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Vol 39 No 5, October 2014 ISSN 1326 -1932

Inside this Issue: Project Profile: Olympus helps keep Ford on track for V8 Supercar success Project Profile: Keeping steep task on track University Profile: Queensland University of Technology Technical Note: Preventing Coastal Corrosion (Tea Staining) Professional Practice Paper: Corrosion in Renewable Energy Power Production

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Proudly presented by:

Adelaide Convention Centre • Adelaide, South Australia, Australia • 15 - 18 November 2015

Corrosion and Prevention is the annual conference of the Australasian Corrosion Association, it’s a 4 day gathering of world experts on corrosion mitigation. This will be a premium networking event as well as a source for the latest information concerning corrosion mitigation.

Entitled Corrosion & Prevention 2015, the conference will feature a program of keynote speakers and presentations under a range of industry streams and is expected to attract approximately 450 - 550 delegates.

In 2015 we invite you to the vibrant city of Adelaide, which is internationally regarded as a wine and food mecca, add in a temperate Mediterranean climate and Adelaide is the ideal place for mixing business with pleasure. All in all, this promises to be an enlightening, exciting and highly enjoyable conference.

Call for Papers Submissions are now welcome on all aspects of corrosion and corrosion control for Corrosion & Prevention 2015. Papers are subject to peer review and if accepted will be published in the Conference Proceedings. Critical dates for acceptance of abstracts and papers are: Close of Abstracts: 13 March 2015 Acceptance of Abstracts: 3 April 2015 Receipt of Papers: 5 June 2015

Submit an Abstract Please refer to www.acaconference.com.au to submit a 200-300 word summary of your proposed paper by the close of abstracts (13 March 2015). Waldron Smith Management, a professional conference management company based in Melbourne will be managing the abstract and paper submission process.

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Guide to Submission Papers submitted to the Corrosion & Prevention 2015 Conference must be unpublished works. It is the responsibility of the author to obtain necessary clearance/permission from their organisation. Copyright of the paper is assigned to the ACA. Abstracts should include the names of all authors, an appropriate title and a brief summary. All authors whose papers are accepted are required to attend the conference to present.

The Destination Nestled between the beautiful Adelaide Hills and the long white beaches of the Gulf of St Vincent, Adelaide is a picturesque city featuring wide boulevards surrounded by parklands around the city centre. Its position on the banks of the Torrens River amongst superb gardens also gives the city a relaxed atmosphere and a lifestyle that is the envy of all who visit.

Adelaide is internationally regarded as a wine and food ‘destination’ - offering locally produced world-class wines matched with fresh local produce; resulting in amazing dining experiences that are unforgettable.

South Australia is made up of spectacular regions, all of which offer a unique and exhilarating experience waiting to be discovered. Amongst the many reasons people visit South Australia are the spectacular scenery, fishing, fauna and national parks - wine and food are often at the top of the list. South Australia’s wineries are legendary - the Barossa Valley, McLaren Vale, Clare Valley, Coonawarra and Adelaide Hills are sought out by many visitors.

www.southaustralia.com

Proudly presented by:

Technical Streams

Conference Committee

Corrosion and Prevention 2015 invites technical papers on all subjects related to corrosion. The conference will bring together leading researchers and industry practitioners who combat corrosion on a daily basis. Diverse technical streams will showcase the latest developments in corrosion, ranging from fundamental corrosion science to hands-on application. Submissions may include research papers, posters, review papers and case studies related to the industry sectors and technical streams listed below.

Conference Convenor Alan Bird

• Advances in Sensing & Monitoring • Asset & Integrity Management • Cathodic/Anodic Protection • Concrete Corrosion & Repair • Corrosion Mechanisms, Modelling and Prediction • Materials Selection & Design • Marine Corrosion • Mining • Non-Destructive Evaluation (NDE) • Novel Materials and Their Application • Oil & Gas • Power & Energy • Protective Coatings • Water & Wastewater

Industry Sectors Attracting approximately 450–550 delegates, this conference will have material of value to: Consultants, Asset Owners, Contractors, Suppliers and Academics within the following industries • Buildings & Construction • Consulting Engineering and Technical Services • Cultural & Historical Materials Preservation • Defence, Aviation, Maritime • Education & Research • Marine Transport & Infrastructure • Mining & Resources • Oil & Gas • Power & Energy • Water & Wastewater

Technical Chair Erwin Gamboa Conference Committee • Mohammad Ali • Brian Hickinbottom • Peter Hosford • Raman Singh • Dean Wall

Sponsorship and Exhibition Corrosion & Prevention 2015 offers strong branding and exposure in a focussed and professional environment. As with every Corrosion & Prevention Conference, the exhibition will be an integral part of the activities. It provides an opportunity for organisations to come face to face with the delegates; providing a marketplace to increase your organisation’s visibility and to showcase and demonstrate your products and services.

For further information, please contact the Australasian Corrosion Association on +61 (0)3 9890 4833 or email conference@corrosion.com.au

Your Hosts The Australasian Corrosion Association Incorporated (ACA) is a not-for-profit, industry association, established in 1955 to service the needs of Australian and New Zealand companies, organisations and individuals involved in the fight against corrosion.

The vision of the ACA is to be leaders throughout Australasia in disseminating knowledge to enable best practice in corrosion management, thereby ensuring the environment is protected, public safety enhanced and economies improved.

The Australasian Corrosion Association Inc PO Box 112 Kerrimuir, Victoria, Australia, 3129 Ph: +61 (0)3 9890 4833, Fax: +61 (0)3 9890 7866 Email: conference@corrosion.com.au Website: www.acaconference.com.au

October 2014 www.corrosion.com.au p.3

CONTENTS

Corrosion & Materials Corrosion & Materials is the official publication of The Australasian Corrosion Association Inc (ACA). Published bi-monthly, Corrosion & Materials has a distribution of 2,500 to ACA members and other interested parties. Each issue features a range of news, information, articles, profiles and peer reviewed technical papers. Corrosion & Materials publishes original, previously unpublished papers under the categories ‘Research’ and ‘Professional Practice’. All papers are peer reviewed by at least two anonymous referees prior to publication and qualify for inclusion in the list which an author and his or her institution can submit for the ARC ‘Excellence in Research Australia’ list of recognised research publications. Please refer to the Author Guidelines at www.corrosion.com.au before you submit a paper to Brendan Pejkovic at bpejkovic@corrosion.com.au with a copy to bruce.hinton@monash.edu ACA also welcomes short articles (technical notes, practical pieces, project profiles, etc.) between 500 – 1,500 words with high resolution photos for editorial review. Please refer to the Article Guidelines at www.corrosion.com.au before you submit a short article to Brendan Pejkovic at bpejkovic@corrosion.com.au The Australasian Corrosion Association Inc The Australasian Corrosion Association Inc (ACA) is a non-profit membership based organisation akin to a ‘learned society’. The ACA was established in 1955 to service the needs of Australian and New Zealand companies, organisations and individuals involved in the fight against corrosion. It is dedicated to ensuring all aspects of corrosion are responsibly managed, protecting the environment and ensuring public safety. ACA members are drawn from a wide cross section of industries united by their common interest – to reduce the impact of corrosion in Australasia.

Front Cover Photo:

Two FPR V8 Supercars on the Mount Panorama circuit.

Photo courtesy Olympus.

Vision Statement Leaders throughout Australasia in disseminating knowledge to enable best practice in corrosion management, thereby ensuring the environment is protected, public safety enhanced and economies improved.

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ISSN 1326 -1932 Published by The Australasian Corrosion Association Inc. ABN: 66 214 557 257 Editor Ian MacLeod – Western Australian Museum ian.macleod@museum.wa.gov.au Associate Editors Research: Bruce Hinton – Monash University bruce.hinton@monash.edu Professional Practice: Willie Mandeno – Opus International Consultants willie.mandeno@opus.co.nz News: Tracey Winn – The Australasian Corrosion Association Inc, twinn@corrosion.com.au Reviewers Andy Atrens – University of Queensland Nick Birbilis – Monash University Frederic Blin – AECOM Lex Edmond Harvey Flitt – Queensland University of Technology Maria Forsyth – Deakin University Rob Francis Warren Green – Vinsi Partners Graeme Kelly – Corrotec Services Grant McAdam – Defence Science & Technology Organisation David Nicholas – Nicholas Corrosion Graham Sussex – Sussex Material Solutions Tony Trueman – Defence Science & Technology Organisation Geoffrey Will – Queensland University of Technology David Young – University of New South Wales

Advertising Sales Tracey Winn – The Australasian Corrosion Association Inc, twinn@corrosion.com.au Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 Subscriptions Print Version: ISSN 1326-1932 Subscription rates: Within Australia: AU$72.60, incl GST Outside Australia: AU$77, excl GST posted airmail The 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.

The ACA is a founder member of the World Corrosion Organization

ACA Branches & Divisions Auckland Division: Grant Chamberlain

64 21 245 9038

Newcastle: Nathan Spencer

61 439 511 836

New South Wales: Jim Galanos

61 2 9763 5611

Queensland: Cathy Sterling

61 7 3821 0202

South Australia: Dennis Richards

61 0 419 860 514

Tasmania: Grant Weatherburn

61 0 418 120 550

Taranaki Division: Ron Berry

64 27 671 2278

Victoria: John Tanti

61 3 9885 5305

Wellington Division: Monika Ko

64 4 978 6630

Western Australia: Phil Schmidli

61 4 5148 0090

The Australasian Corrosion Association Inc PO Box 112, Kerrimuir, Victoria 3129, Australia Ph: 61 3 9890 4833, Fax: 61 3 9890 7866 E-mail: aca@corrosion.com.au | Internet: www.corrosion.com.au

ACA Technical Groups Cathodic Protection: Bruce Ackland

61 3 9890 3096

Coatings: Matthew O'Keeffe

61 437 935 969

ACA Operations Board President: Andrew Hargrave

Concrete Structures & Buildings: Frédéric Blin

61 3 9653 8406

Mining Industry: Ted Riding

61 3 9314 0722

Executive Officer: Wesley Fawaz

Petroleum & Chemical Processing Industry: Fikry Barouky

61 402 684 165

Operations Chairman: Paul Vince

Research: TBA

Senior Vice President: Mohammad Ali

Water & Water Teatment: Matthew Dafter

Junior Vice President: John Duncan

Young Corrosion Group: Dean Ferguson

Immediate Past President: Allan Sterling

* all the above information is accurate at the time of this issue going to press.

Directors: Kingsley Brown Graham Carlisle Matthew Dafter Peter Dove John Duncan Fred Salome Dean Wall

61 419 816 783 61 0 425 784 932

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Vol 39 No 5, October 2014

6 | Chairman’s Message 8 | Executive Officer’s Message 9 | ACA Training Calendar 2015 10 | News 18 | ACA Certification Program 21 | Branch & YCG News 22 | ACA Standards Update 24 | Technical Event Review

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Corrosion in the Oil & Gas Industries – Brisbane

27 | Technical Event Review

Corrosion in the Oil & Gas Industries – New Plymouth, New Zealand

30 | Project Profile:

Olympus helps keep Ford on track for V8 Supercar success

32 | Coatings Group Member Profile 34 | New Product Showcase

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35 | University Profile:

Queensland University of Technology

36 | Technical Note:

Preventing Coastal Corrosion (Tea Staining)

40 | Project Profile:

Keeping steep task on track

42 | Professional Practice Paper:

Corrosion in Renewable Energy Power Production

46 | Suppliers and Consultants

40 October 2014 www.corrosion.com.au p.5

CHAIRMAN’S MESSAGE

with the South Australia Branch and held a number of positions including Branch President before being elected to the Board as Finance Director in 2008. I have been the Chairman for the last three years. It has been an interesting time.

I have just attended the 2014 Corrosion and Prevention Conference in Darwin.

It was wonderfully organised by the ACA staff and the Conference Committee. My congratulations to all involved. During the conference I attended a number of meetings including the ACA Council Meeting and the ACA General Members Meeting and it gave me a chance to reflect on the activities of the ACA. Paul Vince Chairman

Greetings My name is Paul Vince and I am the Chairman of the ACA. This is the first time I have written this column so allow me to introduce myself. I studied metallurgy at the University of South Australia and following graduation, joined the Department of Defence in Canberra. After having a taste of project management I escaped and joined the Australian Submarine Corporation (ASC). I worked there for nine years as Senior Materials Engineer before moving to SA Water where I am the Principal Materials Engineer.

I joined the ACA in 1998 and became more involved after the 2002 Conference in Adelaide. I got involved

We are a very diverse organisation.

Our members come from many different industries and professions.

As such, our activities need to be very diverse to cater for all the needs of our members. This year we have held 80 events and nearly 3,000 people have attended these events. Topics have ranged from coatings and corrosion to cathodic protection and concrete.

But the common theme has been asset protection and long term durability.

At the ACA Council Meeting I reported to the Council about the steps that the ACA is taking to serve our members and remain relevant to industry. We are a growing and active Association. During the past year we undertook a Financial Review, a Governance Review and Strategic Planning. The outcome of the Strategic Planning is that we now have a clear path ahead for our activities. In particular, we are working on updating

and expanding our training programs, we are endeavouring to understand the needs of our members and meet those needs and we are seeking to increase the influence of the ACA, particularly with Government and large corporations.

We are also looking at the feasibility of purchasing our own training facilities.

To underpin these objectives we have a sound financial system and have restructured our Board. During the ACA General Members Meeting at the Conference, members voted on a new structure that will streamline the governance of the Association. Thanks to the many members that attended or submitted proxies. Thanks for your consideration of the issues associated with the changes. The new structure was agreed unanimously. I look forward to working with the new Board Members and the incoming President, Mohammed Ali, on the implementation of the structure.

Congratulations to the incoming Board; Kingsley Brown, Graham Carlisle, Peter Dove, Allan Sterling, and Dean Wall. I look forward to working with you on the initiatives identified above. I will use this column to keep members updated of activities and news. .

For those that attended the Conference, I hope you enjoyed it and that it was valuable to you. If the ACA has a local event or training that you have found valuable, I encourage you to tell a colleague. It could help us all.

Paul Vince ACA Chairman

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e v i t c e t o r P s g n i Coat ng i t n e Prev ion s o r r Co

PROUDLY PRESENTED BY:

ACA EVENTS & TRAINING

20 November 2014 Brisbane SPONSORED BY:

MEDIA PARTNER:

Overview Protective coatings are used across a multitude of industries including construction, infrastructure, oil & gas, and mining. Protective coatings are a widespread and extremely effective approach to controlling and preventing corrosion. The longevity of protective coatings varies enormously with modern protective coatings capable of providing very high levels of corrosion protection and durability even in the most extreme environments.

The ACA Coatings Technical Group is preparing a technical program to bring industry experts together to share their knowledge and investigate ways to better improve the longevity of protective coatings in a variety of applications and environments.

For the coating application contractor, consultants, suppliers and other key stakeholders keeping abreast of the technological advances and understanding the importance of their role in protecting our assets is of utmost importance. This event aims to explore the protective coatings industry by looking at case studies, new technologies, environmental considerations and industry qualifications, standards and training.

If you are interested in corrosion prevention then this event is a great opportunity to get together with your industry colleagues and learn about the latest in the protective coatings industry.

Technical Program & Registration The technical program and online registration portal will be available shortly at www.corrosion.com.au.

Who should attend?

Presentations should appeal to all industry sectors involved in the Coatings Industry – including asset owners, consultants, specifiers, maintenance personal, and suppliers.

Costs (All dollar prices are in Australian currency) Student - $50 (inc GST) New ACA Member - $195* (inc GST) ACA Members - $220 (inc GST) Non Members - $260 (inc GST)

Venue & Accommodation Novotel Brisbane 200 Creek Street Brisbane, QLD

Contact For further information on this event please contact Brendan Pejkovic on +61 (0)3 9890 4833 or bpejkovic@corrosion.com.au

* Join now as an ACA member and receive the ‘new member’ registration price

October 2014 www.corrosion.com.au p.7

EXECUTIVE OFFICER’S MESSAGE

My personal congratulations to Ian MacLeod who was awarded ACA Life Membership.

Ian’s contribution to the ACA has been remarkable over an extended period.

His contribution continues today as the Editor of Corrosion & Materials.

Ian was unfortunately unable to attend the Darwin conference, however the ACA recorded Ian receiving his Life Membership in Perth, prior to the conference and this was replayed during the annual dinner.

Wesley Fawaz Executive Officer

The ACA’s first ever conference in Darwin was held last month and I thank those who attended and supported this conference in the ‘Top End’ of Australia.

The Darwin Convention Centre, surrounded by the Darwin Waterfront Precinct with views of the Darwin Harbour, combined with Darwin’s friendly and relaxed atmosphere was enjoyed by those who attended Corrosion & Prevention 2014.

Although a full wrap up including photos of the conference will be published in the December issue of Corrosion & Materials, I take this opportunity to congratulate Conference Convenor Dean Wall, the Technical and Conference Committee as well as ACA staff for organising this year’s premier event for the Association.

Congratulations to all the award and scholarship recipients including; Rob Francis who was recognised for his contribution to the Protective Coatings industry by receiving the Victor Nightingall Award.

The annual members meeting was held in Darwin on 23 September and I was pleased to see the proposed Constitution and By-Laws voted in. This provides the ACA with a structure that best serves its members for the next decade and beyond. Thank you to John Duncan who managed this process on behalf of the ACA. I must take this opportunity to thank Andrew Hargrave for his tremendous support during his Presidency, in a period of review and restructure for the ACA and I wish Mohammad Ali all the best during the forthcoming year as President. A special thank you also to outgoing Directors; Matthew Dafter, John Duncan and Fred Salome for their contributions to the Operations Committee.

I also take this opportunity to acknowledge long standing employee Jackie Jones in our Accounts team, who recently announced her retirement.

After 8 years with the ACA, we thank her for her efforts and I wish Jackie and her husband Ivan all the best with their retirement and travel plans.

I recently attended the NACE International South East Asia Pacific Rim Area conference in Bali along with Andrew Hargrave. This was a great opportunity to network with members of other corrosion Associations (including; NACE, China, Singapore, India, etc.).

This visit gave me the opportunity to discuss ACA’s involvement with the NACE International sponsored Global IMPACT Study with Project Manager Elaine Bowman. The IMPACT Study is a global initiative to determine the financial and societal impacts of corrosion on industry sectors including utilities, transportation, oil and gas, and infrastructure. The two-year study is being led by NACE International with participation from industry and technology partners worldwide. The ACA will be represented on the Global Technical Advisory Committee and has agreed to participate in the study by providing cost of corrosion data from Australasia.

The collection of this data will occur in the first half of 2014 and more details will be announced accordingly.

Before I go, I ask members to log on to the new ACA website (www.corrosion.com.au) (currently under construction) which has considerably improved functionality and navigation tools. The website will be launched by the end of October 2014.

Wesley Fawaz Executive Officer wesley.fawaz@corrosion.com.au.

In-House Training Throughout the year the ACA delivers multiple in-house training courses to its members and the wider industry throughout Australia and New Zealand.

The ACA can present any one of its courses exclusively for a member: we can also tailor any course to your organisation’s specific needs.

If your organisation would like the convenience of the ACA delivering a training program at your job site or facility, at a time that suits your schedule, contact Renata Fularczyk at the ACA on 614 (0)3 9890 4833 or email rfularczyk@corrosion.com.au

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xxx

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TRAINING

ACA/ACRA Corrosion and Protection of Concrete Structures

Corrosion and CP of Concrete Structures

Member $1060 Non-member $1330

Member $1060 Non-member $1330

Melbourne April 28 – 29

Sydney June 10 – 11

Adelaide August 20 – 21 Perth September 1 – 2

Corrosion Technology Certificate ACA Coating Inspection Refresher Member $605

Non-member $740

ACA Training Calendar

Member $2220 Non-member $2600 Perth February 16 – 20 Brisbane May 18 – 22

Adelaide November 14

New Zealand June 22 – 26

New Zealand December 4

Melbourne September 21 – 25 Sydney November 23 – 27

NACE CIP Level 2 Member $3740 Non-member $4275

Cathodic Protection Advanced Member $2220 Non-member $2600

Home Study

Sydney February 9 – 14 Perth March 16 – 21

Brisbane March 23 – 27

Member $2220 Non-member $2600

Melbourne May 11 – 16

Melbourne May 25 – 30

Start at anytime

Sydney June 22 – 27

Perth November 30 – December 4

New Zealand July 13 – 18 Brisbane July 27 – August 1 Perth August 24 – 29

Cathodic Protection Monitoring

NACE CIP Level 1

Melbourne October 19 – 24

Member $3740 Non-member $4275

Adelaide November 9 – 14

Member $1485 Non-member $1810

Sydney February 2 – 7

Brisbane March 16 – 18

Brisbane February 23 – 28

New Zealand April 27 – 29

Perth March 9 – 14

Sydney August 3 – 5

Adelaide April 13 – 18

NACE CIP Level 3 Peer Review

Adelaide August 31 – September 2

Melbourne May 4 – 9

Member $1470 Non-member $1725

Perth October 5 – 7

Sydney June 15 – 20

Adelaide November 9 – 13

Melbourne October 26 – 28

New Zealand July 6 – 11 Brisbane July 20 – 25 Perth August 17 – 22 Sydney September 7 – 12

Coating Selection and Specification Member $1485 Non-member $1810

Melbourne October 12 – 17 Adelaide November 2 – 7

Melbourne March 2 – 4 Perth August 10 – 12

Protective Coatings Quality Control Member $1485 Non-member $1810 Melbourne March 23 – 25 Sydney July 1 – 3

All courses listed include GST. For NZ courses deduct 10%

Perth September 14 – 16

October 2014 www.corrosion.com.au p.9

NEWS

NIWA Wellington Science and Technology Fair This year’s NIWA Wellington Science and Technology Fair was once again held at Victoria University and ACA Wellington continued its support of the event by providing a prize for the best corrosion related projects.

This year a new option to present results by way of a power point presentation rather than the traditional board approach was introduced.

Unfortunately this new method of delivery was not taken up by any of the corrosion and electrochemistry related project creators.

This year the ACA prize was split between two excellent projects: Marco Davis’ ‘Which Metal Corrodes the Fastest?’ and Liam Anderson’s

‘Shocking Electrochemistry’. Marco, from Seatoun School, looked at which metal corroded fastest in tap and seawater. He measured the area covered in corrosion product to determine which had corroded the most. He explained that he didn’t use a weight loss method because he didn’t think there would be much of a change due to the short exposure time.

Liam, Kelburn Normal School, looked at which pH solution made the best electrolyte. As he did not have access to a pH meter he used solutions from around the home such as vinegar and Ajax with pH figures researched on the internet, which was quite an innovative approach to the problem.

Infracorr Consulting Celebrates 10 years and a New Office Celebrating its 10th birthday Infracorr Consulting also held a launch of their new corporate headquarters. Ian Godson, Managing Director and the Infracorr family welcomed their clients, suppliers and friends to the launch of their new office which was attended by over 60 people.

The Infracorr Consulting office is now located at 20 Business Park Drive, Notting Hill VIC 3168.

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NEWS

RFS launches new NDT website Russell Fraser Sales Pty Ltd (RFS) is excited to announce the launch of their new NDT website: www.rfsales.com.au.

With more features than ever before, you can find all the latest quality and inspection products for the Aviation; Mining; Oil & Gas; Defence; Corrosion; Forensics and Underwater industries.

you don’t miss out on any important events. RFS is constantly updating the website with new information, along with videos featuring product reviews and instructional how-to’s. Be sure to check back with the Special Offers page every so often to see the latest deals and promotions on offer.

Featuring the latest news and events, you can keep up to date with what’s happening in your industry and be sure

Visit the new RFS NDT website today: www.rfsales.com.au and sign up to their newsletter for regular updates.

Water additive on the nose with concrete sewers A team of University of Queensland researchers has found a way to save water providers hundreds of millions of dollars a year by reducing sewer corrosion.

Team leader and Deputy Director of UQ’s Advanced Water Management Centre (AWMC) Professor Zhiguo Yuan said sewer systems were recognised as one of the most critical infrastructure assets for urban societies.

“Maintenance costs for these concrete sewers run into the billions of dollars a year across the world,’’ Professor Yuan said.

In a paper published in the leading international journal Science, the research team shows that a common coagulant added in the drinking water treatment, aluminium sulfate, can be a key contributor to the sulfate levels in sewage.

“This, in turn, is the primary source of hydrogen sulfide, which creates rapid concrete degradation and is the main cause of global sewer corrosion,” he said.

“This could be avoided by switching to sulfate-free coagulants at little or no extra cost compared with the large potential savings in sewer maintenance and corrosion costs.

“To get to this point, we performed a two-year sampling campaign in South East Queensland, an extensive industry survey across Australia, a global literature review, and a comprehensive model-based scenario analysis of the various sources of sulfate.”

Coagulants are added in the drinking water treatment process to remove turbidity from the water.

UQ Vice-Chancellor and President Professor Peter Høj said the publishing of the team’s paper in Science was recognition of the high-calibre of research that had been undertaken and underscored the importance of industry collaboration.

“Strong industry partnerships at both researcher and institution level allow us to better leverage resources and facilities and to ensure the benefits from excellent research flow to end users,” Professor Høj said.

“What Zhiguo and his team have achieved is a perfect example of a successful industry collaboration that has added the ‘plus factor’ to excellent research and delivered an innovative, cost-effective solution to a global problem.

“We are particularly pleased that we were able to simultaneously achieve both academic and industry impact in the same research program – something that we have always strived to achieve.”

The paper, ‘Reducing sewer corrosion through integrated urban water management’, is online at www. http://www.sciencemag.org/ content/345/6198/812.

In undertaking sewer research, The University of Queensland partnered with The University of New South Wales, The University of Newcastle, The University of Sydney, Curtin University of Technology, Barwon Water Corporation, CH2MHILL, City of Gold Coast, Hunter Water Corporation, Melbourne Water Corporation, South Australian Water Corporation, South East Water Limited, Sydney Water Corporation, Veolia Water, Water Research Australia Limited, and Water Corporation of Western Australia.

“We call it the path from excellence to excellence-plus.”

Established ten years ago, Professor Yuan said the AWMC’s sewer research team had received more than $10 million in funding from industry and research grants.

“A decade ago we established the ‘Putting Science into Sewers’ research program and, since then, we have delivered more than $400 million in documented savings to the Australian water industry, with much more to come,” he said.

The collapse of corroded concrete sewer pipes can cause major infrastructure damage, such as this sinkhole created in San Francisco. Picture source: AP via AAP/ George Nikitin

October 2014 www.corrosion.com.au p.11

NEWS

Cathodic Anodes Australasia Commission a New Optical Emission Spectrometer.

CAA are proud to announce the installation of their new OES for chemical analysis of anode samples.

Laboratory Technician, Russell Northey states, “We felt that this investment was necessary to stay at the cutting edge of anode manufacturing”.

The new OES is a Foundry Master Expert (FMX) manufactured by Oxford Instruments in Germany. The “expert” exceeded our requirements straight out of the box. The Oxford technical staff were straight to the point with answers to every question we asked when seeking a replacement instrument.

It utilises a vacuum optic and the latest CCD (charge coupled device) light sensitive detectors. The advances in the analytical industry are forever moving forward and it is exciting to see the changes that have evolved with this

instrument. It can measure 31 elements in Aluminium, 19 elements in Zinc and 32 elements in Magnesium. So the AS2239 (Galvanic Anodes), and other international standards, are very well covered.

The instrument is factory calibrated from a library of hundreds of certified reference material standards. The CCD technology and two light path systems (an argon purged tube system and a short optical fibre system) allow both very, very low and very high detection limits to be utilised. The entire optical system is contained in a vacuum to ensure the high stability of a laboratory instrument.

Anyone interested in having a look at the new instrument, and its capabilities, is welcome. Please feel free to call CAA and arrange a visit.

Vale: Peter Hastings Thorpe Peter Hastings Thorpe (1931-2014) was a foundation member of the ACA and was active in State and Federal committees for most of his working life.

This included serving for various periods as Treasurer of the Victorian Branch, as Federal Councillor representing Victoria and as Secretary of the Federal Committee (1974-9) culminating in his being elected a Life Member. He also produced the Victorian Branch Bulletin and was part of the editorial group for Corrosion Australasia (later Corrosion & Materials) with several editors. For decades Peter was the man with the camera at Branch and Federal events recording the serious and funny for publication and posterity. Perhaps Peter’s greatest publishing challenge was when he made a major contribution to the Association’s International standing by leading the small group who produced the 1,760 page, 2 volume proceedings of the ‘Sixth International Congress on Metallic Corrosion’. It was held in Sydney during 1975 – the first International Corrosion Conference held in Australia. This was a huge

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undertaking since the 161 technical papers and 3 plenary lectures were provided in non-standard paper formats!

Peter was born and educated in Melbourne. He left school with his Leaving Certificate in 1947 and worked part time during his tertiary education at RMIT and then the University of Melbourne where he obtained a Science Degree majoring in Metallurgy. His first job was with the Commonwealth Aircraft Corporation before he moved to Wollongong to work for BHP. However, Melbourne called and in 1964 he and Diana and daughter Lisa moved back to Melbourne to join APM and start his life long career in the Pulp and Paper Industry. While Peter’s work was notionally based around the Fairfield and Maryvale mills, he travelled extensively for APM both here and internationally. He became recognized as the go-to person for materials and corrosion issues in the industry. The job evolved and when Peter became a consultant in the 1980s his client base became wider although his work was

still mainly pulp and paper related.

He continued consulting until about 5 years ago. Outside of work Peter was sociable, good with stories, a chorister, a bushwalker and an Elder of the Uniting Church. Peter will be missed by his many friends and colleagues. He is survived by Diana, his wife of 52 years, their 2 children and their grandchildren.

NEWS

MARCH 15-19, 2015 | THE KAY BAILEY HUTCHISON CONVENTION CENTER | DALLAS, TX

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For more information, visit www.nacecorrosion.org OFFICIAL MEDIA PARTNERS

October 2014 www.corrosion.com.au p.13

NEWS

ACA Welcomes New Members ACA welcomes new members October – December 2014 Corporate Platinum Savcor Products Australia www.savcorproducts.com.au Savcor Products Australia Pty Ltd is one of the leading distributors of brand name corrosion products in Australia. The company provides expert technical support for its wide range of products including Cathodic Protection materials. It also focuses on fast response to enquiries, and can often deliver various products directly from stockpiles, substantially cutting the waiting time for its customers.

Corporate Gold Nukote www.nukoteaustralia.net.au Nukote are driven by the knowledge that Polyurea systems done properly are the best solutions for many projects. Nukote have over 25 years of experience with formulation, manufacturing and supporting these materials around the globe. Their tailored and extensive product range, technical support, R&D and applicator training are best in class, so contact them to efficiently extend your asset life.

Corporate Silver Industrial Minerals www.mineralscorp.com Established 21 years ago, Industrial Minerals partners with the world’s leading equipment and abrasives manufacturers. This allows it to supply proven, top-quality abrasives and specialised equipment to the corrosion control and protective coatings industry in New Zealand and Australia.

Some of the industry leading products offered by Industrial Minerals include ‘Super Garnet’ and its large range and stocks of abrasives which includes steel grit and shot, plastic media, power blast, soda and aluminium oxide.

Its blast equipment includes world leading equipment manufacturers and the dustless Geoblaster wet abrasive system. Specialist products

p.14 CORROSION & MATERIALS

include salt removal, rust inhibitors and surface coating testing equipment.

Containment sheeting is available for abrasive blasting where containment is required. Industrial Minerals has 13 distribution warehouses located throughout Australia and New Zealand.

Corporate Bronze Civil & Pipeline Contractors Civil & Pipeline Contractors Pty Ltd is a family owned and operated company built on four core values: accountability, excellence, innovation and performance. They specialise in civil engineering, coating and pipeline inspection services across the civil engineering, mining and oil & gas sectors. The company’s coating division has the necessary personnel, experience and equipment to undertake field coatings to NACE standards.

Magnatex www.magnatex.com.au Magnatex is a leading provider of concrete spalling (concrete cancer) investigation and repair services to the Strata Industry. Their services include; concrete spalling investigation & repair, magnesite removal and cementitious toppings. Magnatex offers a responsive professional service, thorough investigation and appropriate repair methodologies.

The benefit is asset protection. All residential structural repairs carry a 6 year warranty. Magnatex does it right…the first time!

Asset Alignment Asset Alignment Pty Ltd is a West Australian company specialising in Fixed Plant Maintenance, providing work shop and field services to the mining and energy sectors in the Kalgoorlie goldfields region. Asset Alignment Pty. Ltd. provides services to its clients such as – ixed Plant Maintenance Repairs F and Inspections.

Laser Alignment of Large and Small Drive Lines.

Overhaul of Industrial Gearboxes and pumps.

anufacture of Conveyor Pulleys M and Shafts.

Boring and Keying of Couplings.

Manufacture of Cathodic Anodes.

Any Enquiries, please email: aapl1@bigpond.com Vappro Corrosion Control Australia www.vappro.com.au Based in Melbourne, Vappro Corrosion Control Australia is ready to supply their extensive range of corrosion control products across Australia and New Zealand.

Their products are used in the harshest operating environments, serving many industries including oil & gas production and exploration, mining, maritime, manufacturing and construction etc. In addition, defence forces around the world utilise their products to protect and maintain their equipment. They can protect your assets whilst in operation or in storage.

Depending on your requirements, their protection can be delivered as a coating; as a power; sprayed or in the instance of engines and gear boxes it can be added to lubricating oils.

Vappro Corrosion Control Australia is supported by Magna International Pty Ltd. The Magna Group is one of the world’s leaders in corrosion control technologies, supplying many multinational heavy industry players and defence forces in the Asian region.

VAPPRO - Your Partner In Corrosion Control And Environmental Protection.

NEWS

New Individual & Student Members Type

Name

Surname

Company

Branch

Student

Douglas

Adam

Adelaide University

SA

Individual

Basem

Amer

Origin Energy

QLD

Individual

Simon

Barron

JDP Applications Pty Ltd

QLD

Individual

Nathan

Bolton

Bolton Services

NCL

Individual

Vanessa

Brooks

Blast Marine

QLD

Honorary

Gary

Bunn

GJ Bunn & Associates

VIC

Individual

Anthony

Cameron

Cape Australia

NSW

Individual

Peter

Clark

Peltos (VIC) Pty Ltd

VIC

Individual

Warren

Coffey

Individual

Ry

Collier

Individual

Andrew

Coman

WA Balance AgriNutrients

NZ VIC

Individual

Oluwole

Kazum

James Cook University

QLD

Student

Edward

Kent

Australian Maritime College

TAS

Student

Fiona

Lake

Adelaide University

SA

Individual

Graham

MacKinnon

Corrosion Control Engineering NZ Ltd

NZ

Student

Trina

Majumdar

Forgacs

VIC QLD SA

Individual

David

Mann

Central Coast Inspection Service

Student

Eloisa

Marcon

Adelaide University

Individual

Neil

Marshall

Individual

Peter

Meredith

Forgas Engineering

QLD

Individual

Wayne

Morris

Monash University

NZ

Student

Mudassar

Muhammad

Curtin University

WA

Individual

Pallav

Nanda

Bechtel APLNG

WA

NZ

Student

Chris

Coppard

Australian Maritime College

Individual

Shane

Cranwell

Veolia

Individual

Michael

Creedy

Individual

Stephen

Daddow

Satin Touch

QLD

Student

Patricia

Pereira

Adelaide University

SA

Individual

Michael

Dalla Costa

Dalco Protective Coatings

QLD

Individual

Greg

Reece

Caltex Australia

NSW

Individual

Steven

Davis

Thiess

WA

Student

Anthony

Roccisano

Adelaide University

SA WA

TAS

Individual

Scott

Nicholson

WA

SA

Individual

Nick

Papa

VIC

QLD

Individual

Frank

Papworth

WA

Individual

Siavash

Rostamian

Corrosion Control Engineering

Individual

Kurt

Scholz

Industrial Installation and Maintenance

QLD

Student

Goncalo

Soares

Adelaide University

SA

Individual

Youn

Soo Kim

Forgas Engineering

NSW

Individual

Jin

Soo Kim

Applus RTD

NSW

Student

Adam

Sotora

Adelaide University

SA

Individual

Brian

Stanley

QLD

Individual

Aaron

Sudholz

VIC

Individual

Ali

Talebi

WA

NZ

Individual

Byron

Tolentino

JBST Holdings Pty Ltd

NSW

Adelaide University

QLD

Individual

Johann

Triebe

Monash University

QLD

Grogan

Remedial Services Pty Ltd

NCL

Individual

Ravikumar

Vaka

Direct Connections

WA

Wei

Guo

Adelaide University

SA

Student

Facundo

Varela

Deakin University

VIC

Individual

Matthew

Hales

Vinsi Partners

QLD

Individual

Fletcher

Walker

Bechtel Australia

WA

Murphy Pipe and Civil

Sean

Whelan

Kanwar

Harshmeet Singh Gandey

Individual

Individual

QLD

Student

Jake

Whittenbury

Adelaide University

SA NZ

Student

Rodrigo

de Corralho Lima

Bridgweater Solutions

SA

Student

Mario

De Lorenzo

Adelaide University

SA

Student

Jack

Dunn

Adelaide University

SA

Individual

Craig

Ellis

Ellis Spray Painting

QLD

Student

Isabel

Ferretti

Adelaide University

SA

Individual

Nicholas

Flood

Blastmaster

NSW

Individual

Nicholas

Flyvbjerg

Student

Victor

Francisco

Adelaide University

SA

Student

Julio

Galdino

Adelaide University

SA

Individual

Udaya Shanth Priya

Geekiyanage Don

Individual

Gregory

Ginn

Individual

Nathan

Student

NZ

Individual

Craig

Hobson

QLD

Individual

Craig

Holder

Holder Painting

QLD

Individual

Liam

Holloway

Mend Consulting

WA

NSW

Individual

Regan

Woodward

Super Yacht Coatings International Ltd

Individual

Aaron

Wooldridge

Absolute Blast Ltd

QLD QLD WA

Individual

Ashley

Joubert

Clough

WA

Individual

John

Wright

John Holland Group

Student

Shravan

Kairy

Monash University

VIC

Individual

Javad

Yousefi

Pipeline Integrity

October 2014  www.corrosion.com.au  p.15

TRAINING

. c In n io t ia c o s s A n rrosio o C n ia s la a r t s u A e Th

Cathodic Protection

s e s r u o C Training Cathodic Protection Advanced Sydney October 13–17 Duration: 5 days This course offers the opportunity for participants to understand the principles of corrosion, electricity and Cathodic Protection (CP) and the corrosion features of soils, water and concrete. The course will enable students to define the different protection criteria, interpret potential and current surveys, know how to troubleshoot CP problems and learn of the hardware used in CP such as anodes, backfill, transformers, rectifiers, test instrumentation, etc. The course continues to teach students of the factors which determine current requirements and design of impressed current and galvanic systems, the selection process of a galvanic or impressed current system and more.

Appointments 17-20 November

NACE

CIP Peer Review p.16 CORROSION & MATERIALS

The NACE CIP Peer Review is a detailed oral examination in front of a threemember review board that lasts approximately 2 hours and is graded on a pass/fail basis.

The Peer Review includes a series of questions to test the candidate’s practical and theoretical knowledge of coatings and coating inspection.

Candidates are questioned from a random draw of topics ranging from standards, procedures, ethics, coatings use, inspection instruments, roleplaying, and specific case questions.

Successful completion of the CIP Peer Review is required to achieve recognition as a Certified NACE Coating Inspector.

Anyone wanting to complete his or her Coating Inspection Program (CIP) training to become a Certified NACE Coating Inspector. Those who have successfully completed CIP Level 2 and have two years of verifiable coatingsrelated work experience may register for the Peer Review.

Brisbane 24-28 November

CORROSION TECHNOLOGY CERTIFICATE

Corrosion of Concrete Structures

5 days The Corrosion Technology Certificate is designed to train people working in a corrosion related field in the basics of corrosion and its control. The course covers the basic principles of corrosion, the forms it takes and the methods of control.

Attendees must have completed Year 11 chemistry and maths.

Experience in the corrosion industry is an advantage.

The Corrosion Technology Certificate is required to apply for the ACA’s Certification Scheme.

ACA/ACRA Corrosion & Protection of Concrete Structures Brisbane 27-28 November 2014

This course will provide a solid foundation of knowledge about the corrosion of both reinforcement and concrete, so that those working in this field can reach more effective solutions in the prevention and remediation of this ever-growing problem.

Protective Coatings

All courses listed include GST. For NZ courses deduct 10%.

Course Highlights: • The Characteristics of Cement and Concrete • Concrete Deterioration Mechanisms • Corrosion of Reinforcement in Concrete • Survey and Diagnosis of Concrete • On-site Measurements • Laboratory Measurements • Repair and protection of Reinforced Concrete • Repair of Damaged concrete • Cathodic Protection • Further Electrochemical Methods • Preventive Measures for New Concrete

Protective Coatings Quality Control (3 days) Perth 8-10 December This course aims to formalise or improve the skills of carrying out basic quality control tests associated with protective coatings projects. It uses formal lectures, demonstrations, and extensive practical exercises as teaching methods.

Register now at www.corrosion.com.au October 2014 www.corrosion.com.au

p.17

ACA CERTIFICATION PROGRAM

ACA’s Certification Program The ACA’s Certification program for ACA Corrosion Technicians and Technologists recognises those with education and experience in the corrosion industry. A Corrosion Technician has at least 4 years work experience and has attended a number of formal training courses, whilst those awarded Corrosion Technologist have at least 10 years work experience and have obtained further training. For a more detailed explanation of the

certification number and membership details.

eligibility criteria, please consult our ACA Certification Program brochure which is available on our website www.corrosion.com.au. A schedule of current ACA Corrosion Technicians and Technologists appears below and will be published in Corrosion & Materials in full each June and October and will be continuously updated on the ACA’s web site. All current ACA Technicians and Technologists have been issued a wallet card with their

Corrosion Technicians

Please note continued membership of the ACA is a requirement for certification and therefore all certified Corrosion Technicians and Technologists will have an expiry date which coincides with their ACA membership renewal date.

‘Pending’ expiry dates indicate that a membership payment is overdue.

Trevor Henderson

322

14/10/2014

Name

Cert No: Expiry Date

Stephen Holt

207

28/02/2015

Gary Barber

248

Bradley Jones

258

18/04/2015

*Pending

Heath Boelen

306

4/05/2015

Gary Martin

57

1/06/2015

Stephen Brown

263

4/02/2015

Ian McNair

163

30/06/2015

Christopher Butler

320

24/01/2015

Terence Moore

125

*Pending

Dave Charters

261

21/01/2015

David Morgan

234

16/02/2015

Rodney Clarke

206

20/12/2014

Alan O'Connor

303

*Pending

Craig Clarke

246

25/03/2015

Reg Oliver

223

19/08/2015

Venkatesh Coimbatore

192

30/06/2015

David Parravicini

296

2/09/2015

Ross Darrigan

174

*Pending

Sean Ryder

262

21/11/2014

Glenn Dean

280

20/01/2015

Ian Saunders

251

24/06/2015

Raed El Sarraf

305

25/09/2015

Brendan Schapers

314

5/07/2015

David Fairfull

179

30/06/2015

Justin Tanti

238

14/02/2015

Geoff Farrant

253

30/06/2015

Gavin Telford

244

30/06/2015

Robert Gentry

114

30/06/2015

Akash Deep Verma

319

7/03/2015

Haydn George

307

23/11/2014

Ben Ward

300

16/07/2015

William Guest

316

15/12/2014

Mark Watson

186

*Pending

David Harley

291

17/12/2014

Derek Whitcombe

123

30/06/2015

Expressions of interest sought – coating inspectors Since its establishment in 1985, Corrotek has developed a reputation as a competent and ethical specialist protective coating consultancy.

Recently, we’ve added a comprehensive analytical capability through our involvement with Maatek Pty Ltd. To serve existing clients, we intend to increase our coating inspection and corrosion survey capability across Australia and wish to speak to experienced and certified ACA, NACE, FROSIO or SSPC coating inspectors and ACA certified Corrosion Technicians or Technologists about potential collaboration opportunities.

Interested individuals or organisations are invited to contact, in strict confidence, Corrotek’s principal, Mr Ian Glover by e-mail or mobile as per below.

®

C O N S U LTAN T S www.corrotek.com.au | Telephone 0415 872 994 | Email ian.glover@corrotek.com.au

p.18 CORROSION & MATERIALS

Corrosion Technologists

Barry Gartner

2

30/06/2015

Name

Cert No: Expiry Date

Bill Gerritsen

18

30/06/2015

Bruce Ackland

82

30/06/2015

Ian Glover

129

30/06/2015

Fred Andrews-Phaedonos

153

30/06/2015

Frederick Gooder

141

30/06/2015

Ross Antunovich

214

30/06/2015

Graeme Gummow

318

20/09/2014

Arthur Austin

106

30/06/2015

Wade Guye

313

9/08/2015

Derek Avery

295

19/08/2015

Chris Hargreaves

292

*Pending

Dinesh Bankar

264

23/02/2015

Phil Harrison

145

1/01/2015

Stuart Bayliss

236

7/11/2014

Peter Hart

200

30/06/2015

Tony Betts

74

1/01/2015

Frank Hewitt

67

1/01/2015

Rob Billing

12

30/06/2015

Brian Hickinbottom

138

*Pending

Harvey Blackburn

10

1/01/2015

Brett Hollis

88

30/06/2015

Michael Boardman

30

12/07/2015

Marshall Holmes

293

26/08/2015

Les Boulton

43

1/01/2015

Peter Hosford

216

1/01/2015

301

*Pending

John Bristow

107

1/01/2015

Peter Hunger

Gary Brockett

215

30/06/2015

Paul Hunter

62

30/06/2015

Kingsley Brown

257

30/06/2015

Jeffrey Hurst

202

30/06/2015

Philip Bundy

209

30/06/2015

Craig Hutchinson

249

26/10/2015

Wayne Burns

100

1/01/2015

Luciano Ioan

228

30/06/2015

Brian Byrne

27

1/01/2015

Bruce Jewell

245

10/05/2015

Bryan Cackett

70

30/06/2015

Michael Johnstone

230

*Pending

Neil Campbell

38

30/06/2015

Michael Jukes

90

3/03/2015

Graham Carlisle

281

19/05/2015

John Kalis

166

17/12/2014

Antonio Carnovale

203

17/06/2015

Graeme Kelly

102

1/01/2015

Luis Carro

260

30/06/2015

John Kilby

193

30/06/2015

Reg Casling

11

1/01/2015

Alireza Kouklan

317

13/11/2014

Dylan Cawley

224

29/06/2015

Ulf Kreher

304

11/09/2015

Peter Clark

80

30/06/2015

Boris Krizman

169

17/12/2014

Stan Collins

128

30/06/2015

John Lane

188

20/01/2015

Geoff Cope

71

29/06/2015

Bill Lannen

111

1/01/2015

Leon Cordewener

44

30/06/2015

Harry Lee

19

1/01/2015

Robert Cox

14

30/06/2015

Keith Lichti

133

30/06/2015

Peter Crampton

8

29/06/2015

Verne Linkhorn

39

30/06/2015

Roman Dankiw

208

29/06/2015

Garry Luskan

117

2/02/2015

Rene D'Ath

197

11/03/2015

Willie Mandeno

13

1/01/2015

Robert de Graaf

154

1/01/2015

Brian Martin

60

1/01/2015

Mike Dinon

5

30/06/2015

William McCaffrey

142

30/06/2015

Bradley Dockrill

241

15/07/2015

John McCallum

59

30/06/2015

Peter Dove

210

29/03/2015

Daryl McCormick

1

17/12/2014

Gary Doyle

294

2/08/2015

Murry McCormick

196

28/06/2015

Adrian Dundas

250

1/02/2015

Michael McCoy

109

14/04/2015

Bernard Egan

20

30/06/2015

Brad McCoy

178

14/07/2015

Gary Evans

271

16/06/2015

Bill McEwan

32

1/01/2015

Wayne Ferguson

242

4/09/2015

Stuart McLaughlin

299

17/12/2014

Peter Ferris

195

*Pending

Vic McLean

237

23/08/2015

Gavin Forrester

282

10/02/2015

Jim McMonagle

56

1/01/2015

Rob Francis

23

1/01/2015

John Mitchell

115

30/06/2015

Dale Franke

199

30/06/2015

Elio Monzu

159

30/06/2015

Max Fraser

283

16/03/2015

Greg Moore

97

1/01/2015

Robert Freedman

147

1/01/2015

Hamid Moradi Fard

321

9/04/2015

Jim Galanos

254

17/12/2014

Janet Morris

256

5/07/2015

October 2014 www.corrosion.com.au p.19

ACA CERTIFICATION PROGRAM

Robert Mumford

33

30/06/2015

Gordon Stewart

68

1/01/2015

Tony Murray

134

*Pending

Hussain Sulaiman Abdallah

311

*Pending

David Nicholas

94

1/01/2015

Graham Sussex

136

30/06/2015

Calvin Ogilvie

17

19/01/2015

Tan Swee Hain

189

30/06/2015

Dean Parker

108

5/07/2015

Yongjun Tan

194

30/06/2015

David Pettigrew

297

17/12/2014

Ronald Tan

308

30/06/2015

Dennis Richards

180

1/01/2015

Peter Tomlin

120

*Pending

Steve Richards

110

30/06/2015

Narendra Tripathi

312

*Pending

Gavin Richardson

48

30/06/2015

Frank Turco

309

14/04/2015

Tony Ridgers

36

30/06/2015

Nicholas Van Styn

229

25/02/2015

Geoff Robb

124

30/06/2015

Peter Wade

190

9/03/2015

Bernd Rose

252

1/05/2015

John Waters

121

30/06/2015

John Rudd

243

*Pending

John Watson

239

10/06/2015

Fred Salome

231

1/01/2015

Richard Webster

69

30/06/2015

Philip Schembri

198

17/12/2014

Mark Weston

149

1/01/2015

David Scott

173

29/06/2015

Geoffrey White

182

1/07/2015

Mike Slade

175

7/06/2015

Paul Wilson

290

19/04/2015

Brian Smallridge

201

30/06/2015

Kevin Woodland

323

30/10/2014

Jim Steele

119

17/12/2014

Rodney Wubben

46

30/06/2015

Alan Steinicke

9

1/06/2015

Xiaoda (David) Xu

315

28/11/2014

Allan Sterling

191

31/03/2015

Morris Young

217

30/06/2015

Ian Stewart

155

*Pending

Nizam Yusoff

302

9/02/2015

Please note this list is current as at 8/09/2014 a division of valspar

SUPER GARNET

DTM985

Super Garnet is ISO 11126-10 Certified

High solids, surface tolerant maintenance epoxy

(Meets required Chloride Levels, Free Silica Content, Hardness and Conductivity)

Abrasive Blast Media 8 Grades Available

√ Conforms to ISO 11126-10 √ Mil-Spec Approved √ Low Chlorides (below 25 ppm) √ Quality Certificates (available for every tonne) √ High Purity, Low Dust, √ High Recyclability √ High Profiles, High Performance √ Superior Cleaning & Cost Effective √ Washed (Low TSS)

• Long term corrosion protection

• Atmospheric and immersion applications

• Direct to metal application

• Full AS2700 colour offer

• Rapid curing properties

• Approved to APAS 2793

www.mineralscorp.com sales@industrial-minerals.co.nz

p.20 CORROSION & MATERIALS

ADE IN

US

I

A

M

A

Free Phone AU 1800 309 734 Free Phone NZ 0800 646 372

TRAL

For more information on the Wattyl Industrial Coatings product range call 132 101 or visit www.wattylindustrial.com.au

BRANCH AND YCG EVENTS

ACA Auckland, YCG Meeting 2014 The Tyler Street Garage, in Britomart, Auckland City, was the venue for the annual YCG meeting on the 27 August, sponsored by Les Boulton & Associates Ltd. The gathering commenced with refreshments as the attendees arrived from all around Auckland. The venue for the YCG event was superb, with a night view across the Waitemata Harbour and the adjacent cruise ship terminal the Dawn Princess was in dock, just to remind everyone attending of the perils of the sea if marine corrosion occurs!

The three speakers for the evening were Sean Ryder, YCG Convenor (Phoenix Solutions), Raed El Sarraf (Opus International Consultants), and Wayne Thomson (Anode Engineering).

The speakers took turns to outline their personal introductions to the Corrosion Control Industry and how they had benefited from membership of ACA. In particular, the speakers emphasised networking, the life-long friendships formed, and the relationship-building opportunities that ACA offers to young(er) people entering the industry.

The 2014 YCG event was first–rate, with a good attendance of new ACA members and students present.

Inaugural Christchurch Event After several devastating earthquakes in Christchurch, New Zealand, one of the largest construction projects in the world is underway. Considering the massive rebuild of the city, the Australasian Corrosion Association’s New Zealand committee resolved early in 2014 to push for greater corrosion awareness in the South Island’s largest city. The committee sponsored Brendan Pejkovic from the ACA head office to travel to Christchurch in March 2014 to establish first-hand what sort of demand there might be. The feedback was overwhelmingly positive. This resulted in a technical event being set up for August 2014. The committee were aware that 30 years earlier a similar event was attempted without success.

The concern was unfounded with the site visit to CSP Coatings in Christchurch being fully subscribed.

The site tour covered CSP Coating’s Christchurch galvanizing facility. The tour covered the preparation, pickling, flux and zinc coating processes. There were several production batches underway providing the visitors with

a demonstration of what is involved.

This was followed by 3 technical talks at the Hornby Workingmens Club.

Around 40 attendees heard speakers from Opus International Consultants, Phoenix Solutions and CSP Coatings.

The attendees included representatives of several large consulting firms and contractors. The talks included introduction to corrosion, durability design, materials, cathodic protection and galvanizing processes. This technical insight was well received by the attendees with many questions being asked. A demonstration of the electrolysis process was performed by Sean Ryder of Phoenix Solutions.

The attendees enjoyed a sumptuous refreshment offering afterwards, where many new acquaintances were formed.

Importantly, the impetus was created to start up a Christchurch division of the New Zealand Branch with several people volunteering to get it off the ground.

Thanks must go to CSP Coatings and Altex Coatings for making this event possible.

October 2014 www.corrosion.com.au p.21

ACA STANDARDS UPDATE

ACA Standards Update Welcome to the 5th corrosion related Standards Update for 2014. This Standards report focuses on corrosion issues related to the Mining Industry Technical Group.

In this ‘Standards Update’, Focus 1 & 2 will summarise all relevant standards to the technical group in question.

Focus 1 As previously the focus will be a global standards and publication focus, searching through SAI Global Publications at https://infostore. saiglobal.com/store, for all current publications and standards relating to the ACA technical Groups, with this editions group focuses being the “Mining Industry” technical group.

Summary Through SAIGLOBAL Publications at https://infostore.saiglobal.com/store there were 5 Titles, all from AS, AS/ ASNZS as shown in Focus 1 below.

p.22 CORROSION & MATERIALS

Focus 2 A SAI Global search, as previously, at http://www.saiglobal.com/online/ for new standards, amendments or drafts for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and standards and amendments for ISO & IEC published from 16 July 2014 to 4 September 2014, using the key words and key word groups: ‘durability’. ‘ corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’. ' paint’ or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’.

' galvanize' or ‘galvanized’ or galvanizing’. ' electrochemical' or ‘electrolysis’ or ‘electroplated’. ‘cathode’ or 'cathodic'. ‘anode’ or ‘anodic’. ' corrosion' and 'concrete' or ‘concrete’ and ‘coatings’.

These results are shown in the Focus 2 report following.

ACA STANDARDS UPDATE

Summary Across SAIGLOBAL online Standards Publications there was only 1 new draft standard since 16 July 2014 to 4 September 2014, this was; DR AS 1012.20.2:2014

Methods of testing concrete - Part 20.2: Determination of water-soluble chloride in aggregates and hardened concrete

Focus 1 Report on SAIGLOBAL Publications at https://infostore.saiglobal.com/store, for all current publications and standards relating to “Corrosion and Mining” for the “Mining Industry” Technical Group TG. Focus 1 Report For a search on “Mining” there were 2779 with 65 AS, AS/NZS titles (up from 2,409 titles (but AS, AS/NZS down from 67); on “Corrosion” there were 7365 with 37 AS/NZS titles up from 7,151 (36 AS, AS/NZS) Titles last year; on “Corrosion and Mining” there were 5 titles, all from AS, AS/NZS as shown below.

AS/NZS 2290.1:2014

Electrical equipment for coal mines - Introduction, inspection and maintenance - For hazardous areas

AS 2816-1992

Copper, lead and zinc sulfide concentrates - Determination of hygroscopic moisture in the analysis sample - Gravimetric method

AS/NZS 4812:2003

Non-destructive examination and discard criteria for wire ropes in mine winding systems

AS 2879.9-2002 (R2013)

Alumina - Determination of flow time

AS 1038.17-2000 (R2013)

Coal and coke - Analysis and testing - Higher rank coal - Moisture-holding capacity (equilibrium moisture)

To access these publications, go to https://infostore.saiglobal.com/store and type ‘mining and corrosion’ into the search box and examine the search results.

Focus 2 Report Focus 2 Corrosion related Standards for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and Standards and Amendments for ISO & IEC published from 16 July 2014 to 4 September 2014 for: New standards, amendments or drafts for AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI and Standards or Amendments for ISO & IEC PUBLISHED between 16 July 2014 to 4 September 2014 Key word search on ‘durability’.- 0 citations found related to corrosion Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 0 citation in all – none from AS, AS/NZS Key word search on 'paint’ and or ‘coating’ and corrosion; but not ‘anodizing’ or ‘anodize(d)’– 0 corrosion related Publications found; none from AS/NZS; Key word search on 'galvanize' or ‘galvanized’ or galvanizing’ – 0 Standard Publications found Key word search on 'corrosion' with examination for concrete related standards - 0 Standard Publications found; however one AS draft on testing concrete for water soluble Chloride DR AS 1012.20.2:2014

Methods of testing concrete - Part 20.2: Determination of water-soluble chloride in aggregates and hardened concrete

Key word search on ‘cathode’ or 'cathodic' -0 Standard Publications found Key word search on 'anode' or ‘anodes’ or ‘anodic’ – 0 Standard Publications found Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ - 0 corrosion related Standard Publications found Keyword Search on 'anodize' or ‘anodized’ - 0 Publications found Arthur Austin ACA Standards Officer

October 2014 www.corrosion.com.au p.23

TECHNICAL EVENT REVIEW

PROUDLY PRESENTED BY:

SPONSORED BY:

MEDIA PARTNER:

Corrosion in the Oil & Gas Industries – Brisbane The Petroleum & Chemical Process Industries Technical Group of the ACA held a technical event on Thursday 24 July at the Novotel Hotel in Brisbane.

This full day technical event had over 55 delegates from a broad cross section of the industry from around Australia in attendance. Below is a summary of the presentations that were covered on the day. At the conclusion of the event an open floor forum was held and chaired

by Phil Fleming, which provided much discussion on the key issues.

The ACA would like to thank all speakers, sponsors and delegates who attended this event and for making the day a huge success!

p.24  CORROSION & MATERIALS

Further Developments in Accelerated Laboratory Evaluation of Coatings for Use Beneath Thermal Insulation Andrew Smith, International Paint This presentation objectively reviewed the comparative performance of standard epoxies, epoxy phenolics and epoxy novalac technologies as they pertain to performance at elevated temperatures. The presentation briefly explored the vagaries of current terminologies and the importance of common understanding between specifier and formulator. The presentation looked at the base chemistry behind the generic technologies, and reviewed their relative performance in corrosion under insulation, dry heat resistance

applications, and reviewed the basics of high heat tolerance testing. The output of this presentation was that there should be an appreciation of the comparative merits of the technologies, an understanding of the product parameters that determine good high heat performance, and the need to identify the desired product chemistry correctly.

Review of Autonomous Platforms for Remote Corrosion Inspection Dr Elliot Duff, CSIRO Autonomous Systems This presentation looked at the fact that over the last decade there has been a dramatic increase in the number and variety of autonomous platforms that

TECHNICAL EVENT REVIEW

can be used for inspection. These platforms range from traditional unmanned aerial, ground and underwater vehicles (UAV, UGV, UUV), to robots that may employ legs or new hybrid or bespoke solutions for locomotion. This increase has been driven by a number of factors: firstly there have been significant improvements to the hardware that is required to build such system - both in the performance and cost of sensing, processing, communications and power; secondly, the user interfaces have become easier to use (eg. tablets and phones); and thirdly there has been a widespread adoption of opensource robotic platforms. All of these factors are leading to the development of platforms that are cheaper, lighter, more robust and requiring less infrastructure, less maintenance and less expertise to operate. There are now significant opportunities to use these new platforms for remote corrosion inspection. This is of particular interest for confined spaces, where it may be possible to redesign the structure to remove the need for human access.

Innovative Solutions Assist in Reducing OPEX (Case Study) Peter Jones, Anti Corrosion Technology When an asset is built and commissioned, it has to achieve the specific purpose fit for its design life.

After a period of time, certain elements of the asset start deteriorating or need scheduled maintenance. Nothing is ever perfect. That’s when good old fashion wear and tear comes into play and, therefore, maintenance is

mandated for the asset to reach its design life. The challenge then is for asset managers to ensure this happens within an ever-shrinking OPEX budget.

Technology and innovation are something we are all familiar with in our day-to-day lives but, unfortunately, it’s rarely embraced in the same way when it comes to asset maintenance.

The solution is simply to embrace technology and innovation available in today’s market. Finding new ways and better products are required to solve the boomerang effect. Do it once and do it properly. This has to become the focus so that maintenance OPEX budgets can successfully deliver on the asset’s life cycle design. Peter’s presentation followed the simple philosophy of searching for solutions that solve continual boomerang problems and solve them permanently from a personal point of view.

Remote Monitoring of Cathodic Protection on Oil & Gas Pipelines: The UK Experience Kevin Woodland, SMEC This presentation looked at the UK onshore gas, oil and petrochemical pipeline infrastructure that transports gaseous and liquid hydrocarbons via a network of transmission and distribution pipelines at high and intermediate pressures. These pipelines are protected from corrosion by impressed current Cathodic Protection systems. In the past 5 years, UK utilities have installed monitoring systems to gather CP data remotely.

Such projects have demonstrated an attractive return on investment compared with the manual methods

of collecting CP data that had existed previously. However, they have also been able to demonstrate significant operational gains in terms of improved asset integrity management through early identification of potential corrosion issues as well as reducing risk to the workforce, contributing to environmental KPIs and achieving better regulatory compliance.

Short Segment Pipeline Rehabilitation – Cost Versus Integrity Peter Lather, OSD There are many pipelines in operation today and all have pipewall and/ or coating defects of some sort. This presentation discusses the opportunities that exist to improve pipeline integrity, not simply through advances in the way we investigate pipeline defects, but in the methods we undertake during the investigations to better utilise collected data for planning and undertaking the ongoing operation of the pipelines.

Specifying Materials for Extreme Corrosion in the Oil & Gas Industry Ian Ellis, Metz Specialty Materials Oil and Gas industry assets are subjected to not just environmental corrosion problems. Extreme corrosion can occur to both concrete and steel infrastructure and plant elements due to the presence of various aggressive and high concentration chemicals often at elevated temperatures. Increasing environmental awareness around the world means asset holders are under pressure to do all they can to avoid leaks to the environment. Other risks include exposure of the workforce to dangerous chemicals and in extreme corrosion cases structural failures are also possible.

This presentation covered the basics of lining material and system selection for high concentration chemicals, and further discussed design and installation considerations. Case studies from situations with exposure to extremely corrosive chemicals were given. The presentation aimed to provide some practical insight into this issue for specifiers and asset owners.

Issues & Solutions for Cathodic Protection Isolations in CSG Pipelines Allan Sterling, Anode Engineering This presentation discussed some of the emerging issues with cathodic protection electrical isolation in CSG pipeline systems and canvased possible practical and design solutions to the problems. The presentation focused on issues resulting from glycol and coal dust.

October 2014 www.corrosion.com.au p.25

TECHNICAL EVENT REVIEW

Some Challenging Corrosion Examples in CSG Gas and Produced Water Equipment John Everton & Julian Van der Kley, ALS Global Coal seam gas production in Australia is facing some challenges with regards corrosion of its gas and water infrastructure. This presentation showed some gas and extracted water pipeline corrosion case studies, with a summary of the damage mechanisms observed to date. These case studies contributed to an in-depth understanding of the mechanisms involved; such understanding is required for optimising operational and maintenance programs to minimise loss of production. John also looked at some non-intrusive inspection techniques to enable plant condition assessment which can be used as part of a risk based inspection program.

used to treat CSG water in order to satisfy beneficial reuse requirements; brine management options; and, general corrosion issues facing the CSG industry.

treatment of associated water which is produced during the gas extraction process. The CSG water is brackish in character and typically not suitable for direct reuse. The salt content of the coal seam gas water represents a problem in terms of its corrosion potential in both pipelines and water treatment equipment. This presentation outlined the various CSG water compositions which need to be considered; equipment

For further information on the ACA Technical Groups or to provide suggestions & or comments for future events please contact Brendan Pejkovic in the ACA office on bpejkovic@corrosion.com.au

Corrosion Challenges in the CSG Water Treatment Sector Prof Graeme Millar, Queensland University of Technology Although coal seam gas (CSG) production provides a basis for potential economic growth in Australia, it also represents a source of many challenges.

Of particular concern is the cost effective

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TECHNICAL EVENT REVIEW

Corrosion in the Oil & Gas Industries SPONSORED BY:

PROUDLY PRESENTED BY:

MEDIA PARTNER:

Corrosion in the Oil & Gas Industries – New Plymouth, New Zealand In 2014, one of the Australasian Corrosion Association New Zealand (ACANZ) Committee’s goals was to increase the awareness of corrosion in two of New Zealand’s most opportune regions. One was Christchurch and the other was New Plymouth.

The New Plymouth Corrosion in the Oil & Gas Industries event took place on the 7 August with the help and support of the PCPI Technical Group Committee. It was a stellar success.

Over 85 delegates and speakers descended on the Quality Hotel New Plymouth for a full day of learning, networking and camaraderie.

Supported by key sponsors AntiCorrosion Technology and International Paint with media partner World Oils, the ACA got together speakers from across Australia and New Zealand. Delegates not only hailed from New Plymouth, but also from the likes of Auckland, Wellington, Christchurch and from as far away as Australia.

The carefully chosen speakers gave informed presentations about risk based Inspection methodologies, contractor skill developments,

corrosion under insulation, cathodic protection, specialised coatings for the oil and gas industries, passive fire coatings all interlinked with case studies. The presentations were well received with many delegates asking questions. The formal proceedings of the day concluded with a presenter’s forum in which those burning questions the delegates had saved up could be unleashed on the experts. The presenters were ably tested for half an hour.

Once the full program of 11 speakers and the forum had concluded thanks were expressed to the sponsors, delegates and their companies for their efforts and time. The day then ended with refreshments at the bar. The networking and fellowship continued until late into the evening.

Below is an overview and summary of the presentations: Case Studies of Application of Risk Based Inspections Mick Ellem, Shell Todd Oil Services Risk Based Inspection methodology is often applied following detection of corrosion. However, there are typically a range of degradation modes to

consider, and assessment can be ahead of service. Case studies considered a non-age related failure mode in operation & a plant ‘on-paper’, an existing pipeline for a new project, and corrosion in a new operating mode.

Implementing a Program to Upskill Contractors for the Oil & Gas Industry Shane Coleman, Fitzroy Engineering This presentation looked at an approach to implement a program to meet the oil & gas industry demands for higher skilled workers. The modern blast and painter contractor is now required to meet; igher demands for safety H performance and emphasis on safety training, compliance and behaviour.

Higher demand for skill and productivity with workers to be qualified, multi-skilled, flexible, able to adapt to increased use of technology and apply more sophisticated coatings.

Solutions for pressure on budgets and increased reliability, where facility owners want quality work, done safely and at a reasonable cost.

October 2014 www.corrosion.com.au p.27

TECHNICAL EVENT REVIEW

Increasingly strict controls for environmental compliance and waste management. hallenges of aging workforce, C low levels of industry training and seasonal demand for contractors.

Further Developments in Accelerated Laboratory Evaluation of Coatings for Use Beneath Thermal Insulation Jamie O’Brien, International Paint This presentation objectively reviewed the comparative performance of standard epoxies, epoxy phenolics and epoxy novalac technologies as they pertain to performance at elevated temperatures. The presentation briefly explored the vagaries of current terminologies and the importance of common understanding between specifier and formulator. The presentation looked at the base chemistry behind the generic technologies, and reviewed their relative performance in corrosion under insulation, dry heat resistance applications, and reviewed the basics of high heat tolerance testing. The upshot of this presentation was that there should be an appreciation of the comparative merits of the technologies, an understanding of the product parameters that determine good high heat performance, and the need to identify the desired product chemistry correctly.

p.28 CORROSION & MATERIALS

Evaluating and Assessing Fitness-forPurpose of Pipelines with Defects – Case Study Focusing on Spiral Welded Pipelines Fikry Barouky, Anti Corrosion Technology This case study highlighted the failure of a newly installed seawater injection pipeline during the cleaning and hydro-testing and measures that are taken to make fit-for-service.

The line pipes were made of spiral welded steel conforming to API5L X65 specifications. The leakage occurred on the weldment with the same pattern and having a similar distance from the end of the pipe joint. Metallography, micro hardness, and scanning electron microscopy tests proved that the damage mechanism is irrelevant to mill defects or micro impact. The failure was due to the transit fatigue, which is attributed to the road transportation of line pipes from the mill to the job site.

Oil Refinery Corrosion & Integrity Management Arran Beasley, NZ Refining This presentation provided a PE Integrity management overview. Since 2000, risk based inspection (RBI) principles have been formally used at Refining NZ as an aid to prioritise and target inspection and maintenance activities. Continuous improvements in integrity management have been achieved with updated Inspection Data Management Systems (IDMS).

The current IDMS incorporates an integrated RBI analysis tool to provide

a live risk profile. There is, however, no substitute for thorough process & corrosion experience and knowledge.

The presentation then discussed a naphthenic acid corrosion case study: A brief discussion on a potentially aggressive high temperature (> 220°C) corrosion mechanism caused by organic acids present in crude oils.

There is increasing commercial pressure to process lower cost feed stocks, typically introducing increased corrosion and processing issues.

These issues must be fully reviewed and understood with appropriate monitoring and mitigation systems put in place. The discussion emphasises the importance of collective knowledge, experience and communication amongst a wide group of staff.

Corrosion Under Insulation – A Review and Update Willie Mandeno, Opus International Consultants This overview presentation commenced with illustrations of some local examples of corrosion under insulation (CUI), and then summarised results of investigations into 2 overseas examples where CUI resulted in loss of containment, i.e. at BP Cherry Farm refinery and a Dow Chemical’s ethylene plant. This was followed by a discussion at to why and where CUI occurs, how it was located and how it was prevented, and concluded

TECHNICAL EVENT REVIEW

with a brief review of recent relevant standards and guideline documents.

Long Term Benefits of CP: A 30 year case study on Mounded LPG tanks Jim Galanos, Corrosion Control Engineering Liquigas NZ is New Zealand's leader in bulk LPG handling. Liquigas have a number of mounded LPG storage tanks in Auckland, Pt Taranaki (New Plymouth), Christchurch & Dunedin. The below ground surfaces of the mounded tanks and associated pipework have impressed current cathodic protection (ICCP) systems installed to provide protection against external corrosion. These systems were installed at the time of tank installation & in some cases are over 30 years old. Ultrasonic testing of the tanks show the ICCP systems are operating and performing as expected as no significant corrosion has been found. This presentation outlined the ICCP systems and their performance over the years as part of a routine maintenance plan and the benefits it has delivered to Liquigas.

Specifying Materials for Extreme Corrosion in the Oil & Gas Industry Ian Ellis, Metz Specialty Materials Oil and Gas industry assets are subjected to not just environmental corrosion problems. Extreme corrosion

can occur to both concrete and steel infrastructure and plant elements due to the presence of various aggressive and high concentration chemicals often at elevated temperatures.

Increasing environmental awareness around the world means asset holders are under pressure to do all they can to avoid leaks to the environment.

Other risks include exposure of the workforce to dangerous chemicals and in extreme corrosion cases structural failures are also possible.

This presentation covered the basics of lining material and system selection for high concentration chemicals, and further discuss design and installation considerations. Case studies from situations with exposure to extremely corrosive chemicals were provided. The presentation provided some practical insight into this issue for specifiers and asset owners.

Managing Integrity of Pipework, Case Study – Corrosion Under Pipe Supports Mark Sigley & Dr Varghese Chakko Nettikaden, Vector Vector are replacing pipe supports that are causing corrosion of pipework. The presentation outlined the process followed to identify the at-risk supports, the new designs used and improvements planned for the ongoing identification and prioritisation process.

Oil & Gas Industry Passive Fire Protection Coatings – Review and Case Study Geoff White, Jotun Performance Coatings - Norway Passive Fire Protection materials include Concrete, Light Weight Cementitious / Vermiculite Mortars, Solid Board Materials and Epoxy Based PFP that chars when attacked by flame and temperature. Except for solid boards, all of these materials require the use or installation of some form of reinforcement to either hold them together in passive form or to keep them in place under fire conditions.

Reinforcement include steel re-bar in concrete, wire mesh in cementitious / vermiculite materials or material or wire scrim in Epoxy Systems.

Installation of the reinforcement is time consuming and labour intensive making the combination of labour and material cost expensive. This added to the time for installation has kept production rates and installation costs high. Until now, Jotun Norway has developed and had approved a mesh / scrim free epoxy based charring PFP that can be applied to an approved steel primer by spray without the need to stop for installation of reinforcement. The presentation introduced this new mesh free PFP to the Fire Protection Industry and owner operators in the petrochemical industries of New Zealand.

Overview of CBIP – The Importance of Certification in the Oil & Gas Industry Harvey O’Sullivan, CBIP The Certification Board for Inspection Personnel (CBIP) is NZ’s only personnel certification body for persons carrying out equipment inspection (pressure vessels, cranes, EWPs, lifts etc), and for nondestructive testing, welding, coatings etc. For its certification of pressure equipment and cranes inspectors CBIP has statutory recognition from the regulator. The presentation set out CBIPs approach to personnel certification and the systems it used to provide assurance to end users that inspectors are competent and provide a quality inspection service.

Many CBIP certified persons work for inspection bodies who facilitate the critical inspection function which many industries rely on. To ensure this quality delivery CBIP has become accredited to ISO 17024.

For further information on the ACA Technical Groups or to provide suggestions & or comments for future events please contact Brendan Pejkovic in the ACA office on bpejkovic@corrosion.com.au

October 2014 www.corrosion.com.au p.29

PROJECT PROFILE

Olympus helps keep Ford on track for V8 Supercar success A Ford Performance Racing team win in a V8 Supercar Challenge race is a tribute to all those involved, and among those who celebrate behind the scenes are the engine technicians who use the team's Olympus videoscope before each race to visually inspect the inside of the engine of the car to detect corrosion, cracks, scoring, material transfer or other flaws that could potentially lead to a catastrophic engine failure during the race.

Corrosion in internal combustion engines is most often caused by condensation of water vapour combining with sulphur in the burning fuel to form sulphuric acid.

The chemical composition of E85, the blended ethanol/petroleum fuel used

by V8 Supercars, is more corrosive than standard fuels. Water and acid condenses on to the cold surfaces of the cylinders and crankcase walls, resulting in etched wristpins, valve tappets, timing chains and other engine parts.

The inside story A videoscope is an inspection instrument that consists of a small camera mounted on a length of cable.

The camera can be controlled remotely by an operator while it is inserted in the cavity to be inspected.

The governing body for V8 Supercar racing stipulates the performance characteristics that all vehicles must comply with in order to participate in a race or series. This means that the size and weight of each front-engined, rearwheel drive vehicle is essentially the same. The only differentiation is in the tuning and performance of the engine.

“To us, the videoscope is absolutely essential and we are able to eliminate major failures because we are able to know the condition and viability of an engine throughout its life,” stated FPR’s Chief Engine Builder, Ashley Campbell.

The videoscope has enabled the team to catch many potential failures before they cause problems while racing.

According to Campbell, technicians can detect indications of corrosion in the cylinder wall or evidence of transfer of material from the piston. By removing the engine and stripping it down to its components, the engine technicians are able to limit damage to a single part or component before it impacts the rest of the engine.

The latest videoscope supplied to FPR is lighter, easier to use, and more conducive to how the team operates in the ‘pressure cooker environment’ on the Saturday night of a race meeting.

Engine preparation The highly skilled FPR engine technicians spend the time between V8 events stripping down and rebuilding race car engines in preparation for the next event on the calendar.

It takes between six and ten weeks to build an engine from scratch and about two weeks to strip down and re-build an existing engine. The FPR team has a full CNC (computer numerically controlled) machine shop that is used to custom make components for their engines.

The technicians know the entire history of every part and component.

According to Campbell, each con-rod spends its life in a specific location in

The Olympus iPlex LX videoscope model used by Ford Performance Racing.

p.30 CORROSION & MATERIALS

the engine and each piston is dedicated to a particular cylinder. Cranks and rods are matched to a specific piston weight in order to balance the engine.

Once a part is allocated to a position in an engine, that is where it stays.

Most items go into an engine ‘new’ and remain in that one power plant until they need to be replaced. FPR also makes its own timing gears, manifolds and exhaust systems.

The aluminium sump doubles as the engine mounting block. “We mount the engine rigidly to the chassis cross member to give some stiffening to the front of the car,” said Campbell. “There is no commonality with a car you might buy from a dealership: it may look like a Falcon, but take off the skin and it is a very different machine.”

Once an engine is ready, it is run on a fully automated dynamometer which allows the technicians to check ring seals, pistons and bore seals.

The engine is run under optimum conditions for oil temperature and pressure. It is also connected to a computer ‘mapping’ program that maps the generic tuning to match all the idiosyncracies of a particular powerplant. It is run up from a base RPM to the mandated peak RPM of 7500 rpm. This gives a readout of the horsepower and torque values to ensure that the engine is giving the expected performance. At the end of

Ford Performance Racing engine technician inspecting the engine of a Ford V8 Supercar.

The FPR pit crew in action on one of the team’s V8 Supercars in the 2013 Bathurst 1000 race. the procedure the technicians set the idle rate and shut the engine down.

After the engine is removed from the dynamometer, it is inspected using the videoscope to see if there are any signs of wear or damage or if unplanned events have occurred in the engine.

Preparing the car at the track FPR technicians plan for an engine to be in a car for the full race meeting.

However, the team always has a spare engine in the support truck. Except for the exhaust manifold and pipes, the spare unit is ready to go with all ancillary components and plumbing already attached.

On race days, there is a dedicated team for each car. The team comprises the number one and number two car mechanics assigned to a particular vehicle and, usually, two engine technicians who work on all the team’s four cars as well. There may also be one or two ‘floaters’ who provide extra muscle for moving equipment and tools around the garage. “Any more than this and it gets a bit claustrophobic within the confines of the chassis,” said Campbell.

During an engine change, everything from the harmonic balancer at the

An Olympus iPlex LX in the engine bay of an FPR V8.

front of the unit to the flywheel with the clutch attached is removed and replaced. To assist with the changeover, the engine has lifting tags attached to the exhaust system. When a new engine is placed in the car the first two things connected are the oil and water. “The oil is kept heated and the water is at 65 degrees prior to starting the engine,” said Campbell. “This is to eliminate cold start wear because when engine components are cold, they are not at their operating size.” Once the water and oil supply and return pipes, radiator bleed pipe and fuel line are connected, all the wiring associated with the injectors and all the monitoring sensors need to be plugged back in.

In the workshop Between V8 Supercar race meetings, the cars and engines are returned to the main FPR facility. The workshops are remarkably clean and uncluttered.

“We are spoilt to some extent that we are able to work in this environment,” Campbell mused. “I am continually amazed when I show someone around here that they can be so passionate about the outfit which, for us, we are lucky to have as our day-to-day job.”

During a standard rebuild, the piston rings and pistons are replaced.

Technicians also check the bearings but

usually these can be reused until they do show signs of wear, although gaskets and seals are always replaced. Every ferrous and steel item is crack tested, while aluminium components are tested using dye penetrant procedures. The cylinder head is under high stress during a race so it is checked after a race and technicians inspect the valves and valve seats where they meet the cylinder head.

Meeting the needs of customers Olympus is also willing to work with customers to adapt or modify instruments to meet their needs. “We have worked with FPR for several years now and have upgraded their equipment to the latest, lightweight model,” said Mark Wheatley, Sales Specialist at Olympus. “With the new untethered videoscope, the race technicians can quickly inspect an engine in the pit straight if necessary, rather than bring it into a workshop.”

Campbell concluded that his team is looking forward to trialling new highspeed camera systems that Olympus has been discussing with FPR. “We will be able to view and record the actions of most parts of our engines and see what might be the actual event that causes an engine failure, rather than just the aftermath,” he said.

The two FPR V8 Supercars on the Mount Panorama circuit.

October 2014 www.corrosion.com.au p.31

COATINGS GROUP MEMBER PROFILE

Goldfields Protective Coatings Q: In what year was your company established?

A: Goldfields Protective Coatings (GPC) was established in 2004.

Q: How many employees did you employ when you first started the business?

A: The business was started by 2 ‘hands on’ partners who each had more than 30 years industrial corrosion control experience.

Q: How many do you currently employ?

A: We have steadily grown the business whereby we currently employ 10 specialist applicators and supplement this with sub contractors to meet project requirements.

Q: Do you operate from a number of locations in Australia?

A: From our home base in Kalgoorlie, we cover the Goldfields region in WA from Esperance in the South up to Meekatharra in the North. We have also completed interstate projects such as the OZ Minerals Prominent Hill upgrade in South Australia.

Q: What is your core business? (e.g. blasting and painting, rubber lining, waterjetting, laminating, insulation, flooring etc.)

A: Our core business is industrial corrosion control incorporating coating inspection, testing, preparation and application. In addition to traditional epoxy coatings, we specialise in the application of high performance elastomeric urethanes and passive fireproofing.

Q: What markets do you cover with your products or services? e.g. oil & gas, marine, chemical process, general fabrication, tank lining, offshore etc..

p.32 CORROSION & MATERIALS

A: We provide our services to the infrastructure, mining, construction, transport and local government markets.

Q: Is the business yard based, site based or both A: Both. For our site based work, both local and remote, we maintain 5 mobile surface treatment units incorporating workshop, blast & spray equipment, materials storage, PPE and test equipment. At our Kalgoorlie premises we have a purpose built blast & paint facility allowing us to conduct surface treatment works within a controlled environment.

Q: What is your monthly capacity or tonnage that you can blast and prime?

A: Whilst each site project has different parameters that directly affect productivity such as access, required specification, existing coating, etc, our target is to achieve 8 – 10 sqm of surface treatment per hour per operator.

Q: Do you offer any specialty services outside your core business? (eg. primary yard based but will do site touch up etc.)

A: Yes, we also offer our clients environmental services that complement our corrosion control works. Specifically, we provide vacuum loading, Ultra High Pressure water jetting and emergency spill management. By providing these additional services we have found that we have more effective control on overall project schedule and quality outputs.

Q: What is the most satisfying project that you have completed in the past two years and why?

A: We undertook the refurbishment of a 6 storey cyclone tower at

Goldfields St Ives Goldmine whilst it remained ‘on line’. Applying a two coat specification in this wet and aggressive corrosion environment provided many challenges, but, was ultimately rewarding to all involved, especially our applicators. In addition to corrosion control services, we provided overall project management that also incorporated all mechanical repairs and scaffold services.

Q: What positive advice can you pass on to the Coatings Group from that satisfying project or job?

A: Elevating and maintaining corrosion control works as a priority within a maintenance or new construction project can be challenging, however, the reward is being allowed the required time and access to achieve coating specification to schedule and budget.

Q: Do you have an internal training scheme or do you outsource training for your employees?

A: We utilise both in house and nationally recognised training providers to meet our mandatory and developmental training requirements.

Having certified training staff within our company provides schedule flexibility and allows for one on one consolidation training that is not time limited. This has resulted in higher quality more efficient output and, importantly, personal development of our employees.

Contact Us Goldfields Protective Coatings Pty Ltd 12 Carnegie Street Kalgoorlie, Western Australia Tel: +61 8 9091 1339 Fax: +61 8 9091 1332 e-mail: admin@goldfieldspc.com.au web: www.goldfieldspc.com.au

UNIVERSITY PROFILE

Queensland University of Technology QUT has had a long history of corrosion research specifically related to industry problems. This long standing focus has been further strengthened by the opening of new Institute for Future Environments on the Gardens Point campus. The mission of the institute is to find ways to make the world more sustainable, secure and resilient which fits well with the goals of corrosion and prevention.

The approach of the institute is to: romote Interdisciplinary P collaboration beyond conventional ways of thinking and working.

Facilitate Productive partnerships by collaborating with leading organisations across Australia and the world on practical applications of our research. rovide a Powerful technological P ability in state-of-the-art facilities for modelling complex systems, monitoring the environment, testing pilot equipment and processes, and analysing the properties of solids, liquids and gases.

The facilities include the Central Analytical Research Facility (CARF), the Samford Ecological Research Facility (SERF), the Banyo Pilot Plant Precinct and the Mackay Renewable Biocommodities Pilot Plant.

The corrosion research group has benefited from expanded capabilities

in analytical chemistry, clean rooms, electron microscopy, light microscopy, molecular genetics, physical and mechanical properties and x-ray diffraction. This capability fits well with the multidisciplinary nature of corrosion related issues and many of these facilities are the only one of their kind in Australia and some are the only equipment like it in the southern hemisphere such as the He ion microscope. The facilities are supported by trained research staff that have impressive track records and contribute to the success of cutting edge research efforts. QUT has 6 research staff in the area of electrochemistry looking at a wide range of applications but with focus on battery technology and corrosion research. This work is supported by numerous advanced electrochemical systems and a new scanning electrochemical system providing the ability to measure electrochemical and corrosion events on the micron scale.

The corrosion work is supported through government and private industry funding and is targeted at the understanding and prevention corrosion related issues. We have a long history of basic corrosion research using both electrochemistry and analytical techniques coupled to theoretical models to understand and predict corrosion behaviours. Symadec and other models have been developed to teach students and model corrosion systems for a better understanding of the observed electrochemistry. This

system has been expanded recently for multiple metals and can now generate Pourbaix and Evans diagrams and fit the theoretically derived results to real data. An exciting application of this is in the area of concrete and the corrosion of reinforcement.

Research at QUT has spent many years designing solutions for industry in the area of corrosion prediction and monitoring and have a number of unique options for industrial clients to monitor coating breakdown and predict life to required maintenance as well as monitor corrosion rates in a variety of environments and locations.

Industries where our systems have been deployed include under insulation in the oil and gas industry, atmospheric, pile wrap applications, aircraft and military infrastructure, bridges and civil infrastructure and other areas where inspection can be difficult if not prohibitive. With these monitoring systems we can offer a wide range of communication systems to suit the individual application to provide discrete inspections up to online monitoring solutions.

Contact: Associate Professor Geoffrey Will Science & Engineering Faculty Queensland University of Technology 2 George St Brisbane | GPO Box 2434 Brisbane, Queensland, Australia 4001 phone: 07 3138 2297 | fax: 07 3138 1804 email: g.will@qut.edu.au www.corconres.qut.edu.au

October 2014  www.corrosion.com.au  p.33

NEW PRODUCT SHOWCASE

SHOWCASE New aerospace inspection gear Russell Fraser Sales Pty Ltd (RFS) announces the launch of a new Eddy Current Flaw Detector from Ether NDE. Manufactured exclusively in the United Kingdom for the Aerospace industry, the new AeroCheck Eddy Current Flaw Detector is set to take off here in Australia.

p.34 CORROSION & MATERIALS

and reflection probes without the need for adaptors. The AeroCheck includes rotary capability as standard and can be used with the ETher Mercury, Hocking 33A100, and Rohmann MR3 Drive.

Fully capable of all the typical eddy current inspection applications on an aircraft including paint thickness, sub-surface and surface crack detection, the AeroCheck is ideal for inspecting areas such as: Wheel brakes; Wheels; Landing gear; Fasteners; Engine mounts; Fuselage; Wing surface and hinges; Bulkheads; Door access points; Engine blades; Engine discs and much more.

With a crisp daylight readable LCD colour screen, weighing just 1.2kg and housed in a tough case, the AeroCheck is ideal for working in any environment and can be used for up to ten hours with a pencil probe and seven hours with the rotary drive and probe attached. The intuitive menu options can be configured to the user’s personal preferences and with the built-in “flip” function the AeroCheck works equally well for left or right-handed operators.

Fitted with the industry standard 12-Way Lemo connector and co-axial Lemo 00 connectors the AeroCheck can be used with absolute, bridge

For more information, please call 02 9545 4433, e-mail us on rfs@rfsales.com.au or visit our website at www.rfsales.com.au

NEW PRODUCT SHOWCASE

Cygnus Intrinsically Safe Ultrasonic Thickness Gauge The Cygnus 1 Intrinsically Safe is a rugged, shock-proof multiple echo ultrasonic surface thickness gauge designed for safely measuring metal thickness to determine wastage or corrosion in potentially explosive

environments. By using multiple echo technology the metal thickness gauge measurements are error checked using 3 return echoes to provide repeatable, reliable results.

Graetz GammaSmart One Personal Radiation Protection Device The Graetz GammaSmart One is a robust and easy to handle pocketsized dose rate alarm unit designed

for the personal radiation protection - also for the use in potentially explosive atmospheres of Zone 1.

Fluke 28 Ex Intrinsically Safe Digital Multi-meter Now there’s one intrinsically safe digital multimeter (DMM) you can use in IIC (gas), in Zone 1 and 2 and IIIC (dust), Zone 21 and 22.

Regardless of what environment you work in, all the test and

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Fluke 568 Ex Intrinsically Safe Infrared Thermometer The Fluke 568 Ex Intrinsically Safe Infrared Thermometer can be used in Class I Div 1 and Div 2 or Zone 1 and 2 hazardous environments anywhere in the world. With a rugged, easy-to-use, ergonomic design, the Fluke 568 can stand up

to tough industrial, electrical, and mechanical environments.

For more information on all the above products, please call 02 9545 4433, e-mail us on rfs@rfsales.com.au or visit our website at www.rfsales.com.au

October 2014 www.corrosion.com.au p.35

TECHNICAL NOTE

Preventing Coastal Corrosion (Tea Staining)

When used properly, stainless steel enjoys a strong and enduring reputation for visual appeal and structural integrity in a wide range of applications and environments.

But, like all materials, stainless steel may become stained or discoloured over time, impairing the overall look. This brown discolouration - tea staining - has been identified in coastal applications in Australia and overseas.

This article provides information on tea staining and what fabricators, specifiers and end users should do to help avoid it and enjoy the long life and clean appearance of stainless steel.

What is Tea Staining?

Tea staining is discolouration of the surface of stainless steel by corrosion. It is a cosmetic issue that does not affect the structural integrity or the lifetime of the material. Tea staining occurs most commonly within about five kilometres of the surf and becomes progressively worse closer to the marine source.

However, wind exposure, pollution levels, local sheltering and higher temperatures can create environments where tea staining might occur 20 kilometres or more from the surf. The effect is much less severe around sheltered bays. These same factors also increase corrosion rates of alternative materials.

Other causes of staining that are not tea staining include carbon steel contamination, uncleaned welds and fumes from chemical such as hydrochloric acid or bleach.

Why Does Tea Staining Occur?

The relationships between the contributing factors are complex, but generally become increasingly critical closer to salty water. Tea staining occurs when local conditions (such as temperature, relative humidity and presence of corrosive substances on the surface) are too aggressive for that stainless steel grade in its installed condition.

There are important factors that promote the occurrence of tea staining that should be considered, as shown in the box and explained below.

1. Presence of corrosive substances The presence of sea salt on the surface of the stainless steel is one of the major factors that causes tea staining. Sea salt

p.36  CORROSION & MATERIALS

has the characteristic of staying wet until a very low relative humidity (RH).

The result of this is that the surface stays wet (and is corroding) longer with sea salt compared with sodium chloride. However the presence of industrial pollutants could also make the conditions more aggressive.

2. Atmospheric conditions A combination of atmospheric conditions with high humidity (eg tropical climates) and a high temperature creates worse conditions for the occurrence of tea staining.

The high humidity generates a film of moisture that dissolves the salt deposits and creates a corrosive solution on the surface. The combination of low humidity and absence of corrosive deposits means that tea staining is rarely a problem indoors.

3. Surface orientation and design Poor drainage promotes corrosion whether it is because the surface is near horizontal or has a texture that traps contaminants. Conditions are very aggressive in rain sheltered areas such as the underside of sloping roofs, downpipes under eaves or in a building rain shadow. These can cause significant tea staining. Designs with corners or crevices (such as intermittent welds) can trap water and lead to more serious corrosion than tea staining.

4. Surface roughness Deep grooves or metal folds on a surface are more susceptible to corrosion because they can trap salts (chlorides).

When the surface dries the salts become concentrated, making the conditions more aggressive. A deeper groove will have more trapped water (and salts)

TECHNICAL NOTE

based on the content of these three elements is useful to rank the corrosion resistance of different grades. This Pitting Resistance Equivalent [PRE] number is calculated by %Chromium + 3.3 %Molybdenum + 16 %Nitrogen.

The PRE ranges from 10.5 for the grades with the lowest corrosion resistance to more than 40. For acceptable corrosion resistance, typically a PRE of approximately 18 is adequate away from marine influences, PRE of approximately 24 is required for marine atmospheres while severe marine atmospheres may require PRE of approximately 34. The higher the PRE, the greater the corrosion resistance.

so the bottom of the groove will be exposed to salt concentration above its resistance for longer - which will initiate corrosion. There is a critical surface roughness of approximately 0.5 μm Ra for cut or abraded surfaces. This is probably due to increased levels of grinding debris from coarse polishing.

Abraded surfaces smoother than approximately 0.5µm Ra are much less susceptible to corrosion.

5. Surface characteristics To achieve the best corrosion performance of a stainless steel, the surface should be clean, free of contamination such as carbon steel swarf or manganese sulphide inclusions, and have a continuous passive layer.

Acid pickling, acid passivation or electropolishing for sufficient time will remove these contaminants from the surface as well as restore the passive layer, leaving the stainless steel with a clean and corrosion resistant surface.

If a stainless steel is welded, the heat input will locally destroy the passive layer and a dark non-protective oxide is formed around the weld. To achieve best corrosion performance and restore passivity of the weld, the heat tint and underlying chromium depleted layer must be removed. How this is done is described later.

6. Appropriate grade There are several hundred grades of stainless steel with different chemical composition but only about 10 in common use. All owe their corrosion resistance to the thin chromium oxide film on the surface, although other additions such as molybdenum and nitrogen can improve the corrosion resistance, especially in chloridecontaining environments. A formula

7. Maintenance Stainless steel is a low maintenance material but it is not generally maintenance free. A light and regular wash is best and natural rain washing may be sufficient. If not, then consider washing the stainless steel when you wash an adjacent window. Lower grades will require more regular maintenance and if the environment causes sticky deposits, a solvent and detergent mix may be required. Application of oils or waxes will temporarily restrict chloride access to the stainless steel but they need regular renewal. These temporary protectives also tend to attract debris and dull the surface.

Guidance in Fabrication Design, fabrication and handling Poor design and fabrication can lead to tea staining or more serious corrosion of stainless steels. Surfaces should be free draining, boldly exposed to rain washing and avoid channelling of runoff. Horizontal surfaces or curves which cause ponding are specific problems.

Abraded surfaces should not be rougher than 0.5µm Ra and the grain should be vertical to avoid ponding and collection of contaminants. For abraded surfaces, the best corrosion resistance will be achieved if a nitric acid passivation treatment is carried out as a final step.

Competent stainless steel fabricators will avoid carbon steel contamination (which can cause other corrosion problems), so choose designers and fabricators that are experienced with stainless steel to achieve the best outcome.

Appropriate grade selection Each stainless steel has a limit to the concentration of salts that it can comfortably resist: the higher the alloying content (Cr, Mo and N), the higher the resistance to corrosion.

Exposure of a particular grade of stainless steel to a more aggressive environment than it can resist will cause tea staining.

Conditions Reducing the Risk of Tea Staining 1. Absence of corrosives - especially salt.

2. A tmospheric conditions - lower temperatures and low relative humidity (RH) are better.

3. Surface orientation and design - free drainage and avoidance of traps which can concentrate corrosives. This includes open exposure to allow rain washing.

4. Surface roughness - smoother is better.

5. Chemical cleanliness or passivation of the surface improves the corrosion resistance.

6. Appropriate grade for exposure conditions - increasing PRE increases corrosion resistance.

7. Maintenance - or corrosives will accumulate.

October 2014 www.corrosion.com.au p.37

TECHNICAL NOTE

Grade 316, or a grade with equivalent corrosion resistance, should be selected as a minimum within five kilometres of the surf. For critical applications (eg splash zones, unwashed areas or rough surfaces), higher grades of stainless steel such as duplex or ‘super’ grades may be required.

The lower alloyed and less expensive grades (such as 304 or 430) will probably become tea stained or even suffer more severe corrosion in a marine environment.

Treatment of welds Pickling after welding is one method of promoting good performance of stainless steel near the coast. This chemical treatment normally uses a mixture of hydrofluoric and nitric acids in a gel, paste or bath. It removes the welding oxide and chromium depleted layer underneath and rapidly restores the passive layer, which gives stainless steel its corrosion resistance. A darker heat tint means a thicker oxide and a longer exposure to pickling acids is required. Pickling removes material from the surface in a controlled way and may etch and dull the stainless steel surface. Excellent gas shielding, so there is no more than a pale straw colour, may avoid the need for pickling provided the environment is mild. An alternative is to mechanically remove the scale and underlying chromium depleted layer, followed by a chemical passivation treatment using nitric acid. Any mechanical removal must not unduly roughen the surface – the limit 0.5 μm Ra limit mentioned previously.

Installation and inspection After installation, the completed structure should be visually inspected for surface damage or contaminants.

If contamination is suspected, several cycles of a misting and drying test with tap water is relatively simple.

The sensitive ferroxyl test (described in ASTM A380) may also be used in critical applications. If discovered, imperfections should be removed and the corrosion resistance chemically restored by pickling or passivating treatments or by electropolishing.

Do not use hydrochloric acid Hydrochloric acid, sometimes used to clean cement or mortar residues, must not be used on stainless steel — it will stain the surface and usually start more serious corrosion.

p.38 CORROSION & MATERIALS

Key Design Recommendations Plan to get the desired result Marine environments are the most aggressive for all building materials.

Areas that are sheltered or not rain washed are particularly susceptible.

Tropical and high humidity areas are also more at risk of tea staining.

Stainless steel’s corrosion resistance in marine environments means that installations are likely to remain structurally sound for decades (see image below).

Specify and insist on a smooth and clean surface finish To minimise the risk for tea staining the smoother the surface the better.

A surface roughness of less than 0.5µm Ra is strongly recommended for abraded finishes. Surfaces smoother than 0.5µm Ra will have even better corrosion resistance. The most corrosion resistant, mechanically finished surface is a mirror polish (ASTM A480 No.8 or EN10088.2 class 2P). It is very smooth, resistant to salt accumulation and easy to clean.

The surface roughness of a mirror polished surface is so low that it is not reliably measurable by mechanical (stylus) instruments.

A No.4 finish to ASTM A480 just means an abraded (linished) finish.

Specifying a No.4 finish is inadequate without indicating the required roughness.

The Euronorm standard EN10088.2 (finish 2K) recognises this and requires Ra<0.5µm but also that the abraded profile is clean cut.

It must be recognised, however, that keeping a pristine surface finish requires understanding and, usually, additional cost. Determine your expectation of the structure and plan ahead to achieve and maintain the intended result. This normally includes a maintenance program.

Environment Tea staining is most likely to occur up to five kilometres from a surf beach and one kilometre from still marine waters. There is no hard and fast rule: wind and weather conditions play a big part and the severity of the conditions increases sharply as you approach the surf. AS 2312 suggests that in some special circumstances, 20 kilometres from the coast can still constitute a marine environment.

AS4312 has corrosivity maps which may assist in decisions. The closer to the source of salt, the more critical it is to follow the recommendations in this article.

Components used near the sea can be made more resistant to tea staining if they are passivated to remove surface contaminants such as steel smears, weld spatter or sulphide inclusions. Mild levels of contamination may be removed by nitric acid passivation which should not change the surface appearance although it may slightly cloud a mirror polish. More severe contamination by particles of steel or grinding debris may require pickling which etches and usually dulls the surface. Either process may use pastes or gels (which can be applied on site) or liquids in baths in a factory. These chemical processes take longer if it is cold.

Electropolishing has been found to be extremely effective in removing surface contamination and passivating the surface. It also brightens and slightly smoothes the surface as well as rounding sharp edges and removing the peaks left from polishing operations.

Electropolished surfaces have a characteristic lustre but may not be mirror smooth. A mechanically mirror polished surface will normally lose its mirror reflectance if electropolished.

TECHNICAL NOTE

Smoother mill finishes such as 2B and Bright Annealed (BA) are widely available in flat products. Provided they are not damaged during fabrication, they offer good resistance to collection of salt deposits and hence to tea staining.

Rolled embossed finishes may be suitable for some applications. These have very smooth surfaces but with a pattern that lowers reflectivity. Think carefully about the pattern and how it will be oriented — avoid pools of water sitting on the surface.

Specify and insist on the right grade In marine environments, use grade 316 or one with equivalent corrosion resistance unless a higher grade is required because the job is aesthetically critical and regular maintenance is unlikely.

Where there are high aesthetic expectations a number of more corrosion resistant stainless steel grades can be considered. The first step up from 316 is 2205 and then the super duplex grades, although the high molybdenum austenitics and high molybdenum ferritics may also be useful. Smooth surface finish and maintenance are still important with these grades.

Treatment of welds For general architectural applications welds should comply with AS/NZS 1554.6 Level 2, Class B. (Details of other weld finish classifications are given in the ASSDA Reference Manual). However, this specification does not guarantee the absence of structurally minor surface defects which can act as traps and corrosion initiating sites. The protruding weld can be ground flush, and good resistance to tea staining achieved (a Grade I finish) when polished to 320 grit or finer finish. The smoother the surface, the better the tea staining resistance.

Passivation will occur in chloride free, moist air within a day. Chemical

passivation treatment with nitric acid may be applied to: S ubstantially reduce the time required for passivation Provide a more corrosion resistant passive film Remove possible iron contamination Dissolve exposed manganese sulphide Chemical passivation must be applied after abrasion if the environment is particularly aggressive.

An alternative cleaning treatment is a Grade II blast cleaned finish. This will require a post blasting passivation treatment. The blasting should remove heat tint and the chromium depleted layer but not make the surface roughness worse than 0.5 µm Ra, must not leave folds or crevices and should not embed corrodents. The Grade II stainless steel wire brushing treatment is not adequate to control tea staining.

Where a polished (or linished or ground) finish is desired, abrasives should be used with lubrication if possible. In selecting abrasives, consideration should be given to matching the surrounding finish.

A Grade II pickled finish will provide good tea staining resistance without grinding the weld flush, provided there are no significant surface crevices/ defects. Where linishing or blasting is not performed, pickling of site welds (using mixed hydrofluoric plus nitric acids) should take place as a final step in the weld procedure.

Pickling will remove any fabrication contaminants and restore the passive chromium oxide layer, resulting in a corrosion resistant surface.

Electrocleaning has been used instead of pickling to remove weld scale and heat tint, especially when hydrofluoric acid use is restricted. While passivation treatments do not normally affect

appearance, pickling treatments are likely to dull bright surface finishes.

Electropolishing is also a very effective method of passivation. The ASSDA Reference Manual describes these treatments in more detail.

Specify and insist on regular maintenance Washing removes deposits (such as salt) that can cause corrosion. It is necessary to avoid tea staining. Rain washing the surface is helpful in reducing tea staining, so design the job to take advantage of the rain, but ensure good and even drainage.

Stipulate that the stainless steel also be washed when cleaning of the surrounding area takes place. As a guide, stainless steel should be washed if a window requires washing. For best results, wash with soap or mild detergent and warm water followed by rinsing with clean cold water.

The appearance of the surface can be improved further if the washed surface is wiped dry.

If routine cleaning of the surrounding area does not take place, washing frequency for the stainless steel is recommended as in Table 1 below.

It is essential that abrasive cleaners or those containing chlorides or bleach are NOT used to clean stainless steels as they will damage the surface. If some tea staining does occur, then an assessment of the 7 points is required to determine why the problem occurred. Simple mechanical polishing is unlikely to both remove current and prevent future teastaining. Reasonably simple chemical cleaning and passivation is usually the most effective treatment. The ASSDA Reference Manual has more details.

ASSDA. Reproduced Technical FAQ. No. 6. Edition 3, February 2010.

Table 1: Recommended Cleaning Intervals for 304 Stainless Steel* Building Element

Roof or wall washed by rain

Eave, soffit or under-eave wall not washed by rain

Surface condition

No deposits

Deposits accumulate No deposits

Deposits accumulate

Cleaning** in rural, suburban and residential areas

1/year

1/year

1–2/year

2–12/year

Cleaning for seaside***, industrial and severe urban areas

1/year

1/year

3–4/year

4–12/year

Notes * Cleaning frequency may be less for highly alloyed grades but it is dependant on surface finish ** Cleaning involves washing with potable water, low chloride water or washing with a neutral detergent *** This listing does NOT imply that it is recommended that 304 stainless steel is satisfactory in marine environments.

This table originates from Nickel Institute and Japan Stainless Steel Association publication No. 12 013 'Successful use of stainless steel building materials', page 79

October 2014 www.corrosion.com.au p.39

PROJECT PROFILE

Keeping steep task on track Close collaboration between the steel fabricator and galvanizer allowed for a staged provision of thousands of individual parts for an extensive redevelopment of the world’s steepest incline railway within a tight time frame to allow Scenic World to continually operate during construction.

Not only was it a requirement to ensure continuity of operations to the site’s two other existing rides, but it was also required that the railway be constructed while the existing structure remained largely operational. The staged approach was essential to allow safe public access to parts of the existing platforms.

The physical size of items was not the greatest challenge for applying corrosion protection for this project, but rather due to the quantity and volume of steel being processed, the planning, staging and scheduling of each load of steel was critical and had to be done right to avoid any mix ups of steel sections relating to different stages of the project.

p.40 CORROSION & MATERIALS

All up, the project called for 164 tonnes of hot dip galvanized steelwork for the popular tourist attraction located at Katoomba in NSW’s Blue Mountains for new loading and unloading platforms and stairs for top and bottom stations, service walkways, bottom station towers, module walkways, equipment platforms and a balcony extension, totalling 17,855 individual steel components.

Nepean business, Galserv® was awarded the hot dip galvanizing by longstanding steel fabricator, Combell Steelfab with which the business has a long and close relationship, creating an ad hoc delivery plan spanning two months, focussing on quick turnarounds for full semi loads of material fabricated,

galvanized and delivered to site on time.

SKM and PMDL led the design on behalf of the Scenic World, while Grindley Construction managed the complex building and construction process.

Galserv® treated the support structures for the new upper and lower platforms and all stairways and maintenance access walkways, some of which were installed at an incredible incline of 52 degrees on the track leading into the Jamison Valley.

According to the project’s Account Manager at Galserv®, Adam Chessell, it was recognised right from the outset that the sustained short turnaround time was going to represent the greatest

challenge for Galserv® to meet the fabricator’s requirements.

need for expensive onsite touch ups,” Mr Chessell said.

“The average turnaround time was three days, but it was not uncommon to be given a call with specific items needing to be processed overnight or even on the same day,” he said.

“The nature of the project demanded that the highest quality was maintained at all times but with the added pressure of very short lead times, so pre-planning was essential to ensure a relatively smooth flow of production,” he said.

“The challenge was met by operating three shifts 24 hours a day, facilitated by the close understanding between ourselves and Combell forged over many years.”

Not only that, he said the sheer mountain terrain meant access would make any rework extremely difficult and costly, so a low maintenance requirement was critical.

A Bell UH1H helicopter was required to handle the installation, with some sections even having to be lowered into place weaving through the complex web of the existing steel support structure, so having to reinstall components later on could prove costly.

“Hot dip galvanizing was the obvious solution providing a robust finish ideal for material handling during transportation which eliminated the

“The key was about knowing exactly what the customer needed and wanted at all times, achieved through regular consultation and a high degree of pre-planning.

“During the consultation, much focus was given to the design and fabrication to ensure the optimum finish and to eliminate all drainage and venting concerns to allow for a high quality finish every time.

“Stringent quality control was adhered to ensuring material was readily identifiable and traceable through accurate paperwork and materials lists.

“Delivering a consistent, high quality galvanized finish on time meant that the upgrade did not overly interfere with the operation of existing railway adjacent.

“Importantly, the galvanizing finish is aesthetically appealing in its surrounding environment and will remain so for years to come with the advantage of never having to have its coating reapplied.

“Clearly, the choice of galvanizing represented a logical fit-for-purpose and best overall solution for this world class tourist attraction with a long design life.”

The project recently won the 2014 Engineering Projects category of the Australian Steel Institute’s NSW/ACT Steel Excellence Awards, the 2013 MBA National Commercial Construction Award (Civil/Infrastructure under $25m) along with multiple State MBA Awards, and is an entry into this year’s Galvanizers Association of Australia Sorel Awards.

A 12 minute documentary of the construction is available at https://www. youtube.com/watch?v=VkWmCayL3_w Alan Marshall c/o Australian Steel Institute on behalf of the Galvanizers Association of Australia

October 2014 www.corrosion.com.au p.41

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p.46 CORROSION & MATERIALS

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- Material characterisation(metallurgy/corrosion/welding/fatigue)

- Material characterisation(metallurgy/corrosion/welding/fatigue)

Dr David Tawfik — Principal Materials Engineer

Dr David Tawfik — Principal Materials Engineer

Impartial investigation and independent expert witness in:

BEng(Hons) BDes PhD MIEAust CPEng RPEQ

m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au

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Impartial investigation and independent expert witness in:

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tawfik

- Forensic engineering (material failure, safety/accidents, fire)

- Forensic engineering (material failure, safety/accidents, fire)

- Compliance (metal fabrication, quality, fitness for purpose)

- Compliance (metal fabrication, quality, fitness for purpose)

- Material characterisation(metallurgy/corrosion/welding/fatigue)

- Material characterisation(metallurgy/corrosion/welding/fatigue)

Victoria New South Wales Brisbane Western Australia Distributors all States and Auckland N.Z.

Impartial investigation and independent expert witness in:

1300 782 501 1300 782 503

General Manager

Dr David Tawfik — Principal Materials Engineer

Dr David Tawfik — Principal Materials Engineer

m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au

m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au

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BEng(Hons) BDes PhD MIEAust CPEng RPEQ

Australasian Principal Elcometer Service Centre

Phone: BEng(Hons) BDes PhD MIEAust CPEng RPEQ1300 503 610 Email: sales@phillro.com.au m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au www.phillro.com.au

tawfik

Impartial investigation and independent expert witness in:

31/10/12 12:09 P

BEng(Hons) BDes PhD MIEAust CPEng RPEQ

INTERPROVINCIAL CORROSION CONTROL CO. LTD. Leaders in the Cathodic Protection Industry…Since 1957

SOLID-STATE CATHODIC ISOLATOR® Mitigation Of AC Induced Voltages • Lightning • AC Fault Current

tawfik

Impartial investigation and independent expert witness in:

TEL: 905-634-7751 FAX: 905-333-4313 - Forensic engineering (material failure, safety/accidents, fire)

tawfik

www.cceng.com.au

Cathodic Protection | Integrity Management | Design & Testing | CP Products

Impartial investigation and independent expert witness in:

Sydney | Melbourne | Brisbane | Perth | Townsville | Auckland | New Plymouth

- Forensic engineering (material failure, safety/accidents, fire)

- Compliance (metal fabrication, quality, fitness for purpose) www.Rustrol.com

- Compliance (metal fabrication, quality, fitness for purpose)

- Material characterisation(metallurgy/corrosion/welding/fatigue)

- Material characterisation(metallurgy/corrosion/welding/fatigue)

Dr David Tawfik — Principal Materials Engineer

Dr David Tawfik — Principal Materials Engineer

m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au

m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au

w w w .taw fikg rou p. co m. a u

w w w .taw fikg rou p. co m. a u

BEng(Hons) BDes PhD MIEAust CPEng RPEQ

BEng(Hons) BDes PhD MIEAust CPEng RPEQ

D R MAY Inspections

David May

tawfik

tawfik

- Forensic engineering (material failure, safety/accidents, fire)

- Forensic engineering (material failure, safety/accidents, fire)

- Compliance (metal fabrication, quality, fitness for purpose)

- Compliance (metal fabrication, quality, fitness for purpose)

- Material characterisation(metallurgy/corrosion/welding/fatigue)

- Material characterisation(metallurgy/corrosion/welding/fatigue)

Impartial investigation and independent expert witness in:

Dr David Tawfik — Principal Materials Engineer BEng(Hons) BDes PhD MIEAust CPEng RPEQ

m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au

Welding Supervision Welding Inspection NDT Specialist Coating Inspection Inservice Inspection

Impartial investigation and independent expert witness in:

Geelong Office: 193 Station Street, Corio, Victoria 3214 Australia Postal Address: P.O. Box 1080, Corio, Victoria 3214 Australia Tel: +61 3 5275 3339 Fax: +61 3 5275 0585 Mob: 0412 520 699 Email: dmay@drmay.com.au

Dr David Tawfik — PrincipalOctober Materials Engineer 2014 www.corrosion.com.au BEng(Hons) BDes PhD MIEAust CPEng RPEQ

m +61 (0)4 1225 5112 e tawfikd@tawfikgroup.com.au

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SPECIALITY COATINGS BY HEMPEL

WHY CHOOSE HEMPEL? • Over 40 years experience developing and applying specialised coatings that offer maximum protection • Reliable with strong technical support • Efficient systems and solutions for the Power, Oil & Gas and Process industries to reduce maintenance costs As a global manufacturer and supplier of protective coatings, Hempel develops market-leading solutions for the most challenging coating requirements.

Our Versiline range has been designed to perform in aggressive environments giving superior protection and minimises the risk of production disruptions keeping your assets and your reputation safe.

If you want to know more, please contact us at: protective@hempel.com Toll free 1800-HEMPEL in Australia or 0508-HEMPEL in New Zealand. www.hempel.com/versiline

Trusted in challenging environments