaythatlostdaysofoperationismeasuredindollartermsagainstthecostofcorrosionpreventionorcorrectivemaintenance.
Codes and regulations do not adequately recognise or address the principle of corrosion prevention
IntheurbanWaterUtilitysector
TheWaterSupplyCodeofAustraliaandSewerageCodeofAustraliacoverthedesignandconstructionofwaterandseweragenetworkinfrastructure,andcoverlimitedaspectsofmaterialsandcorrosionprevention.
TheWaterServicesAssociationofAustraliahasrecentlyimplementedaDesignAssuranceScheme,focusedonensuringcompetencyusingtheSewerageCodeofAustraliaandtheWaterSupplyCodeofAustralia.
Therearenospecificregulationsorlegislationthatcouldbedirectlylinkedtofactorsthatmayexacerbatecorrosionorhinderanymeasures,whichmaybeimplementedtomitigatecorrosion.
However
WhiletheAustralianCodescoveraspectsofmaterialsandcorrosion,thefocusisoncivildesignandconstruction;althoughspecificationsandstandardsforindividualitemsoftenaddressmaterialdurabilityissuesincludingcorrosion.
Someregulationcanexacerbatecorrosion.Forexample,inresponsetoodourcomplaints,localauthoritiesmaycloseoffsewerventpipesorenclosetreatmentfacilitiestopreventtheescapeofhydrogensulphidegases;gaseswhichaccelerateconcretecorrosionandcausesignificantdamagetoinfrastructure.
IntheRAN
AustralianDefenceNavalAssetsaresubjecttoanextensiveregulatoryregime,asarticulatedintheNavalTechnicalRegulationsManual(NTRM)iv.
CompliancewithNTRMisaddressedbyanextensivecertificationregimewithacombinationofIndependentThirdPartyorNavalcertification.
However
Existingengineeringpolicycouldbeadaptedtoprovidegreaterassuranceoftechnicalintegrityinconjunctionwithsoundeconomicjudgement.
ApplicationofNavalTechnicalRegulatoryrequirementsappearsinconsistentwithitsintent.
StaffwithinNavalsustainmentorganisationsdonotunderstandthecostbenefitofpreventativemaintenanceasthisisnotrequiredtomaintainClassificationSocietycertificationbutisattheVesselOwner’sdiscretion.
Classconditionandrepaircertificationalwaysdetailscorrectiveactionratherthanpreventativemeasuressothecauseofthecorrosionisnotbeingidentifiedoraddressedearly.
Processestoengagecontractedlabourresultina‘reportandforget’approachwithlimitedornofollowthroughorreviewonceaworkrequesthasbeensentfromtheship.
Alackofconsiderationforcontingentrequirementsinvariablyresultsincostandscheduleblowoutsandsafetyimpactssuchaslowrisksafetyissueselevatingtoahigherrisk.
Education and training programs do not place sufficient focus on corrosion prevention
IntheurbanWaterUtilitysector
Extensivetrainingisavailableforwaterandwastewateroperations(GovernmentSkillsAustralia,NWP07WaterTrainingPackage)whichincludealargenumberofcompetencyrequirementsbutonlyalimitedfocusoncorrosiontheory.
RequirementsfordesignersanddesignauditorstoshowcompetencyinusingtheWaterSupplyandSewerageCodesofAustraliaarebeingintroduced.
However
Moredetailedinformation/trainingandspecificaccreditationoncorrosionpreventionisrequiredaspartof,orasaseparaterequirementto,theWaterServicesAssociationofAustralia’sDesignAssuranceScheme.
Specificcorrosioncoursesaimedatthewaterindustryandcompetencytraininginvolvingaunitspecificallyrelatingtocorrosionarerequired.
CorrosiontrainingcoursesthataresupportiveandcomplementarytotheinitiativesoftheNationalWaterMainsFailureDataBasewouldaidinmoreeffectivedatacollection.
IntheRAN
ConsiderableresourcesareappliedtotheeducationofNavalEngineeringpersonnel,MarineEngineeringOfficers(ME)andMarineTechnician(MT)Sailors.
WithintheMarineTechnicianbranchtherearecoursemodulesonwelding,fabrication,ship’sstabilityandconstruction.
Bosun’sMate(BM)CorrosionControlincludesacourseoncorrosioncontrol,andwillshortlybetheonlyoneofitskind.
ACACorrosionChallengesProject
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au24 25
However
ThereremainsdifficultyinunderstandingandimplementingClassrequirements;inparticularforVesselOwnersdefiningandintegratingtheirvesselmaintenanceobligationswithClassrequirements.
ThefocusonOperatorTechniciantrainingratherthanmaintenanceandpreventionhascreatedagenerationofSeniorSailorswholacktheknowledgeandexperiencewhichunderpinsthemaintenanceofNavalAssets.
Asmentorsandleaders,SeniorSailorsdonothavetheexperienceandinformationtopassontoJuniorSailorssotheirskillscanbepracticedandimproved.
Thereisanunnecessaryrelianceonresourcesexternaltovesselstoperformtasksthatcouldbeconductedbynavalpersonnelwithresultantlong-termsavings.
Inpracticalterms,theMTbranchisresponsibleformanagingtheconditionofthevesselwhilstthoseintheBMbrancharechargedwithship’shusbandry.Themethodsoftrainingwithineachbranchensurethatneitherbranchrelatestheimportanceofthesecomplementaryroles.
Researchindicatesthatexistingtrainingmodulesforship’shusbandryhavefallenintodisuseandrequireresurrectionandreview.
WithintheMTbranchtherearenomodulesonprotectivecoatingsorcorrosion.
TrainingcoursesforjuniorsailorsinvolvingSprayPaintingandShipsPreservationareinactive,whilstBasicCorrosionControlisabouttobecomeinactive.
Recommendations:
TocapitaliseonthecriticalprinciplesofpreventativemaintenanceteamedwithearlyinterventionboththeUrbanWaterandNavalDefencesectorsshould:
Undertakeastrategicshiftinpolicytorecognisethesignificantcorrosioncostavoidancethroughearlypreventionandpreservation,
Educateseniorstaffaboutcorrosionpreventioninassetmanagement,emphasisingthecostbenefitandencouragingmorestrategicin-depthdataanalysis,
Developtrainingmodulestoincludepreventionandearlyinterventionprinciples,therebystrengtheningcorecompetenciesofjuniorstaff,
Employdatacollectionmethodologythatrecognisesandaccountsfortheincidenceandcostofcorrosionandencouragesanticipatoryratherthanreactionarydecisions,
Developstrategyarounddatacollectionthatconsidersaspectsofreturnoninvestmentandtheanalysisrequiredtoenableproperevaluation,
Collectdatausingstructuresthatenablereportingontheimpactofcorrosionuponfinancial,socialandtheserviceofinfrastructureandassets,and
Analyseandimprovecodesandregulationstorecogniseandincorporatetheprinciplesofcorrosionmitigationandrelevantdecision-makingprocesses.
Thisreportwassubjecttoexpertpeerreviewby:
DrNickBirbilisMonashUniversityDavidCoxWSAADrBruceHintonMonashUniversityDrPeterMartDSTOPaulVinceSAWater
iGregMoore-Principal,MooreMaterialsTechnologyPtyLtd,Corrosion Challenges – Urban Water Industry,2010,isbasedondatacollectedbytheWaterServicesAssociationofAustralia(WSAA)NationalPerformanceReport2008/09.TheNPRrecordsandmeasuresupto117indicatorsfrom73waterutilitiesacrossAustralia,servingapproximately75%ofAustralia’spopulation.Thiswassupplementedbyspecificinformationobtainedfromfourmajorwaterutilities.
iiGraemeEmerton-DefenceMaterielOrganisation,Sydney,Corrosion Challenges – Naval Defence,2010,isbasedonanumberofcasestudies.ThereportaimedtoassessthevarioussystemsandstructuresthatexistwithintheAustralianDefenceNavalsectorandevaluatehowtheyinfluencethemanagementofcorrosionandusedselectedcasestudiestoassessthepotentialformoreeffectiveexpenditurebypreventionofdeterioration.
iiiTheCostofCorrosionforUSNavyShips–FromMetricstoAction,MegarustConferenceJune2010
ivABR6492NavalTechnicalRegulationsManual.
1 The National Water Mains database is based on that used in the United Kingdom but tailored to address the Australian context. This data base allows the upload, collation and anonymous comparison of water pipe data between water utilities.
ACACorrosionChallengesProject
Inwhatyearwayyourcompanyestablished?
AlphaBlast was established in 2002, however from 1st December 2010 we have taken on our parent company’s name of ORONTIDE.
WhatdifferencesisthereinthecompanysinceyournamechangeinDecember2010?
The key people and focus of the business remain the same. The only change is that we can now offer additional complementary services with the addition of our Engineering Services division.
Howmanydoyoucurrentlyemploy?
Across the two divisions –Industrial Services and Engineering Services – ORONTIDE employs approximately 250 people Australia wide.
DoyouoperatefromanumberoflocationsinyourhomestateorinotherstatesofAustralia?
Our head office is in Henderson, Western Australia where we also have a state of the art blasting facility and engineering workshop. We also have facilities in Port Hedland, Bunbury, Kalgoorlie and Sydney.
Whatisyourcorebusiness?(egblastingandpainting,rubberlining,waterjetting,laminating,insulation,flooring,etc).
Our core business is Asset Integrity Management. We undertake surface preparation using both UHPWJ and abrasive blasting (wet and dry), together with the application of High Performance Protective Coatings such as Phenolic, Novalac and Intumescent epoxies (incl. conventional coating systems). Our Engineering Division in turn adds to that with Design, Machining, Fabrication and Fitting.
Whatmarketsdoyoucoverwithyouproductsorservices?eg:oil&gas,marine,chemicalprocess,generalfabrication,tanklining,offshore,etc.
We service the oil & gas sector, mining, defence and commercial marine markets.
Isthebusinessyardbased,sitebasedorboth?
We undertake work both in our yard as well as on-site, both on and offshore.
Whatisyourmonthlycapacityortonnagethatyoucanblastandprime?
Approx 500 tonne (yard based).
Doyouofferanyspecialtyservicesoutsideyourcorebusiness?(egprimaryyardbasedbutwilldositetouchup,etc).
We are able to provide NACE Inspection Services and corrosion/coating condition assessments. We have always specialised in Cold Cutting and Hydro-demolition by means of UHP Water Jetting. Our coating capability extends to the application TSA/TSZ and thermoplastic coatings like EnviroPeel.
Whatisthemostsatisfyingprojectthatyouhavecompletedinthepasttwoyearsandwhy?
Cold cutting project. Offshore on the Ngujima Yin M60 which proved to be very technical as well as rewarding.
WhatpositiveadvicecanyoupassontotheCoatingsGroupfromthatsatisfyingprojectorjob?
Use your knowledge and network innovatively to create enduring and economical solutions for your clients needs.
Doyouhaveaninternaltrainingschemeordoyououtsourcetrainingforyouremployees?
Selected staff are undertaking Certificate III in Surface Preparation and Coatings Application. All of our Supervisors, Coordinators and Inspectors are NACE Certified (Level 1 to 3). Ongoing training for all operations staff to keep abreast of industry requirements and ensure continuous professional development. ORONTIDE Invests heavily in people.
ContactDetails:
54SparksRoadHendersonWesternAustralia,6166
E:[email protected]:61892362555F:61894102056
www.orontide.com.au
ORONTIDE Ltd.
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au24 25
However
ThereremainsdifficultyinunderstandingandimplementingClassrequirements;inparticularforVesselOwnersdefiningandintegratingtheirvesselmaintenanceobligationswithClassrequirements.
ThefocusonOperatorTechniciantrainingratherthanmaintenanceandpreventionhascreatedagenerationofSeniorSailorswholacktheknowledgeandexperiencewhichunderpinsthemaintenanceofNavalAssets.
Asmentorsandleaders,SeniorSailorsdonothavetheexperienceandinformationtopassontoJuniorSailorssotheirskillscanbepracticedandimproved.
Thereisanunnecessaryrelianceonresourcesexternaltovesselstoperformtasksthatcouldbeconductedbynavalpersonnelwithresultantlong-termsavings.
Inpracticalterms,theMTbranchisresponsibleformanagingtheconditionofthevesselwhilstthoseintheBMbrancharechargedwithship’shusbandry.Themethodsoftrainingwithineachbranchensurethatneitherbranchrelatestheimportanceofthesecomplementaryroles.
Researchindicatesthatexistingtrainingmodulesforship’shusbandryhavefallenintodisuseandrequireresurrectionandreview.
WithintheMTbranchtherearenomodulesonprotectivecoatingsorcorrosion.
TrainingcoursesforjuniorsailorsinvolvingSprayPaintingandShipsPreservationareinactive,whilstBasicCorrosionControlisabouttobecomeinactive.
Recommendations:
TocapitaliseonthecriticalprinciplesofpreventativemaintenanceteamedwithearlyinterventionboththeUrbanWaterandNavalDefencesectorsshould:
Undertakeastrategicshiftinpolicytorecognisethesignificantcorrosioncostavoidancethroughearlypreventionandpreservation,
Educateseniorstaffaboutcorrosionpreventioninassetmanagement,emphasisingthecostbenefitandencouragingmorestrategicin-depthdataanalysis,
Developtrainingmodulestoincludepreventionandearlyinterventionprinciples,therebystrengtheningcorecompetenciesofjuniorstaff,
Employdatacollectionmethodologythatrecognisesandaccountsfortheincidenceandcostofcorrosionandencouragesanticipatoryratherthanreactionarydecisions,
Developstrategyarounddatacollectionthatconsidersaspectsofreturnoninvestmentandtheanalysisrequiredtoenableproperevaluation,
Collectdatausingstructuresthatenablereportingontheimpactofcorrosionuponfinancial,socialandtheserviceofinfrastructureandassets,and
Analyseandimprovecodesandregulationstorecogniseandincorporatetheprinciplesofcorrosionmitigationandrelevantdecision-makingprocesses.
Thisreportwassubjecttoexpertpeerreviewby:
DrNickBirbilisMonashUniversityDavidCoxWSAADrBruceHintonMonashUniversityDrPeterMartDSTOPaulVinceSAWater
iGregMoore-Principal,MooreMaterialsTechnologyPtyLtd,Corrosion Challenges – Urban Water Industry,2010,isbasedondatacollectedbytheWaterServicesAssociationofAustralia(WSAA)NationalPerformanceReport2008/09.TheNPRrecordsandmeasuresupto117indicatorsfrom73waterutilitiesacrossAustralia,servingapproximately75%ofAustralia’spopulation.Thiswassupplementedbyspecificinformationobtainedfromfourmajorwaterutilities.
iiGraemeEmerton-DefenceMaterielOrganisation,Sydney,Corrosion Challenges – Naval Defence,2010,isbasedonanumberofcasestudies.ThereportaimedtoassessthevarioussystemsandstructuresthatexistwithintheAustralianDefenceNavalsectorandevaluatehowtheyinfluencethemanagementofcorrosionandusedselectedcasestudiestoassessthepotentialformoreeffectiveexpenditurebypreventionofdeterioration.
iiiTheCostofCorrosionforUSNavyShips–FromMetricstoAction,MegarustConferenceJune2010
ivABR6492NavalTechnicalRegulationsManual.
1 The National Water Mains database is based on that used in the United Kingdom but tailored to address the Australian context. This data base allows the upload, collation and anonymous comparison of water pipe data between water utilities.
ACACorrosionChallengesProject
Inwhatyearwayyourcompanyestablished?
AlphaBlast was established in 2002, however from 1st December 2010 we have taken on our parent company’s name of ORONTIDE.
WhatdifferencesisthereinthecompanysinceyournamechangeinDecember2010?
The key people and focus of the business remain the same. The only change is that we can now offer additional complementary services with the addition of our Engineering Services division.
Howmanydoyoucurrentlyemploy?
Across the two divisions –Industrial Services and Engineering Services – ORONTIDE employs approximately 250 people Australia wide.
DoyouoperatefromanumberoflocationsinyourhomestateorinotherstatesofAustralia?
Our head office is in Henderson, Western Australia where we also have a state of the art blasting facility and engineering workshop. We also have facilities in Port Hedland, Bunbury, Kalgoorlie and Sydney.
Whatisyourcorebusiness?(egblastingandpainting,rubberlining,waterjetting,laminating,insulation,flooring,etc).
Our core business is Asset Integrity Management. We undertake surface preparation using both UHPWJ and abrasive blasting (wet and dry), together with the application of High Performance Protective Coatings such as Phenolic, Novalac and Intumescent epoxies (incl. conventional coating systems). Our Engineering Division in turn adds to that with Design, Machining, Fabrication and Fitting.
Whatmarketsdoyoucoverwithyouproductsorservices?eg:oil&gas,marine,chemicalprocess,generalfabrication,tanklining,offshore,etc.
We service the oil & gas sector, mining, defence and commercial marine markets.
Isthebusinessyardbased,sitebasedorboth?
We undertake work both in our yard as well as on-site, both on and offshore.
Whatisyourmonthlycapacityortonnagethatyoucanblastandprime?
Approx 500 tonne (yard based).
Doyouofferanyspecialtyservicesoutsideyourcorebusiness?(egprimaryyardbasedbutwilldositetouchup,etc).
We are able to provide NACE Inspection Services and corrosion/coating condition assessments. We have always specialised in Cold Cutting and Hydro-demolition by means of UHP Water Jetting. Our coating capability extends to the application TSA/TSZ and thermoplastic coatings like EnviroPeel.
Whatisthemostsatisfyingprojectthatyouhavecompletedinthepasttwoyearsandwhy?
Cold cutting project. Offshore on the Ngujima Yin M60 which proved to be very technical as well as rewarding.
WhatpositiveadvicecanyoupassontotheCoatingsGroupfromthatsatisfyingprojectorjob?
Use your knowledge and network innovatively to create enduring and economical solutions for your clients needs.
Doyouhaveaninternaltrainingschemeordoyououtsourcetrainingforyouremployees?
Selected staff are undertaking Certificate III in Surface Preparation and Coatings Application. All of our Supervisors, Coordinators and Inspectors are NACE Certified (Level 1 to 3). Ongoing training for all operations staff to keep abreast of industry requirements and ensure continuous professional development. ORONTIDE Invests heavily in people.
ContactDetails:
54SparksRoadHendersonWesternAustralia,6166
E:[email protected]:61892362555F:61894102056
www.orontide.com.au
ORONTIDE Ltd.
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au26 27
ACA Technical Groups Update
OverthepasttwelvemonthsACAhasbeenworkingtoreinvigorateitseightTechnicalGroups(TG).ForeachTG,acallhasbeenputtomembership,seekingnominationstoformasteeringcommittee.ThefirsttaskofeachnewlyformedsteeringcommitteewastowriteandratifytheirCharter,sixofwhichcanbefoundontheACAwebsiteatwww.corrosion.com.au/contents/10633
ThisprocessresultedinsomechangestonamesofTGwhichmadetheTGmoreinclusiveandreflectiveoftheirmembership.
Currentlyfourgroupshavescheduledmid-yearmeetingsintheformofdaylongseminars.Forfurtherinformation,pleaserefertotheACAwebsiteatwww.corrosion.com.au
AfulllistofsteeringcommitteemembersforeachTGcanbeseentabulatedbelow.ThecontactpointforeachTGistheGroupChairandSecretary(*denotestheseroles).
Ifmembersareinterestedinattendingorcontributingtofuturetechnicalevents,[email protected]
CathodicProtectionMember Company State/BranchBruceAckland* BruceAckland&Associates VictoriaAlirezaKouklan* SPAusNet VictoriaRichardBrodribb M.BrodribbPtyLtd VictoriaGrahamCarlisle Orontide WesternAustraliaFrancisCarroll GHD QueenslandPeterClark PeterClark&Associates NewSouthWalesAndrewHargrave HargravePipelineGroup TasmaniaDougHerd Savcor QueenslandUlfKreheru Aurecon VictoriaNickRiley CloughAMEC SouthAustraliaDaveRobertson UnitedWater SouthAustraliaMarkSigley Watercare NewZealandColinSymonds Shell VictoriaRajkoVukcevic SMPS Victoria
LyndonZimmerman Solaris SouthAustralia
CoatingsMember Company State/BranchDavidHopkins* LeighsPaints QueenslandSteveWickham* Eptec NewSouthWalesGrahamCarlisle Orontide WesternAustraliaMarkDavidson WorleyParsonsLtd WesternAustraliaPeterDove AustralianCorrosionTechnologies VictoriaPeterHart Incospec&AssociatesAustralia SouthAustraliaWillieMandeno OpusInternationalConsultants NewZealandPeterMayes BrederoShaw NewSouthWalesDeanWall RobayneDistributors Tasmania
ConcreteStructures&BuildingsMember Company State/BranchFrédéricBlin* AECOM VictoriaWarrenGreen* VinsiPartners NewSouthWalesMohammadAli GHD NewSouthWalesArthurAustin ALSGlobal QueenslandHalBurkett PaintingInspectionServices WesternAustraliaIanDonoghue StructuralSystems NewSouthWalesAdrianDundas BRS QueenslandPhilipKarajayli SavcorART NewSouthWalesIkeSolomon Aurecon VictoriaDonWimpenny HalcrowGroup Victoria
MiningIndustryMember Company State/BranchPeterFarinha* ExtrinConsultants WesternAustraliaTedRiding* Jotun VictoriaRobDawson OvationInvestments NewSouthWalesLiamHolloway SavcorFinn WesternAustraliaWillieMandeno OpusInternationalConsultants NewZealandMickMorris HarrisonGroup NorthernTerritoryChrisPartington PromatAustralia SouthAustraliaAllanSterling AnodeEngineering Queensland
Refining&ProcessingMember Company State/BranchFikryBarouky* AntiCorrosionTechnology WesternAustraliaPhilFleming* A.S.Harrison&Co NewSouthWalesArthurAustin ALSGlobal QueenslandRichardClegg CQUniversityAustralia QueenslandRolfGubner CurtinUniversity WesternAustraliaLiamHolloway Savcor WesternAustraliaRipanKapoor ShellRefiningAustralia NewSouthWalesDavidMonk MobilRefining VictoriaGregReece Caltex NewSouthWalesFrankThompson Victoria
ResearchMember Company State/BranchNickBirbilis* MonashUniversity VictoriaDavidYoung* UniversityofNSW NewSouthWalesRezaJavaherdashti QatarUniversity QatarRobertJeffrey PacificTesting NewSouthWalesRolfGubner CurtinUniversity WesternAustraliaRajkoVukcevic InfowareConsulting Victoria
Water&WaterTreatmentMember Company State/BranchDavidMavros* SAWater SouthAustraliaMatthewDafter* HunterWater NewSouthWalesNickCritchley Savcor QueenslandWarrenGreen VinsiPartners NewSouthWalesMarkJones MRJIndustrialServices TasmaniaDesMcInnes TarongEnergy QueenslandGregMoore MooreMaterialsTechnologies SouthAustraliaJonathanMorris OpusInternationalConsultants NewZealandDavidNicholas NicholasCorrosion NewSouthWalesKerrynWilson AECOM Victoria
Welding,Joining&CorrosionMember Company State/BranchGrahamSussex* SussexMaterialSolutions VictoriaRomanDankiw DepartmentofDefence SouthAustraliaGrahamFry TechnoWeldInspection SouthAustraliaPaulHilton InternationalWelding
&EngineeringSolutionsWesternAustralia
RipanKapoor ShellRefining NewSouthWales
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au26 27
ACA Technical Groups Update
OverthepasttwelvemonthsACAhasbeenworkingtoreinvigorateitseightTechnicalGroups(TG).ForeachTG,acallhasbeenputtomembership,seekingnominationstoformasteeringcommittee.ThefirsttaskofeachnewlyformedsteeringcommitteewastowriteandratifytheirCharter,sixofwhichcanbefoundontheACAwebsiteatwww.corrosion.com.au/contents/10633
ThisprocessresultedinsomechangestonamesofTGwhichmadetheTGmoreinclusiveandreflectiveoftheirmembership.
Currentlyfourgroupshavescheduledmid-yearmeetingsintheformofdaylongseminars.Forfurtherinformation,pleaserefertotheACAwebsiteatwww.corrosion.com.au
AfulllistofsteeringcommitteemembersforeachTGcanbeseentabulatedbelow.ThecontactpointforeachTGistheGroupChairandSecretary(*denotestheseroles).
Ifmembersareinterestedinattendingorcontributingtofuturetechnicalevents,[email protected]
CathodicProtectionMember Company State/BranchBruceAckland* BruceAckland&Associates VictoriaAlirezaKouklan* SPAusNet VictoriaRichardBrodribb M.BrodribbPtyLtd VictoriaGrahamCarlisle Orontide WesternAustraliaFrancisCarroll GHD QueenslandPeterClark PeterClark&Associates NewSouthWalesAndrewHargrave HargravePipelineGroup TasmaniaDougHerd Savcor QueenslandUlfKreheru Aurecon VictoriaNickRiley CloughAMEC SouthAustraliaDaveRobertson UnitedWater SouthAustraliaMarkSigley Watercare NewZealandColinSymonds Shell VictoriaRajkoVukcevic SMPS Victoria
LyndonZimmerman Solaris SouthAustralia
CoatingsMember Company State/BranchDavidHopkins* LeighsPaints QueenslandSteveWickham* Eptec NewSouthWalesGrahamCarlisle Orontide WesternAustraliaMarkDavidson WorleyParsonsLtd WesternAustraliaPeterDove AustralianCorrosionTechnologies VictoriaPeterHart Incospec&AssociatesAustralia SouthAustraliaWillieMandeno OpusInternationalConsultants NewZealandPeterMayes BrederoShaw NewSouthWalesDeanWall RobayneDistributors Tasmania
ConcreteStructures&BuildingsMember Company State/BranchFrédéricBlin* AECOM VictoriaWarrenGreen* VinsiPartners NewSouthWalesMohammadAli GHD NewSouthWalesArthurAustin ALSGlobal QueenslandHalBurkett PaintingInspectionServices WesternAustraliaIanDonoghue StructuralSystems NewSouthWalesAdrianDundas BRS QueenslandPhilipKarajayli SavcorART NewSouthWalesIkeSolomon Aurecon VictoriaDonWimpenny HalcrowGroup Victoria
MiningIndustryMember Company State/BranchPeterFarinha* ExtrinConsultants WesternAustraliaTedRiding* Jotun VictoriaRobDawson OvationInvestments NewSouthWalesLiamHolloway SavcorFinn WesternAustraliaWillieMandeno OpusInternationalConsultants NewZealandMickMorris HarrisonGroup NorthernTerritoryChrisPartington PromatAustralia SouthAustraliaAllanSterling AnodeEngineering Queensland
Refining&ProcessingMember Company State/BranchFikryBarouky* AntiCorrosionTechnology WesternAustraliaPhilFleming* A.S.Harrison&Co NewSouthWalesArthurAustin ALSGlobal QueenslandRichardClegg CQUniversityAustralia QueenslandRolfGubner CurtinUniversity WesternAustraliaLiamHolloway Savcor WesternAustraliaRipanKapoor ShellRefiningAustralia NewSouthWalesDavidMonk MobilRefining VictoriaGregReece Caltex NewSouthWalesFrankThompson Victoria
ResearchMember Company State/BranchNickBirbilis* MonashUniversity VictoriaDavidYoung* UniversityofNSW NewSouthWalesRezaJavaherdashti QatarUniversity QatarRobertJeffrey PacificTesting NewSouthWalesRolfGubner CurtinUniversity WesternAustraliaRajkoVukcevic InfowareConsulting Victoria
Water&WaterTreatmentMember Company State/BranchDavidMavros* SAWater SouthAustraliaMatthewDafter* HunterWater NewSouthWalesNickCritchley Savcor QueenslandWarrenGreen VinsiPartners NewSouthWalesMarkJones MRJIndustrialServices TasmaniaDesMcInnes TarongEnergy QueenslandGregMoore MooreMaterialsTechnologies SouthAustraliaJonathanMorris OpusInternationalConsultants NewZealandDavidNicholas NicholasCorrosion NewSouthWalesKerrynWilson AECOM Victoria
Welding,Joining&CorrosionMember Company State/BranchGrahamSussex* SussexMaterialSolutions VictoriaRomanDankiw DepartmentofDefence SouthAustraliaGrahamFry TechnoWeldInspection SouthAustraliaPaulHilton InternationalWelding
&EngineeringSolutionsWesternAustralia
RipanKapoor ShellRefining NewSouthWales
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au28 29
The Australasian Corrosion Association Inc
Work experience and work in responsible chargeWork experience in corrosion or corrosion related field is defined as practical experience in corrosion mechanisms, causes, control and monitoring. It covers the investigation, design or
implementation of corrosion control. The work must be technical in nature (not sales for example) and in the corrosion field. Metallurgy, welding inspection, Non Destructive Testing (NDT) etc, are not acceptable, except when directly related
to corrosion.Work in responsible charge in corrosion or a corrosion related field is, work experience as defined above, which includes a level of responsibility requiring technical judgement. The applicant must be in technical control and have technical responsibility. Work such as design, specification,
and failure analysis etc are considered responsible work in charge, as opposed to routine testing or application of corrosion control measures, ie painting or installing anodes.
Affect on ACA MembershipACA accreditation as a Corrosion Technician/Technologist will have no affect on a member’s privileges including their right to vote, hold any office or participate in any associated activity.
Application procedureA completed application form with accompanying payment and documentation should be sent to the ACA Certification Scheme, PO Box 112, Kerrimuir VIC 3129 or faxed to +61 3 9890 7866. Your application will be initially assessed and you will be contacted if any further information is
required. The ACA will contact your referees and then forward your application to the Certification Review Board (which meets periodically - approx every 3 months) for assessment. You may be contacted by the ACA or one of the Certification Review Board members if further information is
needed to properly assess your application. Once reviewed, you will receive notification by letter as to the Certification Review Board’s decision.For further information on the Certification Rules,
Application Form or the Complaints Process, please visit our website at www.corrosion.com or call the ACA on +61 3 9890 4833.
CERTIFICATIO
N P
RO
GR
AM
Working tow
ard Professional Developm
ent in Corrosion
100mm
99mm
98mm
297 x 210 6PP DL ROLL FOLD
FRONT COVER
BACK COVER
ACA Certified Corrosion Technologists and TechniciansTheACA’sCertificationprogramforACACorrosionTechniciansandTechnologistsrecognisesthosewitheducationandexperienceinthecorrosionindustry.ACorrosionTechnicianhasatleast4yearsworkexperienceandhasattendedanumberofformaltrainingcourses,whilstthoseawardedCorrosionTechnologisthaveatleast10yearsworkexperienceandhaveobtainedfurthertraining.Foramoredetailedexplanationoftheeligibilitycriteria,pleaseconsultourACACertification
Programbrochurewhichisavailableonourwebsitewww.corrosion.com.au.AscheduleofcurrentACACorrosionTechniciansandTechnologistsappearsbelowandwillbepublishedinCorrosion & MaterialsinfulleachAprilandOctoberandwillbecontinuouslyupdatedontheACA’swebsite.AllcurrentACATechniciansandTechnologistshavebeenissuedawalletcardwiththeircertificationnumberandmembershipdetails.
CorrosionTechnicians
Name CertNo: ExpiryDate
GaryBarber 248 30/06/2011
StephenBrown 263 4/02/2012
ThomasByrne 91 14/07/2011
DylanCawley 224 30/06/2011
DavidCharters 261 20/01/2012
PasqualeChiaravalloti 274 6/06/2011
CraigClarke 246 25/03/2012
RodneyClarke 206 20/12/2011
RossDarrigan 174 14/07/2011
GlenRichardDean 280 20/01/2012
DavidFairfull 179 30/06/2011
GeoffFarrant 253 30/06/2011
RobertGentry 114 30/06/2011
StephenHolt 207 28/02/2012
PeterHursey 84 30/06/2011
BradleyJones 258 18/04/2012
JohnKilby 193 30/06/2011
BorisKrizman 169 18/02/2012
GaryMartin 57 1/06/2011
MurryMcCormick 196 28/06/2011
IanMcNair 163 30/06/2011
TerryMoore 125 9/06/2011
DavidMorgan 234 16/02/2012
RegOliver 223 30/06/2011
RafaelPelli 164 30/06/2011
KeithPerry 139 31/01/2012
BryanPike 113 6/09/2011
SeanRyder 262 21/11/2011
IanSaunders 251 24/06/2011
JustinTanti 238 14/02/2012
GavinTelford 244 30/06/2011
JohnTomlinson 53 29/02/2012
MarkWatson 186 30/06/2011
DerekWhitcombe 123 30/06/2011
CorrosionTechnologists
Name CertNo: ExpiryDate
BruceAckland 82 30/06/2011
FredAndrews-Phaedonos 153 30/06/2011
RossAntunovich 214 30/06/2011
ArthurAustin 106 30/06/2011
DineshBankar 264 22/02/2012
DonBartlett 15 29/06/2011
StuartBayliss 236 8/11/2011
PeterBeckford 187 28/02/2012
TonyBetts 74 1/01/2012
RobertBilling 12 30/06/2011
DavidBlackburn 10 1/01/2012
MichaelBoardman 30 12/07/2011
LesBoulton 43 1/01/2012
JohnBristow 107 1/01/2012
GaryBrockett 215 30/06/2011
KingsleyBrown 257 27/09/2011
PhilipBundy 209 30/06/2011
WayneBurns 100 1/01/2012
BrianByrne 27 1/01/2012
BryanCackett 70 30/06/2011
RobertCallant 103 30/06/2011
NeilCampbell 38 30/06/2011
GrahamCarlisle 281 17/11/2011
AntonioCarnovale 203 30/06/2011
LuisCarro 260 30/06/2011
RegCasling 11 1/01/2012
PeterClark 80 30/06/2011
IanClark 255 30/06/2011
StanCollins 128 30/06/2011
GeoffCope 71 29/06/2011
LeonCordewener 44 30/06/2011
RobertCox 14 30/06/2011
PeterCrampton 8 29/06/2011
KerryDalzell 28 30/06/2011
RomanDankiw 208 29/06/2011
ReneD'Ath 197 11/3/2012
RobertdeGraaf 154 14/07/2011
MichaelDinon 5 30/06/2011
BradleyDockrill 241 15/07/2011
PeterDove 210 29/03/2012
AdrianPeterDundas 250 1/02/2012
LucasEdwards 273 6/06/2011
BernardEgan 20 30/06/2011
MichaelEllwood 165 17/12/2011
GaryEvans 271 30/06/2011
WayneFerguson 242 4/09/2011
PeterFerris 195 30/06/2011
GavinForrester 282 10/02/2012
RobFrancis 23 29/06/2011
DaleFranke 199 30/06/2011
MaxFraser 283 18/03/2012
RobFreedman 147 1/01/2012
JimGalanos 254 17/12/2011
BarryGartner 2 30/06/2011
BillGerritsen 18 30/06/2011
IanGlover 129 30/06/2011
FredGooder 141 30/06/2011
DavidHarley 24 30/06/2011
PhillipHarrison 145 8/05/2011
PeterHart 200 30/06/2011
FrankHewitt 67 1/01/2012
BrianHickinbottom 138 30/06/2011
BrettHollis 88 30/06/2011
PeterHosford 216 1/01/2012
PaulHunter 62 30/06/2011
JeffreyHurst 202 30/06/2011
CraigHutchinson 249 26/10/2011
LucianoIoan 228 6/06/2011
BruceJewell 245 30/06/2011
MichaelJohnstone 230 18/04/2012
MichaelJukes 90 3/03/2012
JohnKalis 166 17/12/2011
GraemeKelly 102 1/01/2012
JohnLane 188 30/06/2011
WilliamLannen 111 1/01/2012
HarryLee 19 30/06/2011
KeithLichti 133 30/06/2011
VerneLinkhorn 39 30/06/2011
GaryLuskan 117 2/02/2012
WillieMandeno 13 30/06/2011
BrianMartin 60 1/01/2012
WilliamMcCaffrey 142 30/06/2011
JohnMcCallum 59 30/06/2011
DarylMcCormick 1 17/12/2011
MichaelMcCoy 109 14/04/2012
BradMcCoy 178 14/07/2012
BillMcEwan 32 1/01/2012
VicMcLean 237 30/06/2011
JimMcMonagle 56 1/01/2012
JohnMitchell 115 30/06/2011
ElioMonzu 159 30/06/2011
GregMoore 97 1/01/2012
JanetEMorris 256 5/07/2011
RobertMumford 33 30/06/2011
TonyMurray 134 30/06/2011
DavidNicholas 94 1/01/2012
CalvinOgilvie 17 19/01/2012
JohnPalmer 104 30/06/2011
DeanParker 108 5/07/2011
StephenRichards 110 30/06/2011
DennisRichards 180 30/06/2011
GavinRichardson 48 30/06/2011
TonyRidgers 36 30/06/2011
GeoffRippingale 37 30/06/2011
GeoffRobb 124 30/06/2011
BerndRose 252 1/05/2011
JohnRudd 243 21/06/2011
FredSalome 231 1/01/2012
IanSavage 259 30/06/2011
RonScaddan 272 5/02/2012
PhilipSchembri 198 30/06/2011
PaulSchweinsberg 34 1/01/2012
DavidScott 173 29/06/2011
MichaelSlade 175 7/06/2011
BrianSmallridge 201 30/06/2011
JamesSteele 119 17/12/2011
AlanSteinicke 9 1/06/2011
AllanSterling 191 30/03/2012
GordonStewart 68 1/01/2012
IanStewart 155 18/06/2011
GrahamSussex 136 30/06/2011
TanSweeHain 189 30/06/2011
Yong-JunTan 194 30/06/2011
FrankThompson 79 30/06/2011
PeterThorpe 144 1/01/2012
PeterTomlin 120 30/06/2011
NickVanStyn 229 25/02/2012
PeterWade 190 30/06/2011
BrianWalsh 157 14/02/2012
JohnWaters 121 30/06/2011
JohnWatson 239 10/06/2011
RichardWebster 69 30/06/2011
JohnWellburn 220 30/06/2011
MarkWeston 149 30/06/2011
GeoffreyWhite 182 1/07/2011
RodneyWubben 46 30/06/2011
MorrisYoung 217 30/06/2011
CERTIFICATION PROGRAMWorking toward Professional Development in Corrosion
Listcurrentattimeofprinting
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au28 29
The Australasian Corrosion Association Inc
Work experience and work in responsible chargeWork experience in corrosion or corrosion related field is defined as practical experience in corrosion mechanisms, causes, control and monitoring. It covers the investigation, design or
implementation of corrosion control. The work must be technical in nature (not sales for example) and in the corrosion field. Metallurgy, welding inspection, Non Destructive Testing (NDT) etc, are not acceptable, except when directly related
to corrosion.Work in responsible charge in corrosion or a corrosion related field is, work experience as defined above, which includes a level of responsibility requiring technical judgement. The applicant must be in technical control and have technical responsibility. Work such as design, specification,
and failure analysis etc are considered responsible work in charge, as opposed to routine testing or application of corrosion control measures, ie painting or installing anodes.
Affect on ACA MembershipACA accreditation as a Corrosion Technician/Technologist will have no affect on a member’s privileges including their right to vote, hold any office or participate in any associated activity.
Application procedureA completed application form with accompanying payment and documentation should be sent to the ACA Certification Scheme, PO Box 112, Kerrimuir VIC 3129 or faxed to +61 3 9890 7866. Your application will be initially assessed and you will be contacted if any further information is
required. The ACA will contact your referees and then forward your application to the Certification Review Board (which meets periodically - approx every 3 months) for assessment. You may be contacted by the ACA or one of the Certification Review Board members if further information is
needed to properly assess your application. Once reviewed, you will receive notification by letter as to the Certification Review Board’s decision.For further information on the Certification Rules,
Application Form or the Complaints Process, please visit our website at www.corrosion.com or call the ACA on +61 3 9890 4833.
CERTIFICATIO
N P
RO
GR
AM
Working tow
ard Professional Developm
ent in Corrosion
100mm
99mm
98mm
297 x 210 6PP DL ROLL FOLD
FRONT COVER
BACK COVER
ACA Certified Corrosion Technologists and TechniciansTheACA’sCertificationprogramforACACorrosionTechniciansandTechnologistsrecognisesthosewitheducationandexperienceinthecorrosionindustry.ACorrosionTechnicianhasatleast4yearsworkexperienceandhasattendedanumberofformaltrainingcourses,whilstthoseawardedCorrosionTechnologisthaveatleast10yearsworkexperienceandhaveobtainedfurthertraining.Foramoredetailedexplanationoftheeligibilitycriteria,pleaseconsultourACACertification
Programbrochurewhichisavailableonourwebsitewww.corrosion.com.au.AscheduleofcurrentACACorrosionTechniciansandTechnologistsappearsbelowandwillbepublishedinCorrosion & MaterialsinfulleachAprilandOctoberandwillbecontinuouslyupdatedontheACA’swebsite.AllcurrentACATechniciansandTechnologistshavebeenissuedawalletcardwiththeircertificationnumberandmembershipdetails.
CorrosionTechnicians
Name CertNo: ExpiryDate
GaryBarber 248 30/06/2011
StephenBrown 263 4/02/2012
ThomasByrne 91 14/07/2011
DylanCawley 224 30/06/2011
DavidCharters 261 20/01/2012
PasqualeChiaravalloti 274 6/06/2011
CraigClarke 246 25/03/2012
RodneyClarke 206 20/12/2011
RossDarrigan 174 14/07/2011
GlenRichardDean 280 20/01/2012
DavidFairfull 179 30/06/2011
GeoffFarrant 253 30/06/2011
RobertGentry 114 30/06/2011
StephenHolt 207 28/02/2012
PeterHursey 84 30/06/2011
BradleyJones 258 18/04/2012
JohnKilby 193 30/06/2011
BorisKrizman 169 18/02/2012
GaryMartin 57 1/06/2011
MurryMcCormick 196 28/06/2011
IanMcNair 163 30/06/2011
TerryMoore 125 9/06/2011
DavidMorgan 234 16/02/2012
RegOliver 223 30/06/2011
RafaelPelli 164 30/06/2011
KeithPerry 139 31/01/2012
BryanPike 113 6/09/2011
SeanRyder 262 21/11/2011
IanSaunders 251 24/06/2011
JustinTanti 238 14/02/2012
GavinTelford 244 30/06/2011
JohnTomlinson 53 29/02/2012
MarkWatson 186 30/06/2011
DerekWhitcombe 123 30/06/2011
CorrosionTechnologists
Name CertNo: ExpiryDate
BruceAckland 82 30/06/2011
FredAndrews-Phaedonos 153 30/06/2011
RossAntunovich 214 30/06/2011
ArthurAustin 106 30/06/2011
DineshBankar 264 22/02/2012
DonBartlett 15 29/06/2011
StuartBayliss 236 8/11/2011
PeterBeckford 187 28/02/2012
TonyBetts 74 1/01/2012
RobertBilling 12 30/06/2011
DavidBlackburn 10 1/01/2012
MichaelBoardman 30 12/07/2011
LesBoulton 43 1/01/2012
JohnBristow 107 1/01/2012
GaryBrockett 215 30/06/2011
KingsleyBrown 257 27/09/2011
PhilipBundy 209 30/06/2011
WayneBurns 100 1/01/2012
BrianByrne 27 1/01/2012
BryanCackett 70 30/06/2011
RobertCallant 103 30/06/2011
NeilCampbell 38 30/06/2011
GrahamCarlisle 281 17/11/2011
AntonioCarnovale 203 30/06/2011
LuisCarro 260 30/06/2011
RegCasling 11 1/01/2012
PeterClark 80 30/06/2011
IanClark 255 30/06/2011
StanCollins 128 30/06/2011
GeoffCope 71 29/06/2011
LeonCordewener 44 30/06/2011
RobertCox 14 30/06/2011
PeterCrampton 8 29/06/2011
KerryDalzell 28 30/06/2011
RomanDankiw 208 29/06/2011
ReneD'Ath 197 11/3/2012
RobertdeGraaf 154 14/07/2011
MichaelDinon 5 30/06/2011
BradleyDockrill 241 15/07/2011
PeterDove 210 29/03/2012
AdrianPeterDundas 250 1/02/2012
LucasEdwards 273 6/06/2011
BernardEgan 20 30/06/2011
MichaelEllwood 165 17/12/2011
GaryEvans 271 30/06/2011
WayneFerguson 242 4/09/2011
PeterFerris 195 30/06/2011
GavinForrester 282 10/02/2012
RobFrancis 23 29/06/2011
DaleFranke 199 30/06/2011
MaxFraser 283 18/03/2012
RobFreedman 147 1/01/2012
JimGalanos 254 17/12/2011
BarryGartner 2 30/06/2011
BillGerritsen 18 30/06/2011
IanGlover 129 30/06/2011
FredGooder 141 30/06/2011
DavidHarley 24 30/06/2011
PhillipHarrison 145 8/05/2011
PeterHart 200 30/06/2011
FrankHewitt 67 1/01/2012
BrianHickinbottom 138 30/06/2011
BrettHollis 88 30/06/2011
PeterHosford 216 1/01/2012
PaulHunter 62 30/06/2011
JeffreyHurst 202 30/06/2011
CraigHutchinson 249 26/10/2011
LucianoIoan 228 6/06/2011
BruceJewell 245 30/06/2011
MichaelJohnstone 230 18/04/2012
MichaelJukes 90 3/03/2012
JohnKalis 166 17/12/2011
GraemeKelly 102 1/01/2012
JohnLane 188 30/06/2011
WilliamLannen 111 1/01/2012
HarryLee 19 30/06/2011
KeithLichti 133 30/06/2011
VerneLinkhorn 39 30/06/2011
GaryLuskan 117 2/02/2012
WillieMandeno 13 30/06/2011
BrianMartin 60 1/01/2012
WilliamMcCaffrey 142 30/06/2011
JohnMcCallum 59 30/06/2011
DarylMcCormick 1 17/12/2011
MichaelMcCoy 109 14/04/2012
BradMcCoy 178 14/07/2012
BillMcEwan 32 1/01/2012
VicMcLean 237 30/06/2011
JimMcMonagle 56 1/01/2012
JohnMitchell 115 30/06/2011
ElioMonzu 159 30/06/2011
GregMoore 97 1/01/2012
JanetEMorris 256 5/07/2011
RobertMumford 33 30/06/2011
TonyMurray 134 30/06/2011
DavidNicholas 94 1/01/2012
CalvinOgilvie 17 19/01/2012
JohnPalmer 104 30/06/2011
DeanParker 108 5/07/2011
StephenRichards 110 30/06/2011
DennisRichards 180 30/06/2011
GavinRichardson 48 30/06/2011
TonyRidgers 36 30/06/2011
GeoffRippingale 37 30/06/2011
GeoffRobb 124 30/06/2011
BerndRose 252 1/05/2011
JohnRudd 243 21/06/2011
FredSalome 231 1/01/2012
IanSavage 259 30/06/2011
RonScaddan 272 5/02/2012
PhilipSchembri 198 30/06/2011
PaulSchweinsberg 34 1/01/2012
DavidScott 173 29/06/2011
MichaelSlade 175 7/06/2011
BrianSmallridge 201 30/06/2011
JamesSteele 119 17/12/2011
AlanSteinicke 9 1/06/2011
AllanSterling 191 30/03/2012
GordonStewart 68 1/01/2012
IanStewart 155 18/06/2011
GrahamSussex 136 30/06/2011
TanSweeHain 189 30/06/2011
Yong-JunTan 194 30/06/2011
FrankThompson 79 30/06/2011
PeterThorpe 144 1/01/2012
PeterTomlin 120 30/06/2011
NickVanStyn 229 25/02/2012
PeterWade 190 30/06/2011
BrianWalsh 157 14/02/2012
JohnWaters 121 30/06/2011
JohnWatson 239 10/06/2011
RichardWebster 69 30/06/2011
JohnWellburn 220 30/06/2011
MarkWeston 149 30/06/2011
GeoffreyWhite 182 1/07/2011
RodneyWubben 46 30/06/2011
MorrisYoung 217 30/06/2011
CERTIFICATION PROGRAMWorking toward Professional Development in Corrosion
Listcurrentattimeofprinting
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au30 31
Microbiologicallyinfluencedcorrosion(MIC)iscorrosionresultingfromthepresenceandactivitiesofmicroorganisms,i.e.,thoseorganismsthatcannotbeseenindividuallywiththeunaidedhumaneye,includingmicroalgae,bacteria,andfungi.MIChasbeendocumentedformetalsexposedtoseawater,freshwater,distilled/demineralizedwater,processchemicals,foodstuffs,soil,crudeandrefinedpetroleumfuelsthatcontainsmallamountsofwater,humansalivaandplasmaandsewage.MIChasbeenreportedforallengineeringmetalsandalloyswiththeexceptionofpredominantlytitaniumandhighchromium/nickelalloys.Inaddition,thetermMIChasbeenexpandedtoincludebiodegradationofmetalmatrixandpolymericcomposites,polymers/paints,ceramics,glass,sandstone,heritagestoneworks,sealants,caulks,concreteandothernon-metallics.MIChasbeenidentifiedasaprobleminchemical,food,andpulp/paperprocessing;conventionalandnuclearpowergeneration;exploration,production,transportation,storageanduseoffuels;marineindustries,fireprotectionsystemsandapotentialprobleminlong-termnuclearwastestorage.SurveysintheUnitedStates,UnitedKingdom,Japan,AustraliaandGermanyestimatethecostofcorrosion
tobe1-5percentofthegrossnationalproduct(www.corrosion-doctors.org)andMICisreportedtoaccountforapproximately40percentoftheoverallcorrosiondamage(Flemming,1996).
Therelationshipbetweenmicroorganismsandcorrosionisbothpredictableandcomplex.Inaquaticenvironmentsandundersomeatmosphericconditions,microorganismssettleonsurfacesandalterthesurfacechemistrycontrollingtheratesofcorrosionorshiftingthemechanismforcorrosion.
Theresultiscorrosionwherenonecouldbeanticipatedbasedonthecompositionofthebulkmedium,e.g.,low-chloridewaters,andratesthatareexceptionallyfast.TherearenumerousmechanismsandcausativeorganismsforMICthatcanvaryamongmetals/alloysandoperatingconditionsforthesamematerials.ThetypesofmicroorganismsinvolvedincorrosionandconsequentlythemechanismsforMIC,arecontinuouslybeingupdated.ManymechanismsforMICareassociatedwithspecificmicroorganisms,e.g.sulfate-reducing,iron-oxidizing,andmanganese-oxidizingbacteria.However,whileacorrosionmechanismmaybeattributedtoasinglegroupoforganisms,themostaggressiveMICoccurswithnaturalpopulationsmadeupofmanytypesofmicroorganisms.Furthermore,asingletypeofmicroorganismcansimultaneouslyaffectcorrosionviaseveralmechanisms.Celldeathdoesnotnecessarilymeananendtotheinfluenceoncorrosion.
Electrochemical,metallurgical,surfaceanalytical,microbiological,biotechnologicalandbiophysicalanalyseshavebeenusedtostudyMIC.MICdoesnotproduceamacroscopic
uniquemetallographicfeature.MostMICislocalizedcorrosionandcantaketheformofpitting,crevicecorrosion,under-depositcorrosion,andde-alloying,inadditiontoenhancedgalvanicanderosioncorrosion.ThefollowingarerequiredforanaccuratediagnosisofMIC
afterithasoccurred:1)asampleofthecorrosionproductoraffectedsurfacethathasnotbeenalteredbycollectionorstorage,2)identificationofacorrosionmechanism,3)identificationofmicroorganismscapableofgrowthandmaintenanceofthecorrosionmechanismin
theparticularenvironmentand4)demonstrationofanassociationofthemicroorganismswiththeobservedcorrosion.ThreetypesofevidenceareusedtodiagnosisMIC:metallurgical,chemicalandbiological.TheobjectiveistohavethreeindependenttypesofmeasurementsthatareconsistentwithamechanismforMIC.Manytechniqueshavebeendescribedfordiagnosing,measuringandmonitoringMIC,howevernonehasbeenacceptedasanindustrystandard.
Traditionalstrategiestomitigate/controlMICreducethenumbersandtypesoforganismsinthesystembyadditionofbiocidesormechanicalremovalofmicroorganismsfromsurfaces.Moremoderntechniquesmanipulatetheelectrolytetoinfluencethechemistriesproducedbythemicroorganisms.
Source:Brenda Little
FlemmingH.C.(1996)EconomicalandTechnicalOverview.In:E.Heitz,H.C.FlemmingandW.Sand(ed).Microbially Influenced Corrosion of Materials.Springer-Verlag,NewYork.pp6-14.
The Basics of Corrosion Due to Microbial Activity
10th–11th August 2011 Melbourne Marriott Hotel, Melbourne, Victoria, Australia
SYMPOSIUM ON MICROBIOLOGICALLY INFLUENCED CORROSION
Brenda Little of the Naval Research Laboratory in the USA is a keynote speaker for this symposium and will present two papers on ‘Microbiologically Influenced Corrosion: Causative Organisms and Mechanisms’ and ‘Microbiologically Influenced Corrosion: Diagnosing, Measuring and Monitoring’.
Microbially Influenced Corrosion
Visit www.corrosion.com.au for registration and further details
PROUDLY PRESENTED BY: SUPPORTED BY:SPONSORED BY:
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au30 31
Microbiologicallyinfluencedcorrosion(MIC)iscorrosionresultingfromthepresenceandactivitiesofmicroorganisms,i.e.,thoseorganismsthatcannotbeseenindividuallywiththeunaidedhumaneye,includingmicroalgae,bacteria,andfungi.MIChasbeendocumentedformetalsexposedtoseawater,freshwater,distilled/demineralizedwater,processchemicals,foodstuffs,soil,crudeandrefinedpetroleumfuelsthatcontainsmallamountsofwater,humansalivaandplasmaandsewage.MIChasbeenreportedforallengineeringmetalsandalloyswiththeexceptionofpredominantlytitaniumandhighchromium/nickelalloys.Inaddition,thetermMIChasbeenexpandedtoincludebiodegradationofmetalmatrixandpolymericcomposites,polymers/paints,ceramics,glass,sandstone,heritagestoneworks,sealants,caulks,concreteandothernon-metallics.MIChasbeenidentifiedasaprobleminchemical,food,andpulp/paperprocessing;conventionalandnuclearpowergeneration;exploration,production,transportation,storageanduseoffuels;marineindustries,fireprotectionsystemsandapotentialprobleminlong-termnuclearwastestorage.SurveysintheUnitedStates,UnitedKingdom,Japan,AustraliaandGermanyestimatethecostofcorrosion
tobe1-5percentofthegrossnationalproduct(www.corrosion-doctors.org)andMICisreportedtoaccountforapproximately40percentoftheoverallcorrosiondamage(Flemming,1996).
Therelationshipbetweenmicroorganismsandcorrosionisbothpredictableandcomplex.Inaquaticenvironmentsandundersomeatmosphericconditions,microorganismssettleonsurfacesandalterthesurfacechemistrycontrollingtheratesofcorrosionorshiftingthemechanismforcorrosion.
Theresultiscorrosionwherenonecouldbeanticipatedbasedonthecompositionofthebulkmedium,e.g.,low-chloridewaters,andratesthatareexceptionallyfast.TherearenumerousmechanismsandcausativeorganismsforMICthatcanvaryamongmetals/alloysandoperatingconditionsforthesamematerials.ThetypesofmicroorganismsinvolvedincorrosionandconsequentlythemechanismsforMIC,arecontinuouslybeingupdated.ManymechanismsforMICareassociatedwithspecificmicroorganisms,e.g.sulfate-reducing,iron-oxidizing,andmanganese-oxidizingbacteria.However,whileacorrosionmechanismmaybeattributedtoasinglegroupoforganisms,themostaggressiveMICoccurswithnaturalpopulationsmadeupofmanytypesofmicroorganisms.Furthermore,asingletypeofmicroorganismcansimultaneouslyaffectcorrosionviaseveralmechanisms.Celldeathdoesnotnecessarilymeananendtotheinfluenceoncorrosion.
Electrochemical,metallurgical,surfaceanalytical,microbiological,biotechnologicalandbiophysicalanalyseshavebeenusedtostudyMIC.MICdoesnotproduceamacroscopic
uniquemetallographicfeature.MostMICislocalizedcorrosionandcantaketheformofpitting,crevicecorrosion,under-depositcorrosion,andde-alloying,inadditiontoenhancedgalvanicanderosioncorrosion.ThefollowingarerequiredforanaccuratediagnosisofMIC
afterithasoccurred:1)asampleofthecorrosionproductoraffectedsurfacethathasnotbeenalteredbycollectionorstorage,2)identificationofacorrosionmechanism,3)identificationofmicroorganismscapableofgrowthandmaintenanceofthecorrosionmechanismin
theparticularenvironmentand4)demonstrationofanassociationofthemicroorganismswiththeobservedcorrosion.ThreetypesofevidenceareusedtodiagnosisMIC:metallurgical,chemicalandbiological.TheobjectiveistohavethreeindependenttypesofmeasurementsthatareconsistentwithamechanismforMIC.Manytechniqueshavebeendescribedfordiagnosing,measuringandmonitoringMIC,howevernonehasbeenacceptedasanindustrystandard.
Traditionalstrategiestomitigate/controlMICreducethenumbersandtypesoforganismsinthesystembyadditionofbiocidesormechanicalremovalofmicroorganismsfromsurfaces.Moremoderntechniquesmanipulatetheelectrolytetoinfluencethechemistriesproducedbythemicroorganisms.
Source:Brenda Little
FlemmingH.C.(1996)EconomicalandTechnicalOverview.In:E.Heitz,H.C.FlemmingandW.Sand(ed).Microbially Influenced Corrosion of Materials.Springer-Verlag,NewYork.pp6-14.
The Basics of Corrosion Due to Microbial Activity
10th–11th August 2011 Melbourne Marriott Hotel, Melbourne, Victoria, Australia
SYMPOSIUM ON MICROBIOLOGICALLY INFLUENCED CORROSION
Brenda Little of the Naval Research Laboratory in the USA is a keynote speaker for this symposium and will present two papers on ‘Microbiologically Influenced Corrosion: Causative Organisms and Mechanisms’ and ‘Microbiologically Influenced Corrosion: Diagnosing, Measuring and Monitoring’.
Microbially Influenced Corrosion
Visit www.corrosion.com.au for registration and further details
PROUDLY PRESENTED BY: SUPPORTED BY:SPONSORED BY:
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au32 33
With thousands of pile protection projects installed worldwide, Denso is the preferred choice of owners, engineers and contractors. In business for over 125 years, Denso has the experience and expertise to provide the highest quality pile protection systems. SeaShield Marine Systems will add years of life to both new and existing piles.
To receive literature on any of ourSeashield Marine Systems, pleasecontact Denso 1300 658 590 or visit www.densoaustralia.com.au
Call Us At: 1300 658 590Visit Us At: www.densoaustralia.com.auE-mail Us At: [email protected]
SeaShield Series 500 SystemHeavy-duty pile protection system with a SeaShield Fiber-Form Jacket and SeaShield 550 Epoxy Grout.
SeaShield Series 80 SystemFor splash or tidal zone protectionin sheltered environments.
SeaShield Fiber-Form Pile JacketFiberglass jacket to provide a form for encasement of concrete or epoxy grout.
SeaShield Series 100 SystemPile protection system with petrolatum tape and an HDPE outercover secured with a strapping system.
SeaShield Series 2000FD SystemHeavy-duty Fixed Diameter pile protection system with petrolatum tape and an HDPE outercover secured with a bolted system.
SeaShield Series 400 SystemC-GRID® 450 encapsulation system that protects timber piles from saltwater environments and strengthens deteriorated piles.
Re-Lifing a CO2 Absorber Tower Using Welding Robots
1.IntroductionTheMoombaprocessingplantincentralAustraliaprocessesrawgaswith20%CO2downtosalesgasspecifications.ThisiscompletedthroughCO2removaltrainsusingtheUOPBenfieldprocess(arecirculatedhotpotassiumcarbonatesolution).Theplantcommencedprocessingnaturalgasin1969andwasexpandedinthe1970sand80stoseventrainswithacombinedthroughputof600TJ/d.
CorrosionintheCO2trains,andmorespecificallyinthetopoftheCO2absorberswasfirstnoticedinthe1980s.Overtimethisledtooneoftheabsorbertowersrequiringrefurbishment.Aprojectwasinitiatedin2006tore-lifethisAbsorberbyreplacingmetallosttocorrosionandatthesametimeupgradethemetallurgytoprovidecorrosionprotection.Therefurbishmentneededtobecompletedduringaroutineplantshutdownandfitwithintheexistingmaintenancewindow.
2.TechnicalChallenges2.1 The Welding Process TheMIG(MetalInertGas)weldingprocesswaschosenwithweldingrobotsmountedtocircumferentialtracksattachedtothetowerwall(figure1).Theautomatedprocessallowslargeamountsofweldmetaltobeappliedquicklywitharepeatableandhighqualityresult.Theprocessinvolvesfeedingsolidwiretoaweldingheadunderanargon/CO2blanket.Theweldingrobottraversesbackandfortharoundthecircumferenceofthevesselindexingupordownattheendofeachrow.Therobotsaresettotraverseasegmentofthevesselwhichallowsmultiplemachinestobeusedatthesametime.Whiletheyarefullyautomatic,aweldingtechnicianis
stillrequiredtomonitorandfinetuneweldingparameters.
2.2 Proof of Method – Welding Trials Fortunatelyasixmetrehighstrake(figure2)wasavailablewithasimilarmaterial,wallthicknessanddiametertotheAbsorber.Thisprovidedanexcellenttestbedasitalsoincludedamanwaywhichprovidedtheopportunitytoprovethemethodforweldingnozzlesandmanways,whichwouldberequiredlaterinthefinalproject.
AusteniticstainlesssteelsshowexcellentresistancetoCO2corrosionandsowerethelogicalchoicetoprovidecorrosionprotection.Forthetrial,Alloy317Lwaschosenalongwith309Lasthisalloyhasaprovenhistoryasaweldoverlaywithinthehydrocarbonindustry.Thecombinationoftheduallayerofcarbonsteelwithstainlesssteelwasincludedastherewasaneedtobuildupareasthathadcorroded,particularlyaroundweldseams.
Thesetestpanels(figure2)withtheadditionofpostweldheattreatment(PWHT)representedallthevariationsthatwerelikelytoberequired.
AninspectionandtestingprogramwasdevelopedwiththehelpofweldingspecialistsandAS/NZS3992“PressureEquipment,WeldingandBrazingQualification”.Testingfocusedonbonding,porosity,metallurgicalpropertiesanddepositchemistry.Theduallayercarbonsteeland317Lstainlesssteeloverlay(fillerER70S-6andER317Lrespectively)provedtobethebestperformerfromtheweldingtrialandthereforewaschosenasthepreferredmethodofrepair.
3.LogisticsWhilethetechnicalproblemswerebeingresolvedanumberoflogisticalchallengeswerebeginningtoemerge,ofparticularimportancewascontrollingtheambienttemperatureinsidetheabsorberduringwelding.
FIGURE1–WeldingRobotApplyingWeldOverlay
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au32 33
With thousands of pile protection projects installed worldwide, Denso is the preferred choice of owners, engineers and contractors. In business for over 125 years, Denso has the experience and expertise to provide the highest quality pile protection systems. SeaShield Marine Systems will add years of life to both new and existing piles.
To receive literature on any of ourSeashield Marine Systems, pleasecontact Denso 1300 658 590 or visit www.densoaustralia.com.au
Call Us At: 1300 658 590Visit Us At: www.densoaustralia.com.auE-mail Us At: [email protected]
SeaShield Series 500 SystemHeavy-duty pile protection system with a SeaShield Fiber-Form Jacket and SeaShield 550 Epoxy Grout.
SeaShield Series 80 SystemFor splash or tidal zone protectionin sheltered environments.
SeaShield Fiber-Form Pile JacketFiberglass jacket to provide a form for encasement of concrete or epoxy grout.
SeaShield Series 100 SystemPile protection system with petrolatum tape and an HDPE outercover secured with a strapping system.
SeaShield Series 2000FD SystemHeavy-duty Fixed Diameter pile protection system with petrolatum tape and an HDPE outercover secured with a bolted system.
SeaShield Series 400 SystemC-GRID® 450 encapsulation system that protects timber piles from saltwater environments and strengthens deteriorated piles.
Re-Lifing a CO2 Absorber Tower Using Welding Robots
1.IntroductionTheMoombaprocessingplantincentralAustraliaprocessesrawgaswith20%CO2downtosalesgasspecifications.ThisiscompletedthroughCO2removaltrainsusingtheUOPBenfieldprocess(arecirculatedhotpotassiumcarbonatesolution).Theplantcommencedprocessingnaturalgasin1969andwasexpandedinthe1970sand80stoseventrainswithacombinedthroughputof600TJ/d.
CorrosionintheCO2trains,andmorespecificallyinthetopoftheCO2absorberswasfirstnoticedinthe1980s.Overtimethisledtooneoftheabsorbertowersrequiringrefurbishment.Aprojectwasinitiatedin2006tore-lifethisAbsorberbyreplacingmetallosttocorrosionandatthesametimeupgradethemetallurgytoprovidecorrosionprotection.Therefurbishmentneededtobecompletedduringaroutineplantshutdownandfitwithintheexistingmaintenancewindow.
2.TechnicalChallenges2.1 The Welding Process TheMIG(MetalInertGas)weldingprocesswaschosenwithweldingrobotsmountedtocircumferentialtracksattachedtothetowerwall(figure1).Theautomatedprocessallowslargeamountsofweldmetaltobeappliedquicklywitharepeatableandhighqualityresult.Theprocessinvolvesfeedingsolidwiretoaweldingheadunderanargon/CO2blanket.Theweldingrobottraversesbackandfortharoundthecircumferenceofthevesselindexingupordownattheendofeachrow.Therobotsaresettotraverseasegmentofthevesselwhichallowsmultiplemachinestobeusedatthesametime.Whiletheyarefullyautomatic,aweldingtechnicianis
stillrequiredtomonitorandfinetuneweldingparameters.
2.2 Proof of Method – Welding Trials Fortunatelyasixmetrehighstrake(figure2)wasavailablewithasimilarmaterial,wallthicknessanddiametertotheAbsorber.Thisprovidedanexcellenttestbedasitalsoincludedamanwaywhichprovidedtheopportunitytoprovethemethodforweldingnozzlesandmanways,whichwouldberequiredlaterinthefinalproject.
AusteniticstainlesssteelsshowexcellentresistancetoCO2corrosionandsowerethelogicalchoicetoprovidecorrosionprotection.Forthetrial,Alloy317Lwaschosenalongwith309Lasthisalloyhasaprovenhistoryasaweldoverlaywithinthehydrocarbonindustry.Thecombinationoftheduallayerofcarbonsteelwithstainlesssteelwasincludedastherewasaneedtobuildupareasthathadcorroded,particularlyaroundweldseams.
Thesetestpanels(figure2)withtheadditionofpostweldheattreatment(PWHT)representedallthevariationsthatwerelikelytoberequired.
AninspectionandtestingprogramwasdevelopedwiththehelpofweldingspecialistsandAS/NZS3992“PressureEquipment,WeldingandBrazingQualification”.Testingfocusedonbonding,porosity,metallurgicalpropertiesanddepositchemistry.Theduallayercarbonsteeland317Lstainlesssteeloverlay(fillerER70S-6andER317Lrespectively)provedtobethebestperformerfromtheweldingtrialandthereforewaschosenasthepreferredmethodofrepair.
3.LogisticsWhilethetechnicalproblemswerebeingresolvedanumberoflogisticalchallengeswerebeginningtoemerge,ofparticularimportancewascontrollingtheambienttemperatureinsidetheabsorberduringwelding.
FIGURE1–WeldingRobotApplyingWeldOverlay
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au34 35
3.1 Access Internallyapurposebuiltscaffoldwasbuiltforthewelders(Figure3).Thisallowedtheweldingmachinesfreedomofmovement,weldingtocontinueontwolevels,andprovidedaccessforcoolingductsandpowercables.Italsoisolatedandprotectedthetwoteamsofmenwhowereworkingwithpowertoolsandweldingequipmentessentiallyaboveeachother.Externallyscaffoldingwasusedtoprovideaquickandeasymeansofaccesstothetowerfortheheattreatmenttechnicianstosetandadjusttheirheatingpadsandforthenon-destructivetestingteamstocompletetheirinspections.
3.2 Welding Twostrakesofthetowerrequiredrepair(38m2).Atanestimatedfinishedoverlaythicknessof10mm;thisrepresented3200kgofweldmetal.Includedinthisareaweretwomanways,smallborenozzles,aninternaltraysupportring,threeexternalplatformsandnumerousinstrumentationfittings.Abutteringlayerofcarbonsteelwasappliedfirst,followedbythe317Lstainlesssteel(asperthelearningsfromtheweldingtrials).Weldingcontinued24hrsadaysimultaneouslyontwo
levels(4weldingrobotsintotal).Thisrequiredareviewofin-houseconfinedspaceentryprocedureswithtwoteamsworkingverycloselyandaboveeachother.Separateentriesandexitswereprovidedforeachspacealongwithconfinedspacewatchers.Siteoperations,safetyandmaintenanceteamswereheavilyinvolvedinassessingtherisks,completingsafetyassessmentsandrescueplans,anddevelopingthenecessaryprocedurestoallowadoubleentryintoaconfinedspace.Withouttheirconsiderableinputandsupporttheprojectwouldnothavebeencompletedonschedule.
3.3 Cooling TherepairwascompletedinJanuaryincentralAustraliawheredaytimetemperaturesexceed40°C.Ontopofthisthecarbonsteelweldingprocedurecalledforapreheatof150°C.Magneticheatingpadswereemployedexternallytoprovideaccuratetemperaturecontrol,butmoreimportantlytoallowonlytheimmediateareabeingweldedtobepreheatedtoreducetheheatloadontheconfinedspace.Cooledairwassuppliedtothevestsandhelmetswornbytheweldersandchilledairwassuppliedtothetowerthrougha
refrigeratedairconditioningsystem.Airtemperatureswerecontinuallymonitoredinsidethetowerandthewelderswerechangedoutregularlytomanageheatstress.Thesemeasureswereveryeffectivewithnoincidentsofheatstressorfatigueencountered.
4.QualityControl–InspectionandTesting
Afulltimeweldinginspectorandqualitycontrolsupervisorwasemployedtomonitortheweldingmachinesandprocessesagainsttheproceduresdevelopedearlierandtocompileacomprehensivematerialsdatareport.
4.1 Weld Metal Bonding Phasedarrayultrasonicswaschosenbecauseofitsabilitytoquicklyscanlargeareasandprovideadigitalrecord.Thetechniquewasusedtoidentifyanyporosity,lackoffusionorcrackingintheweldoverlayandparentmetal.Thetestingwascompletedexternallywiththeultrasonicstechnicianfollowingtheweldingprocessascloseaspossibletoprovideresultsandfeedbackasthejobprogressedandtofacilitatetimelyrepairsandmanageworkload.Onlyafewdefectswerefound;theywerecausedbylackoffusionbetweenthe
FIGURE2-TrialStrakeandCompletedTestPad
weldingrunsofthestainlesssteeloverlay.Theyweregroundoutandrepairedmanually.
4.2 Weld Metal Chemistry Dilutionofthewelddepositisaconcernwithweldoverlays.Mixingoftheparentmetalwiththestainlesssteelweldmetalbeingdepositedresultsindilutionandalossofalloyingelementswhichadverselyaffectscorrosionresistance.AportableX-rayanalyserwasusedtomeasurethefinalcompositionoftheoverlay.Aswellastestingthesurfaceoftheoverlay,smallareasweregrounddownby2mmtocheckthelevelofdilutionbelowthesurface.Allreadingsmetthealloyspecificationfor317L.
4.3 Hydrotest AS/NZS1210–2010“Pressurevessels”providesthejustification
forhydrostatictesting.Consideringtheamountofweldingthathadbeencompletedonthevesselshell,ahydrotestwasconsideredmandatoryandwascompletedat1.5timesthedesignpressure.Asthevesselwasdesignedtooperatefullofliquidtherewasnoconcernwiththefoundationssupportingtheweightofthe80m3ofwaterthatwouldberequiredtofillthetower.Distilledwaterwithachloridecontentbelow50ppmwasusedtopreventchloridestresscorrosioncrackingofthenew317Lstainlesssteel.
5.ConclusionTherepairandrefurbishmentofanabsorbertowerwassuccessfullycompletedbyapplyingaduallayercarbonsteelandstainlesssteelweldoverlay.Thisrepairwascompletedduringaroutineplantshutdownusingfourweldingrobots
workingontwolevels24hoursaday,andwascompletedin12days(excludingPWHT).
Duetotheremotenessofthesiteandthecomplexityofthetaskanumberoflogisticalandtechnicalchallengesweresuccessfullyresolved;theseincludeddevelopingweldingspecifications,controllingweldqualityandmanagingheatstressontheweldingpersonnel.Acomprehensivetestingregimewasusedtoassesstheintegrityoftheweldoverlayandprovethevesselasfitforreturntoservice.Thevesselwasconsideredtohavebeenre-lifedfortheremainingeconomiclifeoftheasset,20years.
MartynCooper,LeadIntegrityEngineer,SantosLtdJohnFletcher,SeniorIntegrityEngineer,AMISIntegrityLtd
ProjectProfile:Re-LifingaCO2AbsorberTowerUsingWeldingRobots
FIGURE3–ShowingInternalandExternalScaffolding
1
K
Clearance for Welding Machines
Refridge Ducting, Power Cables
Tower Shell
Welding Robot
Entry & Exit
DECK 1
DECK 2Entry & Exit
Scaffold
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au34 35
3.1 Access Internallyapurposebuiltscaffoldwasbuiltforthewelders(Figure3).Thisallowedtheweldingmachinesfreedomofmovement,weldingtocontinueontwolevels,andprovidedaccessforcoolingductsandpowercables.Italsoisolatedandprotectedthetwoteamsofmenwhowereworkingwithpowertoolsandweldingequipmentessentiallyaboveeachother.Externallyscaffoldingwasusedtoprovideaquickandeasymeansofaccesstothetowerfortheheattreatmenttechnicianstosetandadjusttheirheatingpadsandforthenon-destructivetestingteamstocompletetheirinspections.
3.2 Welding Twostrakesofthetowerrequiredrepair(38m2).Atanestimatedfinishedoverlaythicknessof10mm;thisrepresented3200kgofweldmetal.Includedinthisareaweretwomanways,smallborenozzles,aninternaltraysupportring,threeexternalplatformsandnumerousinstrumentationfittings.Abutteringlayerofcarbonsteelwasappliedfirst,followedbythe317Lstainlesssteel(asperthelearningsfromtheweldingtrials).Weldingcontinued24hrsadaysimultaneouslyontwo
levels(4weldingrobotsintotal).Thisrequiredareviewofin-houseconfinedspaceentryprocedureswithtwoteamsworkingverycloselyandaboveeachother.Separateentriesandexitswereprovidedforeachspacealongwithconfinedspacewatchers.Siteoperations,safetyandmaintenanceteamswereheavilyinvolvedinassessingtherisks,completingsafetyassessmentsandrescueplans,anddevelopingthenecessaryprocedurestoallowadoubleentryintoaconfinedspace.Withouttheirconsiderableinputandsupporttheprojectwouldnothavebeencompletedonschedule.
3.3 Cooling TherepairwascompletedinJanuaryincentralAustraliawheredaytimetemperaturesexceed40°C.Ontopofthisthecarbonsteelweldingprocedurecalledforapreheatof150°C.Magneticheatingpadswereemployedexternallytoprovideaccuratetemperaturecontrol,butmoreimportantlytoallowonlytheimmediateareabeingweldedtobepreheatedtoreducetheheatloadontheconfinedspace.Cooledairwassuppliedtothevestsandhelmetswornbytheweldersandchilledairwassuppliedtothetowerthrougha
refrigeratedairconditioningsystem.Airtemperatureswerecontinuallymonitoredinsidethetowerandthewelderswerechangedoutregularlytomanageheatstress.Thesemeasureswereveryeffectivewithnoincidentsofheatstressorfatigueencountered.
4.QualityControl–InspectionandTesting
Afulltimeweldinginspectorandqualitycontrolsupervisorwasemployedtomonitortheweldingmachinesandprocessesagainsttheproceduresdevelopedearlierandtocompileacomprehensivematerialsdatareport.
4.1 Weld Metal Bonding Phasedarrayultrasonicswaschosenbecauseofitsabilitytoquicklyscanlargeareasandprovideadigitalrecord.Thetechniquewasusedtoidentifyanyporosity,lackoffusionorcrackingintheweldoverlayandparentmetal.Thetestingwascompletedexternallywiththeultrasonicstechnicianfollowingtheweldingprocessascloseaspossibletoprovideresultsandfeedbackasthejobprogressedandtofacilitatetimelyrepairsandmanageworkload.Onlyafewdefectswerefound;theywerecausedbylackoffusionbetweenthe
FIGURE2-TrialStrakeandCompletedTestPad
weldingrunsofthestainlesssteeloverlay.Theyweregroundoutandrepairedmanually.
4.2 Weld Metal Chemistry Dilutionofthewelddepositisaconcernwithweldoverlays.Mixingoftheparentmetalwiththestainlesssteelweldmetalbeingdepositedresultsindilutionandalossofalloyingelementswhichadverselyaffectscorrosionresistance.AportableX-rayanalyserwasusedtomeasurethefinalcompositionoftheoverlay.Aswellastestingthesurfaceoftheoverlay,smallareasweregrounddownby2mmtocheckthelevelofdilutionbelowthesurface.Allreadingsmetthealloyspecificationfor317L.
4.3 Hydrotest AS/NZS1210–2010“Pressurevessels”providesthejustification
forhydrostatictesting.Consideringtheamountofweldingthathadbeencompletedonthevesselshell,ahydrotestwasconsideredmandatoryandwascompletedat1.5timesthedesignpressure.Asthevesselwasdesignedtooperatefullofliquidtherewasnoconcernwiththefoundationssupportingtheweightofthe80m3ofwaterthatwouldberequiredtofillthetower.Distilledwaterwithachloridecontentbelow50ppmwasusedtopreventchloridestresscorrosioncrackingofthenew317Lstainlesssteel.
5.ConclusionTherepairandrefurbishmentofanabsorbertowerwassuccessfullycompletedbyapplyingaduallayercarbonsteelandstainlesssteelweldoverlay.Thisrepairwascompletedduringaroutineplantshutdownusingfourweldingrobots
workingontwolevels24hoursaday,andwascompletedin12days(excludingPWHT).
Duetotheremotenessofthesiteandthecomplexityofthetaskanumberoflogisticalandtechnicalchallengesweresuccessfullyresolved;theseincludeddevelopingweldingspecifications,controllingweldqualityandmanagingheatstressontheweldingpersonnel.Acomprehensivetestingregimewasusedtoassesstheintegrityoftheweldoverlayandprovethevesselasfitforreturntoservice.Thevesselwasconsideredtohavebeenre-lifedfortheremainingeconomiclifeoftheasset,20years.
MartynCooper,LeadIntegrityEngineer,SantosLtdJohnFletcher,SeniorIntegrityEngineer,AMISIntegrityLtd
ProjectProfile:Re-LifingaCO2AbsorberTowerUsingWeldingRobots
FIGURE3–ShowingInternalandExternalScaffolding
1
K
Clearance for Welding Machines
Refridge Ducting, Power Cables
Tower Shell
Welding Robot
Entry & Exit
DECK 1
DECK 2Entry & Exit
Scaffold
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au36 37
Refurbishment of the Vessel One and All
SomethingcompletelydifferentfortheDepartmentforTransport,Energy&Infrastructure(DTEI)TheSouthAustralianMinisterforTransportisthe“shipowner”oftheSailTrainingVesselOneandAll.Thisshipisatopriggedschoonerwithaclipperbowandcounterstern–SeeFigure1.TheSTVOneandAllwasbuiltinAdelaideatNorthHavenbyW.G.Porter&SonPtyLtdandwaslaunchedin1985.ItisoperatedbythecompanySATallShipsInc,whichcrews,providestrainingandexcursionsailsforthegeneralpublic.
TheSTVOneandAllwasrecentlyextensivelyrefurbishedtomeetFederalandStateGovernmentrequirementsforvesselsurvey.ThisallowsthevesseltosailwithpayingpassengersaroundAustraliancoastalwaters.TheStateGovernmentprovidedthemajorleadtotheproject
providingfundingandsupportingSouthAustralianyouthwithavesselandtrainingprograms.TherefurbishmentprojectwasconceivedandexecutedbytheMechanicalServicesSectionofDTEI.
SowhyisthissodifferentforDTEI?-Welltheshipispredominatelywooden.
However,majorcomponentsofthevesselareindeedsteelinconstruction:
TheMainMastsThepaintedsteeltubemainmastswereremovedfromthehullforsurveyinspection.Astraditionrequired,goldcoinswereplacedundereachmastfootingduringconstruction.Thesewereretrievedandreinstalledatcompletionofthework(Figure2).
Themaincorrosionthatneededtobedealtwithwasfoundattheareaimmediatelybelowthedeckpenetration(Figure3).Themastpassesthroughthedecktothegalvanizedsteelbaseplatefloorandwassecuredatdecklevelbywoodenwedgesandarubberbootassembly.Overtheyearsseawaterhadseepedthroughthebootassemblyandcausedcorrosionattheareassupportedbythedeck.Theaffectedareaswerecheckedforthicknessandreplacedbycutandshutwelding.Afterweldtestingandprotectivetreatment,theywerepassedassatisfactoryforreplacementwitharevisedbootandsupportsealingdesign(Figures4and5).
Theprotectivetreatmentsystemchosenwasselectedtoprovidebesttopsidemarinepractice,combinedwithexperiencewiththistypeofinstallation,construction,anditsfinalendusage.Themastbaseissubjecttoshipboardgeneralwearandtear,saltandfreshwatersplash,soaprotectivetreatmentsystemwithaheavydutyepoxyprimer,mastic
midcoatandafinalcolourcoatofurethane,providesacoatingwithgoodmarineproperties.
Thetotalminimumdryfilmthicknessfortheappliedsystemwas325µm.
ThecolourofthefinishcoatwasAS2700–N14White.
Thesystemisexpectedtogivealifeofapproximately20years.
BulkheadsandFloorsTheprotectivetreatmentsystemusedherewasalmostentirelyoriginalfromlaunch.Thebulkheadswerepaintedsteelinconstructionandsatinthebilgealongwiththefloors.Thebulkheadssatinthewetbilgeareassotheycouldnotbemaintainedorinspectedeasilyandtheircoefficientofexpansionwasdifferentfromthewoodenhullandsuperstructurearoundthem.Theensuingcorrosioncausedbythecontactwiththebilgewasanissueasitcouldnotbetreatednorreviewedforsurvey.
Theexpansionissuecausedthehulltoopenasthevesselexperiencedchangesintemperatureandstressandthiswasalsohighlightedatthepenetrationsforcablesandpipes.ThesolutionwastoreplacethesteelwithacompositeconstructionofhighgrademarineplywithaKevlarandfiberglassskin(Figures6and7).Thesehaveconsiderablestrengthandaresympathetictoexpansionofthehullandwaterimmersion.
Thefloorsareofnavalbronzeformostofthevesselandwerestillinexcellentcondition.ThefloorsintheareaattherearofthevesselknownastheLazarette,werepaintedplainsteelandwerefoundtobebadlycorroded.ThissteelwasredesignedandgalvanizedtoAS/NZS4680:2006–Hotdipgalvanized(zinc)coatingsonfabricatedferrousarticlesto600g/m2-beforereplacement(Figure8).Theexpectedlifeofthisassemblygroupis20years.Thecentrecasefloorbasesupportwasalsorefurbishedandgalvanized.ThecasewallwasreplacedwithDuplexStainlessSteel2205(Figure9)andtheexpectedlifeofthisstructureis30years.
StandingRiggingShroudsTheshroudsarethemainstandingriggingwhichsupportsthemasts,sailboomsandyardsandhavebeenchangedatleasttwicesincelaunch.Theoriginalconstructionwasgalvanizedwireropeseizedintarcoatedcordagewhichistraditionalinconstruction,butdifficultandexpensivetomanufacture,maintainandsurvey.StainlessSteel316ropeandfittingswerechosenasareplacementasanextremelycosteffectivesolution.Muchtestingandre-riggingwascompletedpriortothevesselreceivingitscertificatesforsailing.Theexpectedlifeofthisriggingisatleast20years.
TheMechanicalServicesSectionhandlessomeinterestinganduniquecorrosionissues.TheSouthAustraliaGovernmentandthedepartment,throughitsprogramsofconstructionandmaintenanceensurethatahighstandardofinfrastructureintegrityisrealised.
By Brian Probert DepartmentforTransport,EnergyandInfrastructure
Figure1–OneandAll-FlotillaforKids.
Figure2–Newgalvanizedsteelbaseplatefloorwithgoldcoin.
Figure3-Mastcorrosionatdeckpenetration.
Figure4–Mastbeinglaunched.
Figure6–Compositeconstructionbulkhead.
Figure5-Newdeckentrypointforthemast.
Figure8–FloorsintheLazarette.
Figure9-Centrecasefloorbasesupport.
Figure7-Compositeconstructionbulkheads.
Duplex stainless 2205
SS316 securing bolt and nuts
Copper thru bolts with SS316 nuts
Tuffnol packer under knee to wooden support structure
Snees or knees
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au36 37
Refurbishment of the Vessel One and All
SomethingcompletelydifferentfortheDepartmentforTransport,Energy&Infrastructure(DTEI)TheSouthAustralianMinisterforTransportisthe“shipowner”oftheSailTrainingVesselOneandAll.Thisshipisatopriggedschoonerwithaclipperbowandcounterstern–SeeFigure1.TheSTVOneandAllwasbuiltinAdelaideatNorthHavenbyW.G.Porter&SonPtyLtdandwaslaunchedin1985.ItisoperatedbythecompanySATallShipsInc,whichcrews,providestrainingandexcursionsailsforthegeneralpublic.
TheSTVOneandAllwasrecentlyextensivelyrefurbishedtomeetFederalandStateGovernmentrequirementsforvesselsurvey.ThisallowsthevesseltosailwithpayingpassengersaroundAustraliancoastalwaters.TheStateGovernmentprovidedthemajorleadtotheproject
providingfundingandsupportingSouthAustralianyouthwithavesselandtrainingprograms.TherefurbishmentprojectwasconceivedandexecutedbytheMechanicalServicesSectionofDTEI.
SowhyisthissodifferentforDTEI?-Welltheshipispredominatelywooden.
However,majorcomponentsofthevesselareindeedsteelinconstruction:
TheMainMastsThepaintedsteeltubemainmastswereremovedfromthehullforsurveyinspection.Astraditionrequired,goldcoinswereplacedundereachmastfootingduringconstruction.Thesewereretrievedandreinstalledatcompletionofthework(Figure2).
Themaincorrosionthatneededtobedealtwithwasfoundattheareaimmediatelybelowthedeckpenetration(Figure3).Themastpassesthroughthedecktothegalvanizedsteelbaseplatefloorandwassecuredatdecklevelbywoodenwedgesandarubberbootassembly.Overtheyearsseawaterhadseepedthroughthebootassemblyandcausedcorrosionattheareassupportedbythedeck.Theaffectedareaswerecheckedforthicknessandreplacedbycutandshutwelding.Afterweldtestingandprotectivetreatment,theywerepassedassatisfactoryforreplacementwitharevisedbootandsupportsealingdesign(Figures4and5).
Theprotectivetreatmentsystemchosenwasselectedtoprovidebesttopsidemarinepractice,combinedwithexperiencewiththistypeofinstallation,construction,anditsfinalendusage.Themastbaseissubjecttoshipboardgeneralwearandtear,saltandfreshwatersplash,soaprotectivetreatmentsystemwithaheavydutyepoxyprimer,mastic
midcoatandafinalcolourcoatofurethane,providesacoatingwithgoodmarineproperties.
Thetotalminimumdryfilmthicknessfortheappliedsystemwas325µm.
ThecolourofthefinishcoatwasAS2700–N14White.
Thesystemisexpectedtogivealifeofapproximately20years.
BulkheadsandFloorsTheprotectivetreatmentsystemusedherewasalmostentirelyoriginalfromlaunch.Thebulkheadswerepaintedsteelinconstructionandsatinthebilgealongwiththefloors.Thebulkheadssatinthewetbilgeareassotheycouldnotbemaintainedorinspectedeasilyandtheircoefficientofexpansionwasdifferentfromthewoodenhullandsuperstructurearoundthem.Theensuingcorrosioncausedbythecontactwiththebilgewasanissueasitcouldnotbetreatednorreviewedforsurvey.
Theexpansionissuecausedthehulltoopenasthevesselexperiencedchangesintemperatureandstressandthiswasalsohighlightedatthepenetrationsforcablesandpipes.ThesolutionwastoreplacethesteelwithacompositeconstructionofhighgrademarineplywithaKevlarandfiberglassskin(Figures6and7).Thesehaveconsiderablestrengthandaresympathetictoexpansionofthehullandwaterimmersion.
Thefloorsareofnavalbronzeformostofthevesselandwerestillinexcellentcondition.ThefloorsintheareaattherearofthevesselknownastheLazarette,werepaintedplainsteelandwerefoundtobebadlycorroded.ThissteelwasredesignedandgalvanizedtoAS/NZS4680:2006–Hotdipgalvanized(zinc)coatingsonfabricatedferrousarticlesto600g/m2-beforereplacement(Figure8).Theexpectedlifeofthisassemblygroupis20years.Thecentrecasefloorbasesupportwasalsorefurbishedandgalvanized.ThecasewallwasreplacedwithDuplexStainlessSteel2205(Figure9)andtheexpectedlifeofthisstructureis30years.
StandingRiggingShroudsTheshroudsarethemainstandingriggingwhichsupportsthemasts,sailboomsandyardsandhavebeenchangedatleasttwicesincelaunch.Theoriginalconstructionwasgalvanizedwireropeseizedintarcoatedcordagewhichistraditionalinconstruction,butdifficultandexpensivetomanufacture,maintainandsurvey.StainlessSteel316ropeandfittingswerechosenasareplacementasanextremelycosteffectivesolution.Muchtestingandre-riggingwascompletedpriortothevesselreceivingitscertificatesforsailing.Theexpectedlifeofthisriggingisatleast20years.
TheMechanicalServicesSectionhandlessomeinterestinganduniquecorrosionissues.TheSouthAustraliaGovernmentandthedepartment,throughitsprogramsofconstructionandmaintenanceensurethatahighstandardofinfrastructureintegrityisrealised.
By Brian Probert DepartmentforTransport,EnergyandInfrastructure
Figure1–OneandAll-FlotillaforKids.
Figure2–Newgalvanizedsteelbaseplatefloorwithgoldcoin.
Figure3-Mastcorrosionatdeckpenetration.
Figure4–Mastbeinglaunched.
Figure6–Compositeconstructionbulkhead.
Figure5-Newdeckentrypointforthemast.
Figure8–FloorsintheLazarette.
Figure9-Centrecasefloorbasesupport.
Figure7-Compositeconstructionbulkheads.
Duplex stainless 2205
SS316 securing bolt and nuts
Copper thru bolts with SS316 nuts
Tuffnol packer under knee to wooden support structure
Snees or knees
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au38 39
University of New South Wales
IntroductionTheSchoolofMaterialsScienceandEngineeringatUNSWisaleadingAustralianacademicunitinresearchandteachinginmaterialsscienceandengineering.Theschooliscurrentlycomposedof45academicstaffofwhom33areresearch-onlystaff,132higherdegreeresearchstudents,andabout200undergraduatestudents.TheSchool’sresearchactivitiesareextensive,attractingexternalfundingofover$7minboth2008and2009,and$8min2010.ThefieldsofMaterialsEngineeringandMaterialsChemistryatUNSWwerescoredhighlyat4and5,respectively,intherecentnationalresearchevaluation(www.arc.gov.au/pdf/ERA_s4.pdf).
TheHighTemperatureGroupintheSchool,isinternationallyrecognisedforitsmixedgascorrosionresearch,andistheonlygroupinAustraliacarryingoutthisnationallysignificantwork.ResearchonhightemperaturealloycorrosionhasbeenconductedatUNSWformanydecades.Thegrouphasgraduatedover50PhDandMastersstudentsinthelast30years.Ithasenjoyedsuccessfulcollaborationswithinternationalresearchinstitutes,universitiesandindustries.e.g.OakRidgeNationalLab,USA;CIRIMAT-ENSIACET,France;HaynesInternational,USA;Max-Planck-InstituteforIronResearch,Germany;Karl-Winnacker-InstituteDECHEMA,Germany;StateKeyLabforCorrosionandProtection,InstituteofMetalResearch(IMR),China.
ResearchfacilitiesThecurrentHighTemperatureGrouplaboratoryhasexcellentfacilities,andiswidelyrecognised
foritscapabilities,particularlyinthefieldofcorrosionbymixedgases.Thesefacilitiesincludeanarc-meltingapparatus,3setsofthermogravimetricanalysers(TGA),and4hightemperaturetubularreactorsequippedwithmixedgascontrolsystems.Thesefacilitiesareusedforalloymaking,processingandreactingwithcontrolledgasmixturesineitherisothermalorcyclicconditions.TheSchoolprovidesstrongtechnicalsupportinalloymelting,samplepreparationandmetallographicanalysis.Thegroup’sresearchisfurtherenhancedbyitsclosecollaborationwiththeMarkWainwrightAnalyticalCentreatUNSW,whichhousesXRD,SEM,TEM,EPMAandFIBfacilities.
CorrosionresearchersCurrentlytherearetworesearchersinthegroup,ProfessorDavidYoungandDrJianqiangZhang.Groupleader,EmeritusProfessorYoung,isaninternationallyrecognisedresearcherinthefieldofhightemperaturecorrosion.DrJianqiangZhanghasbeenworkingintheGrouponhightemperaturematerialscorrosionsincehereturnedfromMax-Planck-InstituteforIronResearchin2003.Thetwohavecollaboratedcloselysincethen,jointlysupervisingseveralPhDstudents,winningresearchfunding,andpublishingextensively.
ResearchProjectsTheprincipalcurrentresearchprojectsare1.Metaldusting–mechanismsandprevention,and2.ControllingcorrosionofsteelbyCO2-richgasesathightemperature.BothareARCDiscoveryprojects:thefirstoncarboncorrosionandthesecondrelatedtooxidationandcarburizationingasstreamsofCO2+H2O.
Metal dusting project Metaldustingisacorrosionphenomenonwhichdegradesiron,lowandhighalloysteelsandNi-orCo-basedalloysbydisintegrationofbulkmetalsandalloysintometalparticlesdispersedinacokemass(seeFigure1).Itoccursinstronglycarburisinggasatmospheres(carbonactivityac>1),atelevatedtemperatures(400-800°C).Metaldustinghascausedsubstantialequipmentdamageinsomeimportantindustrialprocesses,forexamplesteamreforming,directironorereductionandsomepetrochemicalprocesses.Theaimofthisresearchistodeterminetheeffectsofgasandalloycompositionsandreactiontemperatureondustingreactionrate,graphitenucleationandgrowth,andformationofmetalnano-particles.Thisinvestigationisyieldingadetailedunderstandingofmetaldustingmechanismsandtherebyleadingtoanabilitytocontroltheprocess:byalteringreactionconditions;properlyalloyingtoachievemoreprotectivesurfaceoxidescaleproperties;orsuppressinggraphitenucleationbycopperalloying.
CO2-H2O gas corrosion ThisprojectaddressestheimportantproblemofhandlinghotCO2-richgascorrosionincoalcombustionforpowergeneration.AgrowingdifficultyforAustraliaistheneedtoreduceCO2emissionswhilstmaintainingtheeconomicadvantagesofcoalfiredpowerstations.TechnologiesforcapturingCO2fromthesestationsarebeingdeveloped,butinevitablyinvolvetheneedtohandlehotCO2-richgases.Thesearesurprisinglycorrosivetothematerialsofwhichpowerstationsareconstructed,inawaywhichisnotfullyunderstood.
Thisprojectaimstoachievethisunderstanding,andtoprovidethebasisforfuturealloydesign.
ConsultingInadditiontoitsresearchactivities,thegroupalsoprovidesconsultingtolocalindustriesandcommunitiesthroughUNSWGlobal.Allthisworkhasbeenaimedatidentifyingreasonsforcorrosionfailures,andrecommendingwaysofavoidingtheminthefuture.Examplesincludeadviceoncorrosionofmetalsrangingfrommurder
weaponstosheetmetalroofing,butmainlyinvolvesassistancetoprocessindustrieswithhightemperaturematerialsproblems.
ContactDetailsFormoreinformationonresearchopportunities,collaboration,andconsultingwiththeHighTemperatureGroupintheSchoolofMaterialsScienceandEngineering,UNSW,[email protected],[email protected].
University Profile
School of Materials Science and Engineering High Temperature research group
Figure1.(a)TransmissionElectronMicroscopycross-sectionand(b)surfacecokemorphologyofdustedironinCO-H2-H2Ogasat680°C.The“dust”isFe3C,seenasdarkparticlesin(a)andasbrightpartriclesatthetipsofcarbonnanofilamentsin(b).
ProfessorYoung DrZhang
Coke
1µm
Fe3C
ACA Newcastle Branch YCP Award – AU$3500 to attend 18th ICCIfyouarea‘youngcorrosionprofessional’eitherworkingorstudyinginacorrosionrelatedfieldwithinAustraliaorNewZealandandhavealwayswantedtoattendtheannualACAconferencebutneverhadtheopportunity,thismaybeyourchance.
TheACANewcastleBranchissponsoringaYoungCorrosionProfessionalAwardtosubsidisetheattendanceattheannualACAconference(thisyearthe18thInternationalCorrosionCongressinPerth)toavalueofuptoAU$3,500.
Theawardisopentoundergraduatestudents,post-graduatestudentsandthoseworkinginthecorrosionindustryfromacrosstheACAmembershipthatmeetthecriteriaofyoungprofessionalstatus(undertheageof35)intheACA.
Applicantsarerequiredtopresentashorttalk(15-20minutes)totheACANewcastleBranchmembersthataddressesthequestion“WhyIshouldbesponsoredtoattendtheannualACAconference”.Itcouldbebasedon(butisnotlimitedto)aresearchorfieldproject,itemofparticularlocal
orhistoricalrelevanceorindustrialcasestudy.
TheNewcastleBranchwillcovertravelandaccommodationcostsforthoseapplicantsinvitedtopresenttotheBranchduringMay-August2011.
Applicationsclosesoononthe30thApril2011–todownloadanapplicationform,pleaserefertowww.corrosion.com.au/contents/11019/
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au38 39
University of New South Wales
IntroductionTheSchoolofMaterialsScienceandEngineeringatUNSWisaleadingAustralianacademicunitinresearchandteachinginmaterialsscienceandengineering.Theschooliscurrentlycomposedof45academicstaffofwhom33areresearch-onlystaff,132higherdegreeresearchstudents,andabout200undergraduatestudents.TheSchool’sresearchactivitiesareextensive,attractingexternalfundingofover$7minboth2008and2009,and$8min2010.ThefieldsofMaterialsEngineeringandMaterialsChemistryatUNSWwerescoredhighlyat4and5,respectively,intherecentnationalresearchevaluation(www.arc.gov.au/pdf/ERA_s4.pdf).
TheHighTemperatureGroupintheSchool,isinternationallyrecognisedforitsmixedgascorrosionresearch,andistheonlygroupinAustraliacarryingoutthisnationallysignificantwork.ResearchonhightemperaturealloycorrosionhasbeenconductedatUNSWformanydecades.Thegrouphasgraduatedover50PhDandMastersstudentsinthelast30years.Ithasenjoyedsuccessfulcollaborationswithinternationalresearchinstitutes,universitiesandindustries.e.g.OakRidgeNationalLab,USA;CIRIMAT-ENSIACET,France;HaynesInternational,USA;Max-Planck-InstituteforIronResearch,Germany;Karl-Winnacker-InstituteDECHEMA,Germany;StateKeyLabforCorrosionandProtection,InstituteofMetalResearch(IMR),China.
ResearchfacilitiesThecurrentHighTemperatureGrouplaboratoryhasexcellentfacilities,andiswidelyrecognised
foritscapabilities,particularlyinthefieldofcorrosionbymixedgases.Thesefacilitiesincludeanarc-meltingapparatus,3setsofthermogravimetricanalysers(TGA),and4hightemperaturetubularreactorsequippedwithmixedgascontrolsystems.Thesefacilitiesareusedforalloymaking,processingandreactingwithcontrolledgasmixturesineitherisothermalorcyclicconditions.TheSchoolprovidesstrongtechnicalsupportinalloymelting,samplepreparationandmetallographicanalysis.Thegroup’sresearchisfurtherenhancedbyitsclosecollaborationwiththeMarkWainwrightAnalyticalCentreatUNSW,whichhousesXRD,SEM,TEM,EPMAandFIBfacilities.
CorrosionresearchersCurrentlytherearetworesearchersinthegroup,ProfessorDavidYoungandDrJianqiangZhang.Groupleader,EmeritusProfessorYoung,isaninternationallyrecognisedresearcherinthefieldofhightemperaturecorrosion.DrJianqiangZhanghasbeenworkingintheGrouponhightemperaturematerialscorrosionsincehereturnedfromMax-Planck-InstituteforIronResearchin2003.Thetwohavecollaboratedcloselysincethen,jointlysupervisingseveralPhDstudents,winningresearchfunding,andpublishingextensively.
ResearchProjectsTheprincipalcurrentresearchprojectsare1.Metaldusting–mechanismsandprevention,and2.ControllingcorrosionofsteelbyCO2-richgasesathightemperature.BothareARCDiscoveryprojects:thefirstoncarboncorrosionandthesecondrelatedtooxidationandcarburizationingasstreamsofCO2+H2O.
Metal dusting project Metaldustingisacorrosionphenomenonwhichdegradesiron,lowandhighalloysteelsandNi-orCo-basedalloysbydisintegrationofbulkmetalsandalloysintometalparticlesdispersedinacokemass(seeFigure1).Itoccursinstronglycarburisinggasatmospheres(carbonactivityac>1),atelevatedtemperatures(400-800°C).Metaldustinghascausedsubstantialequipmentdamageinsomeimportantindustrialprocesses,forexamplesteamreforming,directironorereductionandsomepetrochemicalprocesses.Theaimofthisresearchistodeterminetheeffectsofgasandalloycompositionsandreactiontemperatureondustingreactionrate,graphitenucleationandgrowth,andformationofmetalnano-particles.Thisinvestigationisyieldingadetailedunderstandingofmetaldustingmechanismsandtherebyleadingtoanabilitytocontroltheprocess:byalteringreactionconditions;properlyalloyingtoachievemoreprotectivesurfaceoxidescaleproperties;orsuppressinggraphitenucleationbycopperalloying.
CO2-H2O gas corrosion ThisprojectaddressestheimportantproblemofhandlinghotCO2-richgascorrosionincoalcombustionforpowergeneration.AgrowingdifficultyforAustraliaistheneedtoreduceCO2emissionswhilstmaintainingtheeconomicadvantagesofcoalfiredpowerstations.TechnologiesforcapturingCO2fromthesestationsarebeingdeveloped,butinevitablyinvolvetheneedtohandlehotCO2-richgases.Thesearesurprisinglycorrosivetothematerialsofwhichpowerstationsareconstructed,inawaywhichisnotfullyunderstood.
Thisprojectaimstoachievethisunderstanding,andtoprovidethebasisforfuturealloydesign.
ConsultingInadditiontoitsresearchactivities,thegroupalsoprovidesconsultingtolocalindustriesandcommunitiesthroughUNSWGlobal.Allthisworkhasbeenaimedatidentifyingreasonsforcorrosionfailures,andrecommendingwaysofavoidingtheminthefuture.Examplesincludeadviceoncorrosionofmetalsrangingfrommurder
weaponstosheetmetalroofing,butmainlyinvolvesassistancetoprocessindustrieswithhightemperaturematerialsproblems.
ContactDetailsFormoreinformationonresearchopportunities,collaboration,andconsultingwiththeHighTemperatureGroupintheSchoolofMaterialsScienceandEngineering,UNSW,[email protected],[email protected].
University Profile
School of Materials Science and Engineering High Temperature research group
Figure1.(a)TransmissionElectronMicroscopycross-sectionand(b)surfacecokemorphologyofdustedironinCO-H2-H2Ogasat680°C.The“dust”isFe3C,seenasdarkparticlesin(a)andasbrightpartriclesatthetipsofcarbonnanofilamentsin(b).
ProfessorYoung DrZhang
Coke
1µm
Fe3C
ACA Newcastle Branch YCP Award – AU$3500 to attend 18th ICCIfyouarea‘youngcorrosionprofessional’eitherworkingorstudyinginacorrosionrelatedfieldwithinAustraliaorNewZealandandhavealwayswantedtoattendtheannualACAconferencebutneverhadtheopportunity,thismaybeyourchance.
TheACANewcastleBranchissponsoringaYoungCorrosionProfessionalAwardtosubsidisetheattendanceattheannualACAconference(thisyearthe18thInternationalCorrosionCongressinPerth)toavalueofuptoAU$3,500.
Theawardisopentoundergraduatestudents,post-graduatestudentsandthoseworkinginthecorrosionindustryfromacrosstheACAmembershipthatmeetthecriteriaofyoungprofessionalstatus(undertheageof35)intheACA.
Applicantsarerequiredtopresentashorttalk(15-20minutes)totheACANewcastleBranchmembersthataddressesthequestion“WhyIshouldbesponsoredtoattendtheannualACAconference”.Itcouldbebasedon(butisnotlimitedto)aresearchorfieldproject,itemofparticularlocal
orhistoricalrelevanceorindustrialcasestudy.
TheNewcastleBranchwillcovertravelandaccommodationcostsforthoseapplicantsinvitedtopresenttotheBranchduringMay-August2011.
Applicationsclosesoononthe30thApril2011–todownloadanapplicationform,pleaserefertowww.corrosion.com.au/contents/11019/
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au58 59
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ZINGA Film Galvanizing System.
D R MAYInspections
Geelong Office: 193 Station Street,Corio, Victoria 3214 AustraliaPostal Address: P.O. Box 1080,Corio, Victoria 3214 AustraliaTel: +61 3 5275 3339Fax: +61 3 5275 0585Mob: 0412 520 699Email: [email protected]
David May
Welding SupervisionWelding InspectionNDT SpecialistCoating InspectionInservice Inspection
Queensland (Head Office)Phone: +61 7 5476 9788 Fax: +61 7 5476 8268MelbournePhone: +61 3 9755 3770Email: [email protected] ABN: 93 821 370 828
Cathodic Diecasting
www.cathodicdiecasting.com.au
Manufacturing anodes since 1984
Cathodic Diecating - small advert 3-2-10.indd 1 3/3/10 10:51:21 AMAPPLIED MAGNESIUM PTY LIMITEDManufacturers and suppliers of Extruded Galvanic Magnesium Anodes
• Round section from 17 mm to 89 mm diameter• Rectangular ribbon section in 305 metre coils• All anodes have continuous length core wire• High potential (Galvomag) and low potential (Galvorod)Mail PO Box 520 Winston Hills NSW 2153Telephone 02 9838 8544Facsimile 02 9838 7690Email [email protected]
(formerly )
DE NORA
CATHODIC PROTECTION
Agent for:LIDA® – Mixed Metal Oxide Anodes• Strip, Rod, Tubular, Ribbon, Disk and Wire
• Sacrificial Anodes• Silicon Iron Anodes• Transformer Rectifiers• Reference Electrodes
–Zinc, Aluminium and Magnesium• Calcined Petroleum Backfill• Surge Protection, Insulation–Copper, Zinc and Silver
Prevent corrosion on your:-PIPELINES, TANKS, BRIDGES, WHARVES, OFFSHORE PLATFORMS
Tel: +61 (03) 94672520 or 0413 201562
Committed to Professional Service, Competitive Pricing and Customer SatisfactionEmail: [email protected] • www.pipecorr.com.au
RESPONSIVE SERVICEEXPERTISEINDEPENDENCE
Corrosion and Coating Failure InvestigationsCoating Specification and ReviewFitness for Purpose and Remnant Life AssessmentExpert Witness and Litigation SupportCorrosion, Materials & Mechanical EngineersApplied Scientists, Metallurgists, Coating InspectorsNDT Technicians
Australia Wide Phone: +61 7 3718 0300
Gareth van Loggerenberg
t: +61 (0) 8 9256 4499f: +61 (0) 8 9256 4599m: +61 (0) 408 931 072e: [email protected] w: www.telpro.com.au
Front
Back
Unit 2, 26 Baile RoadCanning ValeWestern Australia6155
CATHODIC PROTECTION Applications include:
- Oil and gas pipelines - Water pipelines - Above and below ground storage tanks - Reinforced steel in concrete - Ships’ hulls - Jetties and wharves - Condenser water boxes in power stations
Some Products Offered:
- Tubular Anodes - Mesh Anodes - Rod Anodes - Ribbon Anodes - Wire Anodes - Plate Anodes - Disc Anodes - Canistered Anodes
TITANUM ELECTRODE PRODUCTS
Vol 36 No 2 April 2011 Corrosion & Materials www.corrosion.com.au58 59
David PocockMANAGER
22 Irvine StreetBayswater WA 6053T: 08 9721 2265F: 08 9271 2235M: 0409 112 010E: [email protected]
Industrial Chimney ServicesWindshield / Flue / Lining
CrownDams / Bridges / JettiesSilos / Towers / Buildings
Concrete SurveysRemedial RepairsProtective Coating
Industrial Rope Access & Suspended Platforms
Confined Space Entry & Standby Rescue
Height Safety System
M: 0413 806 [email protected]
www.atlasaccess.com.auP: 61-2-9700 0812F: 61-2-9700 0813
9/41 – 43 GREEN STBOTANY NSW 2019
IRATA - LEEA - AINDT - NATA - ACA - CICIND
Russell Fraser Sales Pty LtdSuPPLying inSPection &
teSting equiPment
• Ultrasonic Thickness Gauges• Holiday Detectors• Coating Thickness Gauges• Pit Gauges• Borescopes & Magnifiers• Surface Replication products
SYDNEY
t: 02 9545 4433
F: 02 9545 4218
www.rfsales.com.au
SICK OF RUST EATING YOUR ASSETS?THEN USE RUST CONQUEROR .........................TO BEAT RUST!WITH A 20+ YEAR HISTORY, THIS PROVEN, COST EFFECTIVE, ORGANIC BASED, SIMPLE & SAFE TO USE PRODUCT, REALLY WORKS!
Available Australia wide! www.xtrollglobal.com.au
Email: [email protected] Phone 07 3865 1077
Xtroll offers a wide range of excellent products that work.
Tel: 02 4952 6593 Int: (+612) Mob: 0421 745 0598 Bambara Close, Lambton, NSW 2299, Australia
Email: [email protected]
N I C H O L A S C O R R O S I O N P T Y LT D
Materials and CorrosionConsultancy to the Water Industry
Principal Consultant
Dr David NicholasPh.D, B.Sc (Hons), FIE Aust, CP Eng
David DawsonNational Sales/Operations Manager
DeHumidification Technologies PTY LTD
Mobile: 0450 008 259
Fax: (02) 8525 8850
www.rentdh.com
113 Bonds Road Riverwood NSW 2210 Australia
Specialist Infrastructure and durability consultants
Ph: 1300 763 319 | www.bcrc.com.au
1300 723 924 www.industrialpainter.com.au
MR JUSTIN RIGBYBusiness Development Manager
Factory 5, 227 Wells RdChelsea Heights 3196
[email protected] www.industrialpainter.com.au1300 723 924 Fax 9773 3522 0417 338 773
•• •
• Anti Graffi ti • Sign Writing • Line Marking • Pressure Cleaning • • PCCP/NACE Accredited
• Protective Coatings • All Related Services • Building Maintenance •
A.B.N. 82 101 032 788
PREMIUM PROTECTION
Rhino Linings Australasia Pty Ltd 501-505 Olsen Avenue, Ph: +61 7 5585 7000 Molendinar Qld 4214 Fax: +61 7 5539 6399
Providing proven, tested & superior spray applied elastomeric protective coating
solutions against Impact, Abrasion, Corrosion, Chemical Attack & Containment issues.
[email protected] www.rhinolinings.com.au
Specialist Manufacturer of DIMET Aluminium & Zinc Anodes (CathodicProtection.) ICCP design and commissioning are also available byNACE certified CP Engineers.
MASTERCOTE PTFE Coated, and other special fasteners.
ZINGA Film Galvanizing System.
D R MAYInspections
Geelong Office: 193 Station Street,Corio, Victoria 3214 AustraliaPostal Address: P.O. Box 1080,Corio, Victoria 3214 AustraliaTel: +61 3 5275 3339Fax: +61 3 5275 0585Mob: 0412 520 699Email: [email protected]
David May
Welding SupervisionWelding InspectionNDT SpecialistCoating InspectionInservice Inspection
Queensland (Head Office)Phone: +61 7 5476 9788 Fax: +61 7 5476 8268MelbournePhone: +61 3 9755 3770Email: [email protected] ABN: 93 821 370 828
Cathodic Diecasting
www.cathodicdiecasting.com.au
Manufacturing anodes since 1984
Cathodic Diecating - small advert 3-2-10.indd 1 3/3/10 10:51:21 AMAPPLIED MAGNESIUM PTY LIMITEDManufacturers and suppliers of Extruded Galvanic Magnesium Anodes
• Round section from 17 mm to 89 mm diameter• Rectangular ribbon section in 305 metre coils• All anodes have continuous length core wire• High potential (Galvomag) and low potential (Galvorod)Mail PO Box 520 Winston Hills NSW 2153Telephone 02 9838 8544Facsimile 02 9838 7690Email [email protected]
(formerly )
DE NORA
CATHODIC PROTECTION
Agent for:LIDA® – Mixed Metal Oxide Anodes• Strip, Rod, Tubular, Ribbon, Disk and Wire
• Sacrificial Anodes• Silicon Iron Anodes• Transformer Rectifiers• Reference Electrodes
–Zinc, Aluminium and Magnesium• Calcined Petroleum Backfill• Surge Protection, Insulation–Copper, Zinc and Silver
Prevent corrosion on your:-PIPELINES, TANKS, BRIDGES, WHARVES, OFFSHORE PLATFORMS
Tel: +61 (03) 94672520 or 0413 201562
Committed to Professional Service, Competitive Pricing and Customer SatisfactionEmail: [email protected] • www.pipecorr.com.au
RESPONSIVE SERVICEEXPERTISEINDEPENDENCE
Corrosion and Coating Failure InvestigationsCoating Specification and ReviewFitness for Purpose and Remnant Life AssessmentExpert Witness and Litigation SupportCorrosion, Materials & Mechanical EngineersApplied Scientists, Metallurgists, Coating InspectorsNDT Technicians
Australia Wide Phone: +61 7 3718 0300
Gareth van Loggerenberg
t: +61 (0) 8 9256 4499f: +61 (0) 8 9256 4599m: +61 (0) 408 931 072e: [email protected] w: www.telpro.com.au
Front
Back
Unit 2, 26 Baile RoadCanning ValeWestern Australia6155
CATHODIC PROTECTION Applications include:
- Oil and gas pipelines - Water pipelines - Above and below ground storage tanks - Reinforced steel in concrete - Ships’ hulls - Jetties and wharves - Condenser water boxes in power stations
Some Products Offered:
- Tubular Anodes - Mesh Anodes - Rod Anodes - Ribbon Anodes - Wire Anodes - Plate Anodes - Disc Anodes - Canistered Anodes
TITANUM ELECTRODE PRODUCTS
We’ve changed our name to ORONTIDE Industrial Services.
For years, we’ve offered our clients in the Oil & Gas, Naval Defence, Marine and Commercial Industries the highest level of
service for UHP Water Jetting, Abrasive Blasting and Surface Protection. As part of ORONTIDE we can now offer you an even
wider range of preservation and integrity maintenance services, including engineering, machining, fabrication and fitting services.
Delivering Integrityorontide.com.au
ORON
318887