C&M April Edition by Australasian Corrosion Association

Official

Publication

The

Australasian

Corrosion

Association

Vol 37 No 2, April 2012 ISSN 1326-1932

Inside this Issue: University Profile: The University of Auckland Project Profile: Concrete Protection in Strong Chemical Conditions Project Profile: Fremantle Ports – Protecting the Unseen Technical Note: Pipeline External Corrosion Analysis Using a 3D Laser Scanner Technical Note: The Tiger Stripe Effect Observed When MIC Occurs at Welds of Stainless Steel Vessels Containing Stagnant Water Research Paper: Investigation Into the Effect of Nano-Silica Particles on the Protective Properties of Polyurethane Coatings

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www.corrosion.com.au

seMinar series: LoCations: darWin tUesdaY 1st MaY Engineers Australia, 14 Shepherd St, Darwin

gLadstone tHUrsdaY 3rd MaY CQUniversity, Bryan Jordan Drive, Gladstone

neWCastLe tUesdaY 8tH MaY Engineers Australia, 122 Parry Street, Newcastle West

WoLLongong WednesdaY 9tH MaY Medina Executive, 19 Market Street, Wollongong

tasMania tUesdaY 15tH MaY Zeps Café, 92–94 High Street, Campbell Town

MeLBoUrne tHUrsdaY 17tH MaY Engineering House, 21 Bedford Street, North Melbourne

Corrosion and risk ManageMent It is not hard to imagine the risk that corrosion poses to plant and equipment. What is less considered is the threat this risk also poses to human safety and to the environment. Managing and mitigating this risk can be done through developing and maintaining a management plan. Industry recognised best practice is to implement a regime of inspections and risk assessments, thereby determining the condition of equipment or a section of plant. An evaluation may then be made of the likelihood of failure or damage due to corrosion and a measure of severity of outcome estimated; key steps in the development of options to mitigate, manage or remove this risk. Corrosion risk mitigation may be as simple as altering materials or applying a coating or it might involve other design changes. ACA is holding its annual travelling series of technical seminars on corrosion and risk management. Please use this form to register your attendance at any of the locations as listed here. The schedule for each location will be released in advance and can be accessed at www.corrosion.com.au. Please note that the schedule may vary because of local contributions.

Supported by:

adeLaide tUesdaY 22nd MaY Mercure Grosvenor Hotel, 125 North Terrace, Adelaide

PertH tHUrsdaY 24tH MaY The Old Brewery, 173 Mounts Bay Road, Perth

Engineers Australia members can choose to record CPD hours for attendance at this event in their personal CPD logs. Members should refer to Engineers Australia’s CPD Policy for details of requirements and conditions.

SPONSORED BY:

Corrosion and

Coating

PROUDLY PRESENTED BY:

Durability

ACA Coatings Technical Group Meeting 6-7th June 2012 â&#x20AC;˘ Courtyard by Marriott North Ryde, Sydney

The use of protective coatings across multiple industries, including oil and gas, mining and infrastructure, is a widespread and extremely effective approach to controlling and preventing corrosion. The durability 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 operating conditions - such as high temperature, chemical contact, severe environments and often combinations of all of these. However the successful performance of protective coatings in any environment or operating condition depends on more than just the chemicals in the can! The final coating performance is only realised when cured as a dry film on a surface, and the coating contractor plays a vital part in achieving this. Increasingly, coating manufacturers and coating contractors are being required to provide longer lasting products and longer warranties. Subsequently the training of coating contractors by both coatings manufacturers and industry bodies is more relevant and important than ever before. For the coating application contractor keeping abreast of the technological advances is coupled with the onerous duty to comply with ever changing work place safety and environmental requirements and the increasing liabilities in an ever more litigious society. This seminar aims to explore these issues and share with the audience selected topics to reflect the importance of appropriate coating system selection and contractor compliance and education to achieve good corrosion prevention outcomes.

April 2012â&#x20AC;&#x192; www.corrosion.com.auâ&#x20AC;&#x192; p.9 For registration and further details see www.corrosion.com.au

EDITOR’S NOTE

Corrosion & Materials; a Journal or a Magazine? What is Corrosion & Materials? Is it a journal or a magazine? The distinction is important, as it affects the way authors write for it and the attitude of people who read it. A scientific or technological journal is a publication that depends for its growth and very existence on its reputation for authoritative papers on technological or scientific matters of interest to its readers. Papers that can be relied upon by its readers to have been well refereed by peer reviewers. It may contain editorial matter concerning matters of technical interest to the readers, but when it does so, such matter must be identified by means of a by-line. A trade or professional magazine, on the other hand consists of contributions of more general interest to members of a trade or profession, and achieves its growth by means of news, notices, personalia, general educative matter and matters of concern and interest to the practitioners of the particular trade or practice. The papers are not necessarily authoritative, but must be based upon the relevant technology and particularly when controversial matters are discussed must carry a by-line that identifies the authors’ special interest. A magazine may carry advertising material but this should be identified as such. Corrosion & Materials is currently a hybrid (and not, I hope, a bastard off-spring) between a journal and a magazine. This must be so if it is to fulfil its twin functions as the magazine for The Australasian Corrosion Association Inc and at the same time serve as the journal of record for the growing technological effort in Australasia and Oceania and to demonstrate to the world–wide corrosion community the strength of corrosion research and professional practice in our region. It is because of the dual nature of Corrosion and Materials that the various roles which it undertakes have been divided into three groups, “Research and Professional Practice”, “Short Articles” and “News”.

The “Research and Professional Practice” section is the “journal” portion of Corrosion & Materials. It aims to present the strength of the original work that is being carried out in Australasia and Oceania and to provide a forum in which new ideas can be transmitted with the priority of publication that can be gained from publishing in a well refereed journal. To this end all publications in this section are subjected to a rigorous refereeing process and because of this can be included as a Research Paper that meets the requirements of the ARC “Excellence in Research Australia” list submitted by research institutions*. The ERA Identification Designation of the journal is 123306 and the normal “Field of Research” is 0912 – Materials Engineering, but other fields are also accepted by the ARC. Because the publication time is usually quite short by comparison with many corrosion and electrochemistry journals, Corrosion & Materials is often very appropriate for the early publication of research results which might form the basis of a more extended paper to be submitted later on to a more widely distributed journal. “Research Notes” (generally <1000 words), will be rushed through the refereeing process to give priority of publication. As well as “Research and Professional Practice” papers, Corrosion & Materials publishes “Short Articles”. These consist of short (500 – 1500 word) technical and practical based articles of general interest to members of the corrosion community written in a style to be readily understandable by the average corrosionist. Although a project profile or a technical note does provide an opportunity to publicise an organisation or a product, such Short Articles can not be overtly commercial. Articles are sought and solicited by members of the editorial staff. These short articles are not subject to the rigorous refereeing process used for the Research and Professional Practice section, but are reviewed at an Editorial Board level just to assist writers to make their writings more easily understood and authors are

given the opportunity to discuss with the editorial panel changes to the submitted piece of work. For these short articles we are dependent upon the membership of the ACA, and in particular the membership of the Technical Groups who are often the people who know what is going on in the industry and more importantly who is moving the technology. The section can only be kept alive if we have a constant stream of good short articles submitted by the membership of the ACA. All the items in the magazine section of the publication (with the exception of “Branch news”, “Standards Update”, President’s Message”, “Events Calendar” and similar items), need to be subjected to the process of refereeing by the editorial board both to ensure the technological appropriateness of the article and, hopefully, the absence of small errors. We hope to keep this review process to as short a time as possible. So if Corrosion & Materials is to be both a Journal and a Magazine it depends upon the membership of the ACA to contribute to either (or both) by writing, by being available to act as referees and by providing feed back to the editorial committee about what they want to see in this “Hybrid”. *The system is currently in abeyance, but will no doubt return in another form. Brian Cherry Editor Official

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Vol 36 No 5, October 2011 ISSN 1326-193 2

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18th ICC issue!

Inside this Issue: Corrosion through out WW2 wrecks threaten Microne sian environment Concrete Structu Inside this Issue: res & Buildings Technical Group Inside this Report Technical Note: Develop Issu e: ment

18th ICC 2011 Review

in Tank Coating Technol Cathodic Protect Technic ogies for Aggress University Profile: ion Technic al Note: ive Storage al Group Corrosion of Fastene Queensland Univers rs in Treated Timbers Findings from Field Report of Technology (QUT) ity University Profile: – Experimental Charles Darwin Exposures Project Profile: University Project Profile: Extendi Concrete Mine Thicken Project Profile: Management of Tasman ng the Life of a Wharf Asset for PNG Tank Repaired with er Hybrid CP Ports Univers University Profile: ian Bridges ity Profile: Curtin Project Profile: Monash University Univers Rust Never ity Sleeps: Project Profile: Aboveground Protecti Technic Research Paper: Recoating of veal Coating Note: of Dehumi the dification Bulk Water Pipes Gates on the Ord Improvi in Brisban e ng the Corrosion Resista Equipm River Diversion Dam byent a Plasma SelectioElectrol Technical Note: nce of Magnesium n ytic Oxidatio Project Profile: Next Generation Alloy AJ62 Offshore Cathodi Technical Note: Metallic Coatings n (PEO) Coating Process c Protecti Selecting the Right Profess on Anode ional Research Paper: Retrofit Practic Stainless Steel! Project ting e Paper: Corrosi Corrosi Profile: Restorin on and on of Building Assets and Prevent g Timeles Blisteri ionthe Role of ng at sthe Beauty – Problems Coating for/Substr Futureate Generat Research Note: 18th Interna ions Interfac e Corrosion of a Gold tional Corrosi onch Congre AlloyResear in Saline and Acidic Paper: ssContinu Sponso and Exhibit alr Remote Environch Resear ments or Profile Monitor Verification of AC ing Paper: Microbi s for Mitigation ologically Influenc Research Paper: ed Corrosion in Maritim High Temperature e Vessels ch Paper: Investig Corrosion Problem Resear ations of s in Designing Graded ged Steel and Wooden Microbiologically Influenced Corrosi Thermal Barrier of Submer Coating on Ship Wrecks and Play ins these Degene the Role that Bio-Con (MIC) 1 rative Processes cretions Research Paper: Metabolomic Footprin ting and MIC within Water Supply Networks

Inside this Issue:

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Australasi an

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Vol 36 No 3, June 2011 ISSN 1326-193 2

Corrosion

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Vol 36 No 4, August 2011 ISSN 1326-193 2

Vol 37 No 1, February 2012 ISSN 1326-193 2

Publicatio n

e t e r c n o C f o n io s o r Cor s e s r u o C s e r u t c u r t S ACA/ACRA Corrosion and Protection of Reinforced Concrete Tasmania, 3-4 October 2012 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. 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

Corrosion & CP of Concrete Structures Sydney, 21-22 August 2012 This course covers the background theory on corrosion and cathodic protection, including such aspects as selection and design of cathodic protection systems (impressed current and sacrificial), installation of cathodic protection systems, materials and equipment, problem troubleshooting and assessment and repair of structures. Course Highlights Modes of Concrete Deterioration Assessment and Repair of Structures Corrosion Fundamentals Remediation Options Selection & Design of Cathodic Protection Systems Materials and Equipment Installation of Cathodic Protection Systems Control of Interference Currents Commissioning of Systems Criteria for Cathodic Protection Operation and Maintenance of Systems Problem Troubleshooting System Records and Documentation

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NEWS

ACA membership continues positive growth trend ACA membership at the end of 2011 reached 1534. This was the highest level of membership at the end of any membership year in ACA’s 50 plus year history. Based on the trend in membership growth in recent years, the target for membership at the end of 2012 has been set at 1670. Already ACA is well on the way to achieving its 2012 target. Over a longer period, ACA expects its membership to increase to 2000 by the end of 2014.

During the past year the strongest percentage growth in membership has come from branches in South Australia (28%), Western Australia (20%) and Newcastle (14.5%). Numerically, the strongest growth has come from Western Australia (47), Victoria (38) and South Australia (30). Growth has also come from most other ACA branches during the past 12 months. Like most similar organisations, ACA lose some members each year. Staff are working with ACA’s board to better understand the reasons why some members leave. Based on further

investigation the board will introduce strategies which directly respond to the changing nature of membership patterns and retention issues. The recent appointment of Solange Brave as ACA’s branch and membership support officer is part of ACA’s strategies not only to address any loss of membership but also to improve service delivery across the organisation. Further information on membership is available from Solange Brace at ACA’s Melbourne office on +61 3 9890 4833.

350 ACA Membership – 31st December 2011. Total = 1534

301

300

276

265

250 211 200 159

148

150 100 50 0

Australasia

Newcastle

New South Wales

New Zealand

Queensland

South Australia

Tasmania

Victoria

Western Australia

ACA seeks membership of Standards Australia council Standards Australia has confirmed that it has received an application from ACA to become a member of their council. The board of Standards Australia has supported the application and has resolved to recommend the membership to the council when it meets in Melbourne on 1 June 2012. ACA’s board, in developing its strategic plan, has determined that membership of the council of Standards Australia is

p.12 CORROSION & MATERIALS

key in developing a closer working relationship between the two organisations and emphasises ACA’s support of the Standards development process. By gaining membership of the council of Standards Australia, ACA will be able to actively participate in the policy development processes which are being undertaken as Standards Australia continues to refine its approach to Standards development.

ACA’s membership is expected to be granted on 1 June 2012. Further information is available from Ian Booth or Caitlin Granowski at ACA’s office in Melbourne – phone +61 3 9890 4833.

NEWS

Nick Birbilis awarded the 2012 H.H. Uhlig Award ACA member Nick Birbilis was recently awarded the 2012 H.H. Uhlig Award at the Corrosion 2012 NACE International Conference in Salt Lake City, Utah, USA. The H.H. Uhlig Award is given in recognition of outstanding effectiveness in post-secondary corrosion education as exhibited by an educator who excites their students through outstanding and innovative teaching in corrosion. To qualify, nominations must be received within 10 years of the nominee entering the field of education.

An educator may qualify who has effectively conveyed and instilled in students the principles and applications of corrosion science and technology, and has simulated students to enter professional pursuits in defining and mitigating corrosion problems. As published by NACE International; Dr Nick Birbilis is recognised for his extraordinary accomplishments in mentoring and educating students in corrosion and corrosion science. Dr Birbilis has shown that he considers teaching to extend beyond the classroom and encourages the transferring of knowledge towards his students in a research setting. Teaching involves both mentorship and classroom instruction. Dr Birbilis has a

huge research effort that is supporting a large number of students, including postdocs and several undergraduates. Dr Birbilis is an innovative educator who adopts a practical action-oriented approach to his undergraduate teaching, which is reflected in the high student unit evaluation scores he routinely receives. Dr Birbilis’s diligence, bright mind, inquisitive nature, and unwavering commitment to helping others has led him to achieve success not only in the classroom, but in industry as well. The ACA takes this opportunity to congratulate Nick on receiving this 2012 NACE International award.

Carboline has been global leader in the High Performance Coatings industry for over 63 yrs. For corrosion solutions and coating systems that are cost effective, talk to the Protective Coatings Professionals. Whether it be protective coatings, tank linings or fire-proofing, Carboline’s team of dedicated and trained professionals can assist you in choosing the right solution for your next project.

April 2012 www.corrosion.com.au p.13

NEWS

ACA welcomes new members Corporate Gold Members BAAM Consulting www.baam.com.au BAAM Consulting is an independent and pragmatic remedial consultancy, established more than 15 years ago. They advise on maintenance management of all asset types mostly in the built environment. Resources include engineers and building consultants, and access to a wide range of specialists including heritage and remedial contractors, and specialist consultants in coatings, Non Destructive Evaluation, waterproofing and materials. Conqual www.conqual.com.au Conqual offers independent advice, service and design solutions for utility and civil construction companies. The company specialises in network design, electrical works, ‘end to end’ project management and utility network tendering over a range of technologies. Conqual’s clients are predominately in the telecommunications industry,

including fixed/mobile operators, broadband and satellite service providers and constructors. Corporate Silver Members Mears Integrity Solutions www.mears.net Mears Integrity Solutions are a recognised world leading service provider for Integrity Management. For over 40 years they have delivered customised solutions by offering engineering, technical and construction services to meet the challenges and demands of the power and pipeline industry by providing optimum integrity solutions through corrosion evaluation, corrosion control, and remedial action. Mears is headquartered in the USA and has recently opened an Australian office. Corporate Bronze Members Dapcor Building Services www.dapcor.com.au Dapcor Building Services provides integral remedial services to both

the residential and commercial construction industry. Dapcor Building Services has been established since 1974. During this time we have gained extensive knowledge in the specialised remedial building sector. Dapcor have experienced teams to carry out concrete repair projects such as spalling concrete, crack injection, strengthening/replacement and concrete protection. Rust Bullet www.rustbullet.com.au Rust Bullet is the Australian distributor for Rust Bullet LLC in the USA. The Rust Bullet product range can be applied directly over rusted and clean metal surfaces with little or no surface preparation. Rust Bullet protects various metals, as well as, other substrates including concrete, wood and fiberglass. Protecting the environment is important to Rust Bullet, so their product range is environmentally friendly containing no lead, zinc, chromates, heavy metals, acids or pesticides.

Individual Members Name

Company

Branch

Frank Borgward

Under Raps

Western Australia

Rodney Fisher

Engineering Innovations & Construction

New South Wales

Daniel Frazer

Veolia Environmental Services

Western Australia

Marian Gheorghe

DMS Maritime

Western Australia

Craig Hayden

Western Australia

Craig Hobson

Queensland

Conor Kinsella

Clough AMEC

Western Australia

Andres Laserna

Australasian Corrosion Consultants

Victoria

Sean Lewer

Guardian Air

Western Australia

Mark Linsley

FM Solutions

New South Wales

Alan McKenzie

Victoria

Shane Mace

Forgacs Engineering

Newcastle

Tony Mans

Bloxam Burnett & Olliver Ltd

New Zealand

Garry Matthias

Corrsafe

Queensland

Eric Morris

Asset & Facility Management

Western Australia

Steve Noteboom

Under Raps

Western Australia

Michael Psalios

Santos

South Australia

Steve Storey

NT Inspections

Western Australia

Jerry Sunarho

Sydney Water

New South Wales

Douglas Yeo

QCoat

Queensland

Nizam Yusoff

Mighty River Power

New Zealand

Malcolm Teasdale

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Western Australia

NEWS

Elcometer Limited acquires Dakota Ultrasonics Inc Earlier this year Elcometer Limited announced the acquisition of Dakota Ultrasonics Incorporated. “Dakota’s commitment to high quality products and service to the non destructive testing community is second to none,” stated Michael Sellars, Managing Director of Elcometer Limited. A complete range of Elcometer NDT Ultrasonic equipment is now

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April 2012 www.corrosion.com.au p.15

YCG UPDATE

Inaugural Future Leaders Forum an outstanding success from across the spectrum of the corrosion industries. It focussed on developing competencies in how to present technical papers, chair technical sessions, conduct group discussions and develop the art of expression and communication. The Forum presented participants with a professional and friendly environment which removed any resistance to participation. The skills developed during the forum can easily be applied to work and other professional environments.

in the program. Applicants were drawn from all areas of the corrosion industries. Applications were accepted based on the information provided in their applications and each applicant had to demonstrate they were supported in their application by a senior executive in the organisation for which they work.

There were 20 delegate places available for applicants aged 30 years or under

Attendees at the inaugural ACA Future leaders Forum were:

Name

Organisation

Location

Blane McGuiness

Savcor ART

NSW

Owen Harvey

GHD (Sydney office)

NSW

Rana Everett

Equi-Librium

Monika Ko

Quest Integrity

New Zealand

Don Macisaac

ALS Industrial

QLD

Hugo Duque

Australian Maritime Systems

QLD

David Mavros

SA Water

Thomas Button

Robayne Distributors

TAS

Christine Crawshaw

AECOM

VIC

Andrew Czerwinski

HRL Technology

VIC

Ann Sheehan

Galvanizers Association of Australia

VIC

Luke Thompson

Infracorr Consulting

VIC

Dean Ferguson

GHD (Melbourne office)

VIC

Dimitri Ross

Savcor ART

VIC

Dhana Dissanayake

ITW Buildex

VIC

Giles Harrison

Extrin Consultants

Rob Baker

Hempel

Jonathan Gilfillan

Savcor Finn

Jinny Collet

SVT Engineering

Erwin Gamboa

University of Adelaide

At the concluding session of the ACA/18th ICC in Perth in 2011 ACA Foundation Limited announced its intention to launch an ambitious program of funding to support development activities across the corrosion industries during 2012. A significant undertaking to which the Foundation committed support was ACAâ&#x20AC;&#x2122;s Future Leaders Forum scheduled to be conducted in Sydney on 23 and 24 February 2012. The ACA Future Leaders Forum was a two day personal and professional development program aimed at drawing together young professionals

ACA Future Leaders Forum p.16â&#x20AC;&#x192; CORROSION & MATERIALS

All travel, accommodation and catering costs for participants were met by ACA with the generous support of ACA Foundation Limited.

YCG UPDATE

“It was all good.” “ ACA staff were fabulous – Geoff did a great job facilitating.” “ Very well organised, topics were relevant to young professionals.” “ Great event and thank you for the opportunity.” “ The forum as a whole was quite good and run fantastically.”

ACA Future Leaders Forum participants including ACA staff and Geoff Witherow from Changing Organisations This Forum was the first event in 2012 for the ACA Young Corrosion Group (YCG) which serves the purpose of organising and implementing events of value to younger members and those new to the corrosion industry and to provide a platform of access to information and networks which are of benefit to personal, professional and business development. Day 1 of the Forum focussed on presentation skills. Geoff Witherow from Changing Organisations facilitated both days of the Forum and also introduced topics including Corporate Behaviour ‘101’ and Recovering from indiscretions within the workplace. Day 2 continued work on presentation skills and also included sessions on Maximising Associations — the benefits of Association Membership, the Importance of Networking, Using Conferences/Seminars for Personal Development and Mentoring.

All participants were required to make a presentation during the two day event so that they could showcase their skills and demonstrate how they could apply their newly developed skills. And so, what did the participants have to say after two days of hard work? “ It was an excellent forum and the ACA conducted it extremely well.” “ I would like to thank the ACA for having the foresight to organise such an event.” “ It was conducted with professionalism.” “ Overall the event is very valuable. I would definitely recommend the FLF to other young corrosion professionals.”

Participants in the Forum especially mentioned the support received from a number of ACA members who were in attendance at the Forum at different times during the two days. Special thanks go to Peter Dove (President – Australasia), Warren Green, Brad Dockrill (Finance Director), Paul Vince (ACA Board Chairman), Dean Wall (ACA Director and ACA Foundation Limited Chairman), Grahame Vile President – NSW), Alan Bird and Peter Hosford. Based on the success of the inaugural ACA future Leaders Forum, planning is well under way for a 2013 event to be conducted in Adelaide on Thursday and Friday, 21 and 22 February. Application procedures will be announced in July 2012. Based on the feedback from this year’s participants we strongly recommend young corrosionists keep a watchful eye out for further details. Information on the Future Leaders Forum and Young Corrosion Group activities is available from Katherine Webber at ACA’s office in Melbourne on +61 3 9890 4833 or by email to kwebber@corrosion.com.au

“Overall the event is very valuable. I would definitely recommend the FLF to other young corrosion professionals.” Hard at work on day 2 and some still had a smile on their faces…

April 2012 www.corrosion.com.au p.17

BRANCH NEWS

ACA Auckland Division March Meeting Report The Auckland Division meeting held at The Landing hotel on 22nd March was addressed by NZ Branch Secretary Dr John Duncan, who gave a presentation entitled “Recent Corrosion Issues – New Directions, Collaboration and Research”. John has recently represented the NZ Branch at ACA Council meetings, ACA Operations Board meetings, the 18th International Corrosion Congress (ICC), and he has attended various international corrosion conferences over the years. John recently retired from BRANZ but he continues with them in a part-time consulting role. John commenced his presentation with an overview of the current status of ACA as outlined by the ACA’s Strategic

Plan. He described progress being made towards the goals that have been set for ACA. He then outlined his view of where ACA sits in relation to other corrosion global societies, including NACE (USA), ICC, EFC (European Federation of Corrosion), SSPC (USA) and WCO (World Corrosion Organisation). Considering its size (1500 members in Australasia) ACA is faring well against the big corrosion organisations in the Northern Hemisphere. ACA is financially sound and it continues to provide and develop a wide range of services for the membership. John described how the Internet now provided technical resources that were

Chairman Mark Sigley (left) with speaker Dr. John Duncan

formerly the role of Corrosion Societies. Some websites are highly regarded internationally and ACA needs to keep up with internet developments. Finally, John gave his views on the status of corrosion research in NZ tertiary institutions. The future outlook for research in NZ seemed to be “more of the same”, and the NZ Branch needs to interact more actively with the researchers. The commercial uptake of corrosion research in NZ was good, but researchers need to avoid duplication of research projects, which happens in some countries. After a stimulating Q&A session, Chairman Mark Sigley thanked John for his thoughtprovoking presentation.

Dr. John Duncan

Western Australia Branch - A night at the Bell Tower There was a gentle buzz in the air as members crossed the boardwalk over the moat and entered the Bell Tower for the new Members Night on the 10th of February 2012. Ian MacLeod welcomed members, partners and friends wearing his corrosion hat and also as chair of the Swan Bells Foundation. The liquid refreshments began to flow as members got through the traffic snarls and domestic responsibilities and settled in for more than four hours of great and lively conversations.

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It was clear that the committee members and some of our stalwarts were doing what was expected of making new contacts and reaching out and letting the new members know that they are joining a vibrant and lively organisation this is totally committed to servicing their needs.

The nature of the ringing experience was demonstrated by Ian MacLeod who took time to show how a 1.5 tonne mass of the tenor bell can be moved from its upside down resting place and made to ring out across the city as the massive iron clapper struck the sound bow of the bell.

The food was excellent and many members tried their hand at chiming the bells and at one stage six friends and partners were clocking the bells in good time and with skill.

Thanks go to the 60 members who took up the offer of the special night and who made our new members feel very welcome.

BRANCH NEWS

South Australia Branch AGM The Annual General Meeting (AGM) of the South Australia Branch was conducted on Tuesday 6th March 2012 at the British Hotel. The meeting was well attended by 26 members and there were a significant number of nominations for committee positions which required a vote to decide final committee positions. The new South Australia Branch committee for 2012/2013 consists of: President: Kingsley Brown Secretary: Erwin Gamboa Treasurer: David Mavros I mmediate Past President: David Towns Past President: Paul Vince

Senior Vice President: Dennis Richards Junior Vice President: Alex Shepherd ommittee Members: C Rob Butcher Neville Phillis Justin Rayner Stephen Sutton The AGM was followed with a meal and drinks and the opportunity for members to catch up on what is happening locally within the industry.

Engineering Advance Diploma and now is working as a Mechanical Designer at the ASC. Paul has achieved excellent results in his studies and has a keen interest in corrosion, attending many of the Branch technical meetings to increase his knowledge. He is the fourth recipient of this prestigious award. Reg Casling was unfortunately unable to attend the AGM to present the award but Paul was presented with his certificate and a $200 cheque at the AGM by the Branch president Kingsley Brown.

Reg Casling Corrosion Award The South Australia Branch sponsors the prestigious annual Reg Casling Corrosion Award which this year was awarded to Mr Paul Van Gameren for his achievement of most outstanding student in corrosion. This year’s recipient is studying at TafeSA in the field of Mechanical and Civil

Newcastle Branch AGM The Newcastle Branch held its AGM on Valentines Day, February 14th, at the romantic Fort Scratchley in Newcastle Harbour.

Vice President: Simon Krimser

An enjoyable night was prepared by the Branch with 33 people attending. With Rob Freedman graciously acting as convenor, the election of the Newcastle Committee for 2012 was undertaken, with the following positions finalised:

reasurer: Scott Bacon (re-elected from T last year)

S ecretary: Karen Swain (re-elected from last year)

ommittee Members: C Matt Dafter Brad Dockrill Robert Freedman Robert Jeffrey Robert Melchers David Nicholas Wayne Sharman

Coating Supplies RM resident: Phillip Layton (re-elected P from last year)

pty ltd

A special mention and thank you was made to Torill Pape who retired from the committee last year due to a move to Brisbane. The outgoing committee would like to take this opportunity to again thank Torill for her dedication and support. The committee election was followed by an excellent meal along with three, five-minute show and tell presentations from local metallurgists with various corrosion problems they have recently encountered. These presentations were from Karen Swain (Austpower Engineering), Simon Krismer (Bureau Veritas), and Peter Wilk (Aurecon).

Sales: 1300 854 862 Fax: 1300 554 862

Web: www.rmcoatingsupplies.com.au

Respiratory and PPE Equipment Testing Instruments & Gauges Cartridge Filters Dust Collector Service & Repairs

All your coating supplies and service from one source April 2012 www.corrosion.com.au p.19

ACA STANDARDS UPDATE

ACA Standards Update ACA Standards Officer Arthur Austin has prepared a schedule of the latest Standards developments. This report will comprise two parts; a search of SAI Global publications at https:// infostore.saiglobal.com/store for new standards, amendments and drafts, and a search for all current publications and standards relating to one of the ACA Technical Groups.

amendments of ISO & IEC published from 25th January 2012 to 20th March 2012 was conducted using the following 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 cathode or cathodic anode or anodic electrochemical or electrolysis or electroplated corrosion and concrete, or concrete and coatings

This issue will have a focus for the Coatings Technical Group. Results of the search can be found in Table 1. A search of SAI Global at http:// www.saiglobal.com/online/ for new Standards, amendments or drafts of AS, AS/NZS, EN, ANSI, ASTM, BSI, DIN, ETSI, JSA, NSAI, and Standards and

The search results showing 94 new Standards Drafts and Amendments

in the general search can be found in Table 2. There were no new AS or AS/ NZS Standards of Draft Publications since 25 January 2012. Table 1, below, lists all current publications and standards relating to “coating and corrosion” (718 publications) and “paint and corrosion” (519 publications) as found at https://infostore.saiglobal.com/ store. There will be duplication in each category when paint and coatings occur together. A copy of the full report can be downloaded from the ACA’s website www.corrosion.com.au

Table 1. Title search by publisher with keywords ‘coating and corrosion’ – 718 publications found Results by publisher Ford Motor Company

German Institute for Standardisation (Deutsches Institut für Normung)

British Standards Institution

Association Francaise de Normalisation

Interstandard (Russia)

Polish Committee for Standardization

Osterreichisches Normungsinstitut

Standardiserings-Kommissionen I Sverige

Italian Standards

Norwegian Standards (Norges Standardiseringsforbund)

Comite Europeen de Normalisation

Swiss Standards

National Standards Authority of Ireland

Asociacion Espanola de Normalizacion

Nederlands Normalisatie Instituut

Belgian Standards

International Organization for Standardization

Standards Australia

American Society for Testing and Materials

US Military Specs/Standards/Handbooks

Brazilian Standards

Japanese Standards Association

South African Bureau of Standards

National Association of Corrosion Engineers

p.20 CORROSION & MATERIALS

ACA STANDARDS UPDATE

Standardization Administration of China

Bureau of Indian Standard

Society of British Aerospace Companies

Society of Automotive Engineers

Wirtschafts und Verlagsgesellschaft Gas und Wasser

American Architectural Manufacturers Association

American Welding Society

Det Norsk Veritas

Germanischer Lloyd

The Society for Protective Coatings

Union Internationale des Chemins de Fer

Verlag Stahleisen GmbH

Results by subject - Manufacturing engineering – 352 results Surface treatment and coating

351

Industrial automation systems

Results by subject - Paint and colour industries – 116 results Paints and varnishes

Paint coating processes

Results by subject - Construction materials and building – 72 results Structures of buildings

Construction materials

Elements of buildings

Protection of and in buildings

Results by subject - Aircraft and space vehicle engineering –37 results Fasteners for aerospace construction

Coatings and related processes used in aerospace industry

Results by subject - Metallurgy –35 results Corrosion of metals

Iron and steel products

Results by subject - Precision mechanics. Jewellery – 22 results Jewellery

Results by subject - Fluid systems and components for general use– 19 results Pipeline components and pipelines

Results by subject - Generalities. Terminology. Standardization. Documentation –18 results Vocabularies

Results by subject – Testing – 4 results Environmental testing

Mechanical testing

Results by subject – Chemical technology – 2 results Analytical chemistry

Results by subject - Mechanical systems and components for general use – 2 results Fasteners

April 2012 www.corrosion.com.au p.21

ACA STANDARDS UPDATE

Results by subject - Electrical engineering – 1 result Electrical engineering in general

Results by subject – Electronics – 1 result Electronic components in general

Results by subject - Environment. Health protection. Safety – 1 result Environmental protection

Results by subject - Health care technology – 1 result Laboratory medicine

Results by subject - Metrology and measurement. Physical phenomena – 1 result Linear and angular measurements

Results by subject - Petroleum and related technologies – 1 result Petroleum products and natural gas handling equipment

Results by subject - Road vehicles engineering – 1 result Road vehicle systems

Title search by publisher with keywords ‘paint and corrosion’ – 591 publications found Results by publisher British Standards Institution

Association Francaise de Normalisation

German Institute for Standardisation (Deutsches Institut für Normung)

Osterreichisches Normungsinstitut

National Standards Authority of Ireland

Nederlands Normalisatie Instituut

Comite Europeen de Normalisation

Italian Standards

Norwegian Standards (Norges Standardiseringsforbund)

Swiss Standards

Polish Committee for Standardization

Standardiserings-Kommissionen I Sverige

International Organization for Standardization

Belgian Standards

Asociacion Espanola de Normalizacion

Interstandard (Russia)

Ford Motor Company

South African Bureau of Standards

Aerospace & Defence Industries Association of Europe

Union Internationale des Chemins de Fer

Brazilian Standards

Society of Automotive Engineers

Standardization Administration of China

Standards Australia

American Society for Testing and Materials

Japanese Standards Association

p.22 CORROSION & MATERIALS

ACA STANDARDS UPDATE

Verlag Stahleisen GmbH

Results by subject - Paint and colour industries – 363 results Paints and varnishes

186

Paint coating processes

176

Paint coating equipment

Results by subject - Aircraft and space vehicle engineering – 160 results Coatings and related processes used in aerospace industry

154

Materials for aerospace construction

Aerospace electric equipment and systems

Aircraft and space vehicles in general

Results by subject - Construction materials and building – 78 results Structures of buildings

Results by subject - Manufacturing engineering – 15 results Surface treatment and coating

Results by subject - Metallurgy – 8 results Corrosion of metals

Iron and steel products

Results by subject - Road vehicles engineering – 4 results Road vehicle systems

Results by subject - Testing – 3 results Environmental testing

Mechanical testing

Results by subject - Railway engineering – 2 results Materials and components for railway engineering

Results by subject - Generalities. Terminology. Standardization. Documentation – 1 result Vocabularies

Results by subject - Services. Company organization, management and quality. Administration. Transport. Sociology – 1 result Company organization and management

The search of SAI Global http://www.saiglobal.com/online/ produced 94 documents as listed in Table 2 below. There were no AS or AS/NZS listings. Table 2. 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 25 January and 20 March 2012 Key word search on ‘durability’ - 2 citations found BS EN 12226:2012

Geosynthetics. General tests for evaluation following durability testing

BS EN 16051-2:2012

Inflation devices and accessories for inflatable consumer products. Safety requirements, durability, performance, compatibility and test methods of inflators

Key word search on ‘corrosion’ or ‘corrosivity’ or ‘corrosive’; but not ‘anodizing’ or ‘anodize(d)’- 18 citations found ISO 17474:2012

Corrosion of metals and alloys - Conventions applicable to electrochemical measurements in corrosion testing

ISO 9223:2012

Corrosion of metals and alloys - Corrosivity of atmospheres - Classification, determination and estimation

ISO 9224:2012

Corrosion of metals and alloys - Corrosivity of atmospheres - Guiding values for the corrosivity categories

April 2012 www.corrosion.com.au p.23

ACA STANDARDS UPDATE

ISO 9225:2012

Corrosion of metals and alloys - Corrosivity of atmospheres - Measurement of environmental parameters affecting corrosivity of atmospheres

ISO 9226:2012

Corrosion of metals and alloys - Corrosivity of atmospheres - Determination of corrosion rate of standard specimens for the evaluation of corrosivity

ISO/DIS 15158

Corrosion of metals and alloys - Method of measuring the pitting potential for stainless steels by potentiokinetic control in sodium chloride solution

ISO/DIS 16539

Corrosion of metals and alloys - Accelerated cyclic corrosion tests with exposure to synthetic ocean water salt-deposition process -”Dry” and “wet” conditions at constant absolute humidity

IEC 60811-604 Ed. 1.0 (Bilingual 2012)

Electric and optical fibre cables - Test methods for non-metallic materials - Part 604: Physical tests Measurement of absence of corrosive components in filling compounds

I.S. EN ISO 9223:2012

Corrosion of Metals and Alloys - Corrosivity of Atmospheres - Classification, Determination and Estimation (iso 9223:2012)

I.S. EN ISO 9224:2012

Corrosion of Metals and Alloys - Corrosivity of Atmospheres - Guiding Values for the Corrosivity Categories (iso 9224:2012)

I.S. EN ISO 9225:2012

Corrosion of Metals and Alloys - Corrosivity of Atmospheres - Measurement of Environmental Parameters Affecting Corrosivity of Atmospheres (iso 9225:2012)

I.S. EN ISO 9226:2012

Corrosion of Metals and Alloys - Corrosivity of Atmospheres - Determination of Corrosion Rate of Standard Specimens for the Evaluation of Corrosivity (ISO 9226:2012)

12/30237859 DC BS ISO 16539

Corrosion of metals and alloys. Accelerated cyclic corrosion tests with exposure to synthetic ocean water salt-deposition process. “Dry” and “wet” conditions at constant absolute humidity

BS ISO 17474:2012

Corrosion of metals and alloys. Conventions applicable to electrochemical measurements in corrosion testing

BS EN 4540:2011

Aerospace series. Bearings, spherical plain, in corrosion resisting steel with self-lubricating liner elevated load under low oscillations. Technical specification

BS EN ISO 9223:2012

Corrosion of metals and alloys. Corrosivity of atmospheres. Classification<(>,<)> determination and estimation

BS EN ISO 9224:2012

Corrosion of metals and alloys. Corrosivity of atmospheres. Guiding values for the corrosivity categories

DIN EN 4540 (201203)

Aerospace series - Bearings, sperical plain, in corrosion resisting steel with self-lubricating liner, Elevated load under low oscillations - Technical specification; German and English version EN 4540:2011

Key word search on 'paint’ and or ‘coating’; but not ‘anodizing’ or ‘anodize(d)’ or corrosion– 29 citations found. ISO 8503-1:2012

Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 1: Specifications and definitions for ISO surface profile comparators for the assessment of abrasive blast-cleaned surfaces

ISO 8503-2:2012

Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 2: Method for the grading of surface profile of abrasive blast-cleaned steel - Comparator procedure

ISO 8503-3:2012

Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 3: Method for the calibration of ISO surface profile comparators and for the determination of surface profile - Focusing microscope procedure

ISO 8503-4:2012

Preparation of steel substrates before application of paints and related products - Surface roughness characteristics of blast-cleaned steel substrates - Part 4: Method for the calibration of ISO surface profile comparators and for the determination of surface profile - Stylus instrument procedure

ISO/DIS 16474-1

Paints and varnishes - Methods of exposure to laboratory light sources - Part 1: General guidance

ISO/DIS 16474-2

Paints and varnishes - Methods of exposure to laboratory light sources - Part 2: Xenon-arc lamps

ISO/DIS 16474-3

Paints and varnishes - Methods of exposure to laboratory light sources - Part 3: Fluorescent UV lamps

ISO/DIS 16474-4

Paints and varnishes - Methods of exposure to laboratory light sources - Part 4: Carbon-arc lamps

BS EN ISO 111271:2011

Preparation of steel substrates before application of paints and related products . Test methods for nonmetallic blast cleaning abrasives. Sampling

BS EN ISO 111272:2011

Preparation of steel substrates before application of paints and related products . Test methods for nonmetallic blast-cleaning abrasives. Determination of particle size distribution

BS EN ISO 111273:2011

Preparation of steel substrates before application of paints and related products . Test methods for nonmetallic blast-cleaning abrasives. Determination of apparent density

p.24 CORROSION & MATERIALS

ACA STANDARDS UPDATE

BS EN ISO 111274:2011

Preparation of steel substrates before application of paints and related products . Test methods for nonmetallic blast-cleaning abrasives. Assessment of hardness by a glass slide test

BS EN ISO 111275:2011

Preparation of steel substrates before application of paints and related products . Test methods for nonmetallic blast-cleaning abrasives. Determination of moisture

BS EN ISO 111276:2011

Preparation of steel substrates before application of paints and related products . Test methods for non-metallic blast-cleaning abrasives. Determination of water-soluble contaminants by conductivity measurement

BS EN ISO 111277:2011

Preparation of steel substrates before application of paints and related products . Test methods for nonmetallic blast-cleaning abrasives. Determination of water-soluble chlorides

BS EN 4159:2011

Aerospace series. Paints and Varnishes. Determination of resistance to microbial growth

BS EN 4171:2011

Aerospace series. Paints and varnishes. Test method for determination of phosphoric acid index

BS EN 4195:2011

Aerospace series. Paints and varnishes. Test method for determination of chromate leaching

DIN EN ISO 7783 (2012-02)

Paints and varnishes - Determination of water-vapour transmission properties - Cup method (ISO 7783:2011)

ISO/FDIS 11347

Ships and marine technology - Large yachts - Measurement and assessment of the visual appearance of coatings

ISO/DIS 1891-2

Fasteners - Terminology - Part 2: Vocabulary and definitions for coatings

I.S. EN 1096-2:2012

Glass in Building - Coated Glass - Part 2: Requirements and Test Methods for Class a, b and s Coatings

I.S. EN 1096-3:2012

Glass in Building - Coated Glass - Part 3: Requirements and Test Methods for Class c and d Coatings

12/30227277 DC BS ISO 9211-4

Optics and photonics. Optical coatings. Part 4. Specific test methods

12/30247181 DC BS ISO 28340

Combined coatings on aluminium. General specifications for combined coatings of electrophoretic organic coatings and anodic oxidation coatings on aluminium

12/30252071 DC BS ISO 16145-4

Ships and marine technology. Protective coatings and inspection method. Automated measuring method for the total amount of water-soluble salts

BS EN ISO 13123:2011

Metallic and other inorganic Coatings. Test method of cyclic heating for thermal barrier coatings under temperature gradient

BS EN ISO 17186:2011

Leather. Physical and mechanical tests. Determination of surface coating thickness

JIS H 8651:2011

Conversion and anodic oxide coatings on magnesium and magnesium alloys

Key word search on 'galvanize' or ‘galvanized’ or galvanizing’ – 0 publications found. Key word search on 'corrosion' and 'concrete' or ‘concrete’ and ‘coatings’ – 0 publications found. Key word search on ‘cathode’ or 'cathodic' - 3 publications; each a different Country edition of the same ISO standard. ISO 12696:2012

Cathodic protection of steel in concrete

I.S. EN ISO 12696:2012

Cathodic Protection of Steel in Concrete (iso 12696:2012)

BS EN ISO 12696:2012

Cathodic protection of steel in concrete

Key word search on 'anode' or ‘anodes’ or ‘anodic’ – 0 publications found Keyword Search on 'electrochemical' or ‘electrolysis’ or ‘electroplated’ - 0 publications found Keyword Search on 'anodize' or ‘anodized’ - 4 publications found I.S. EN 4704:2012

Aerospace Series - Tartaric-sulphuric-acid Anodizing of Aluminium and Aluminium Wrought Alloys for Corrosion Protection and Paint Pre-treatment (tsa)

ISO/DIS 7583

Anodizing of aluminium and its alloys - Terms and definitions

12/30247181 DC BS ISO 28340

Combined coatings on aluminium. General specifications for combined coatings of electrophoretic organic coatings and anodic oxidation coatings on aluminium

JIS H 8651:2011

Conversion and anodic oxide coatings on magnesium and magnesium alloys

April 2012 www.corrosion.com.au p.25

Proudly presented by: Major sponsor:

corrosion & prevention

Corrosion Management for a Sustainable World: Transport, Energy, Mining, Life Extension and Modelling Crown Conference Centre • Melbourne, Victoria, Australia • 11–14 November 2012

keynote speakers Bruce Ackland

Tony Hughes

Bruce Ackland & Associates Pty Ltd Australia

CSIRO Australia

Dr Bruce Ackland obtained a Bachelor of Science with Honours in Physics at Monash University in 1979 and a Doctor of Philosophy in 1984, also at Monash University in the Department of Materials Engineering. Bruce has worked in the corrosion and cathodic protection industry since 1982, forming Bruce Ackland and Associates in 1985. Cathodic protection projects have involved work throughout Australia, New Zealand, Asia, the Middle East and North Africa. Bruce maintains an active role as a member and chairman in Australian Standards committees; is the current Chairman of the Australian Electrolysis Committee and is an accredited ACA lecturer and Corrosion Technologist.

p.26 CORROSION & MATERIALS

Dr. A.E. Hughes received a B.App.Sc. with distinction (1978) and M.App. Sc. (1982) from the Royal Melbourne Institute of Technology (Melbourne). He subsequently received his PhD 1991 from RMIT University. He joined the Commonwealth Scientific and Industrial Research Organisation (CSIRO) Materials Science Division in 1982 working as a surface scientist to study surface reactions and catalysis. He has worked in a range of different materials science areas including surface science, catalysis, segregation in solid oxide electrolytes, metal finishing, rare earth conversion coatings and prognostic health management of structures and . He is currently working in self healing coatings, chromate replacement inhibitors and heterogeneous catalysis. He has over 130 publications (book, journal and patents). Dr Hughes has led on major projects with Boeing, BAE SYSTEMS in the corrosion and corrosion mitigation area and with Orica in catalysis. He has been an Adjunct Professor at RMIT University Physics Department and has received awards from the Royal Society of Chemistry (2004), BAE SYSTEMS Chairman’s Silver Award for Innovation (2002) and an award from CSIRO for Innovation in 1994. He has lifetime citations over 2800 and an h-index of 29.

Patrick Jones Dulux Protective Coatings Australia Patrick Jones is General Manager, Dulux. Patrick joined DuluxGroup in 1999 and was appointed to his current position in May 2011. Patrick has undertaken a variety of commercial and business management roles including General Manager of the Paints New Zealand business from May 2008. Other roles previously held by Patrick include National Retail Manager for Dulux Paints Australia, Bunnings Business Manager, Independents Business Manager and State Sales Manager.

Paul Natishan US Naval Research Laboratory United States of America Dr. Natishan received a B. S. in Biology from Wilkes College and a M.S and Ph.D. in Materials Science and Engineering from the University of Virginia. He came to the Naval Research Laboratory (NRL) as a National Research Council post-doc and joined NRL as a Research Metallurgist in 1985. Dr. Natishan is currently Head of the Corrosion Science and Environmental Effects Section. He has worked in the fields of corrosion and materials science and engineering and electrochemistry for 28 years. His research has resulted in 99 publications and 7 U.S. patents. He was inducted as a Fellow of NACE International in 1998 and a Fellow of the Electrochemical Society (ECS) in 2005. He is a Past President and Past Secretary of ECS and was appointed Adjunct Full Professor at Duke University in 2006. Dr. Natishan was the recipient of the Blum and Foley Awards from the National Capital Section of ECS and the Kruger Award from the NACE International Baltimore/Washington Section. He was a section editor for the ASM Handbook on Corrosion, an associate editor for Corrosion Journal, co-wrote the chapter Corrosion and Corrosion Control for the Kirk-Othmer Encyclopedia of Chemical Technology and has edited 9 books/proceeding volumes.

Graham Sussex Sussex Materials Solutions Pty Ltd Australia Graham Sussex started his professional career with a PhD in Solid State Physics at Melbourne University. However, following in his fatherâ&#x20AC;&#x2122;s footsteps, he moved into corrosion in 1979, initially on electrochemical research projects at UMIST and, since 1985, on industrial problem solving in corrosion and materialsâ&#x20AC;&#x2122; properties. He worked at CAPCIS for 2 years and then returned to Australia for an 8 year stint with an NDT and engineering consulting company. This included problem solving and research for small and

large companies often in a multidisciplinary group. It included corrosion investigations, accelerated corrosion and product testing as well as broader engineering and non-metallic projects. In 1996, he moved to Materials Australia (MA) for 5 years and continued consulting although his main technical work was preparing and presenting lectures and short courses, an activity that continues until today. He left MA in 2001 to establish Sussex Materials Solutions Pty Ltd. Since then he has spent 50% of his time as the Technical Specialist for the Australian Stainless Steel development Association (ASSDA) answering technical questions for the users of stainless steel. The limitations of a small consultancy have somewhat restricted the scope of the other 50% of problems undertaken but not the range of industries nor the interest.

Geraint Williams Swansea University United Kingdom Dr Williams is a senior lecturer in materials science and engineering at the College of Engineering in Swansea University. He holds a 1st class degree in chemistry and a PhD in physical/inorganic chemistry from the Chemistry Department of Swansea University. After post-doctoral appointments in both semiconductor gas sensors and corrosion science, he became a member of the academic staff of the College of Engineering in 2007. He is the author of over 200 journal and conference papers and the co-originator of 6 patents in fields ranging from aqueous corrosion of metals and gas sensors, to the photochemistry of semiconductor colloids and powder dispersions. He is a leading expert in the use of the advanced electrochemical scanning techniques such as the Scanning Kelvin probe (SKP) technique both to quantify organic coating integrity and to visualise fingerprints on metal surfaces. His research interests lie in the areas of localised corrosion mechanisms, novel protective coating technologies, chemical sensors and fingerprint detection techniques. He has given invited lectures on novel anti-corrosion coating technologies at numerous international conferences, including the 2008 Gordon Research Conference in aqueous corrosion (New Hampshire, USA) , the 2011 Electrochemical society meeting (Boston), NACE Corrosion 2010 (San Antonio) and 2009 (Atlanta), the 2009 European Coatings Conference (Berlin) and Eurocorr 2004 (Nice). In the field of fingerprint detection he has been an invited speaker at the 2008 Institute of Materials conference on Forensic Materials (London) and the 2009 International Fingerprint Research group meeting held in Lausanne.

C&P 2012 Registration Registrations for Corrosion & Prevention 2012 will be open in June 2012. Please refer to www.acaconference.com.au for details.

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 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 April 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 certification number and membership details.

Arthur Austin

106

30/06/2012

Name

Cert No: Expiry Date

Derek Avery

295

19/08/2012

Gary Barber

248

30/06/2012

Dinesh Bankar

264

23/02/2013

Stephen Brown

263

4/02/2013

Don Bartlett

29/06/2012

Thomas Byrne

14/07/2012

Stuart Bayliss

236

7/11/2012

187

28/02/2013

Corrosion Technicians

Dave Charters

261

21/01/2013

Peter Beckford

Pasquale Chiaravalloti

274

6/06/2012

Tony Betts

1/01/2013

Rodney Clarke

206

20/12/2012

Rob Billing

30/06/2012

Craig Clarke

246

26/03/2013

Harvey Blackburn

1/01/2013

Ross Darrigan

174

14/07/2012

Michael Boardman

12/07/2012

1/01/2013

Glenn Dean

280

20/01/2013

Les Boulton

Clint Doherty

298

22/02/2013

John Bristow

107

1/01/2013

David Fairfull

179

30/06/2012

Gary Brockett

215

30/06/2012

Geoff Farrant

253

30/06/2012

Kingsley Brown

257

27/09/2012

Robert Gentry

114

30/06/2012

Philip Bundy

209

30/06/2012

100

1/01/2013

David Harley

291

30/06/2012

Wayne Burns

Stephen Holt

207

28/02/2013

Brian Byrne

1/01/2013

Bradley Jones

258

18/04/2012

Bryan Cackett

30/06/2012

Boris Krizman

169

18/02/2013

Robert Callant

103

30/06/2012

Gary Martin

1/06/2012

Neil Campbell

30/06/2012

Ian McNair

163

30/06/2012

Graham Carlisle

281

6/07/2012

Terence Moore

125

9/06/2012

Antonio Carnovale

203

30/06/2012

David Morgan

234

16/02/2013

Luis Carro

260

30/06/2012

David Parravicini

296

2/09/2012

Reg Casling

1/01/2013

Rafael Pelli

164

30/06/2012

Dylan Cawley

224

29/06/2012

Keith Perry

139

31/01/2013

Peter Clark

30/06/2012

Sean Ryder

262

21/11/2012

Ian Clark

255

30/06/2012

Ian Saunders

251

24/06/2012

Stan Collins

128

30/06/2012

Justin Tanti

238

14/02/2013

Geoff Cope

29/06/2012

Gavin Telford

244

30/06/2012

Leon Cordewener

30/06/2012

John Tomlinson

28/02/2013

Robert Cox

30/06/2012

Ben Ward

300

16/07/2012

Peter Crampton

29/06/2012

30/06/2012

Mark Watson

186

30/06/2012

Kerry Dalzell

Derek Whitcombe

123

30/06/2012

Roman Dankiw

208

29/06/2012

Rene D’Ath

197

11/03/2013

Bruce Ackland

30/06/2012

Robert de Graaf

154

1/01/2013

Fred Andrews-Phaedonos

153

30/06/2012

Mike Dinon

30/06/2012

Bradley Dockrill

241

15/07/2012

Corrosion Technologists

Ross Antunovich

p.28 CORROSION & MATERIALS

214

ACA CERTIFICATION PROGRAM Peter Dove

210

29/03/2013

Bill McEwan

1/01/2013

Gary Doyle

294

2/08/2012

Stuart McLaughlin

299

17/12/2012

Adrian Dundas

250

1/02/2013

Vic McLean

237

30/06/2012

Lucas Edwards

273

6/06/2012

Jim McMonagle

1/01/2013

Bernard Egan

30/06/2012

John Mitchell

115

30/06/2012

Gary Evans

271

30/06/2012

Elio Monzu

159

30/06/2012

Wayne Ferguson

242

4/09/2012

Greg Moore

1/01/2013

Peter Ferris

195

30/06/2012

Janet Morris

256

5/07/2012

Gavin Forrester

282

10/02/2013

Robert Mumford

30/06/2012

Rob Francis

29/06/2012

Tony Murray

134

30/06/2012

Dale Franke

199

30/06/2012

David Nicholas

1/01/2013

Max Fraser

283

17/03/2013

Calvin Ogilvie

19/01/2013

Robert Freedman

147

1/01/2013

Dean Parker

108

5/07/2012

Jim Galanos

254

17/12/2012

David Pettigrew

297

17/12/2012

Barry Gartner

30/06/2012

Steve Richards

110

30/06/2012

Bill Gerritsen

30/06/2012

Dennis Richards

180

1/01/2013

Ian Glover

129

30/06/2012

Gavin Richardson

30/06/2012

Frederick Gooder

141

30/06/2012

Tony Ridgers

30/06/2012

Chris Hargreaves

292

26/07/2012

Geoff Rippingale

30/06/2012

Phil Harrison

145

8/05/2012

Geoff Robb

124

30/06/2012

Peter Hart

200

30/06/2012

Bernd Rose

252

1/05/2012

Frank Hewitt

1/01/2013

John Rudd

243

21/06/2012

Brian Hickinbottom

138

30/06/2012

Fred Salome

231

1/01/2013

Brett Hollis

30/06/2012

Ian Savage

259

30/06/2012

Marshall Holmes

293

25/08/2012

Ron Scaddan

272

5/02/2013

Peter Hosford

216

1/01/2013

Philip Schembri

198

30/06/2012

Paul Hunter

30/06/2012

Paul Schweinsberg

1/01/2013

Jeffrey Hurst

202

30/06/2012

David Scott

173

29/06/2012

Craig Hutchinson

249

26/10/2012

Mike Slade

175

7/06/2012

Luciano Ioan

228

6/06/2012

Brian Smallridge

201

30/06/2012

Bruce Jewell

245

30/06/2012

Jim Steele

119

17/12/2012

Michael Johnstone

230

18/04/2012

Alan Steinicke

1/06/2012

Michael Jukes

3/03/2013

Allan Sterling

191

31/03/2013

John Kalis

166

17/12/2012

Gordon Stewart

1/01/2013

Graeme Kelly

102

1/01/2013

Ian Stewart

155

18/06/2012

John Kilby

193

30/06/2012

Graham Sussex

136

30/06/2012

John Lane

188

30/06/2012

Tan Swee Hain

189

30/06/2012

Bill Lannen

111

1/01/2013

Yongjun Tan

194

30/06/2012

Harry Lee

30/06/2012

Peter Thorpe

144

1/01/2013

Keith Lichti

133

30/06/2012

Peter Tomlin

120

30/06/2012

Verne Linkhorn

30/06/2012

Nicholas Van Styn

229

25/02/2013

Garry Luskan

117

2/02/2013

Peter Wade

190

30/06/2012

Willie Mandeno

30/06/2012

John Waters

121

30/06/2012

Brian Martin

1/01/2013

John Watson

239

10/06/2012

William McCaffrey

142

30/06/2012

Richard Webster

30/06/2012

John McCallum

30/06/2012

Mark Weston

149

1/01/2013

Daryl McCormick

17/12/2012

Geoffrey White

182

1/07/2012

Murry McCormick

196

28/06/2012

Paul Wilson

290

19/04/2012

Michael McCoy

109

14/04/2012

Rodney Wubben

30/06/2012

Brad McCoy

178

14/07/2012

Morris Young

217

30/06/2012

April 2012 www.corrosion.com.au p.29

ACA COATING INSPECTION CERTIFICATE

ACA Coatings Inspection Certificate Up until 2005 The Australasian Corrosion Association Incorporated conducted a 5 day Coatings Inspection Certificate Course. It was designed to provide the requisite skills and knowledge to inspect protective coatings following the requirements of Australian/New Zealand Standards. The list below contains the names of qualified ACA Coatings Inspectors who have satisfied the requirements to be issued with an ACA Coatings Inspection Certificate and who have ‘refreshed’ their certificate within the 5 year time frame required by the ACA Council. Some inspectors have cross – accredited to the internationally recognised

NACE Coatings Inspection Program. In those cases, the validity of their ACA certification has been reconfirmed. Every care has been take to ensure that at the time of publishing the information is correct. The Australasian Corrosion Association Incorporated does not accept any responsibility for any consequences which may arise from the use of this information. Those wanting to engage a Coatings Inspector should rely on their own judgement and if necessary seek other advice as to whether the person has suitable work experience and references for the work proposed.

ACA Coatings Inspectors

No legal liability for negligence or otherwise can be accepted by The Australasian Corrosion Association Incorporated for the information or the use of the information contained in this listing. If you have any queries please contact The Australasian Corrosion Association Incorporated directly on +61(0)3 9890-4833 or via email to aca@corrosion.com.au. Please note: this list is current as at 19 March 2012

Ian Clifton

1160

31/07/2014

Name

Cert No: Expiry Date

Gregg Cobban

2213

2/12/2014

Gary Abbott

4080

31/12/2017

John Cooke

3235

18/07/2013

Richard Adams

1230

19/04/2015

Cameron Cooper

466

6/07/2016

Andrew Aidulis

1404

30/06/2013

Darrel Murray Craig

2810

3/08/2014

Dennis Ashman

390

30/01/2014

Dean Crase

4137

6/07/2016

Travis Baensch

4209

12/08/2015

Jay Cumner

3492

11/06/2014

Trevor Baensch

2211

12/08/2015

Dean Currie

2092

3/08/2014

Stuart Bayliss

247

23/04/2014

Kerry Dalzell

1052

30/05/2013

Mark Blacklock

3501

2/07/2015

Cheryl Dalzell

3940

19/04/2015

Timothy Blair

2088

31/01/2014

Roman Dankiw

872

30/11/2013

Michael Boardman

1051

13/04/2012

Ross Darrigan

1489

27/10/2013

Jason Bourke

2597

4/05/2012

Robert de Graaf

719

31/12/2017

Matthew Boyle

1429

30/04/2013

John Dixon

1118

11/06/2014

Greg Bracey

1212

4/05/2012

Trevor Domin

4031

11/06/2014

Kingsley Brown

2603

31/10/2012

Peter Donovan

1888

30/01/2014

Sean Anthony Burke

3428

30/01/2014

Murray Dormer

2251

13/04/2012

Harold Burkett

361

18/01/2013

Peter Dove

1203

31/05/2013

Elliot Burns

972

19/04/2015

Phill Dravitski

1593

13/04/2012

Micah Butt

2397

1/10/2013

William Dunn

3386

27/10/2013

Brian Carrick

1792

27/10/2013

Kenneth Dunn

1296

6/07/2016

Terry Carroll

1477

11/06/2014

Dave Elder

155

13/04/2012

Wayne Clarke

3603

11/06/2014

Todd Elkin

3402

19/04/2015

p.30 CORROSION & MATERIALS

ACA COATING INSPECTION CERTIFICATE

John Elomar

4204

19/04/2015

Gary Hussey

3984

2/07/2015

Tony Emery

4130

2/07/2015

Clinton Iliffe

4034

12/08/2015

Tony Evans

2086

6/07/2016

Luciano Ioan

2965

18/07/2013

Wayne Ferguson

893

18/01/2013

Basyl Jakimow

3230

23/04/2014

Nathan Fernance

2219

30/01/2014

Tom Jensen

2889

2/12/2014

Chris Fisher

2985

9/09/2013

Matthew Johnson

2359

12/08/2015

Jerry Forslind

1129

31/10/2014

Robert Johnson

3354

12/08/2015

Phillip Foster

2254

3/08/2014

Robert Johnson

2625

9/09/2013

Rob Francis

720

31/12/2017

Michael Johnstone

2964

18/07/2013

John Paul Fraser

3773

11/06/2014

Ron Jonker

1674

4/05/2012

Robert Freedman

31/12/2017

Ross Kaddatz

3793

30/05/2013

Brett Gale

3774

12/08/2015

Roger Kearney

1121

30/05/2013

David Gates

2599

19/04/2015

Stephen Keller

3212

30/05/2013

Collin Gear

2623

13/04/2012

Shane Kennedy

3373

9/09/2013

Robert Glover

1362

13/04/2012

Donald Kirchner

1905

11/06/2014

Shane Goggin

2857

13/08/2013

Robert Kirkham

2009

30/01/2014

Phil Goldsworthy

2083

27/10/2013

Leonard Kong

3538

3/08/2014

Frederick Gooder

3/08/2014

Joseph Kowal

553

30/06/2014

Wayne Gray

3606

2/12/2014

Harry Kronberger

1516

2/12/2014

Jim Haig

394

12/08/2015

Narend Lal

3355

11/06/2014

Ray Harcourt

1326

23/04/2014

John Lane

1784

2/12/2014

Brian Harris

1054

9/09/2013

Alan Lee

3539

9/09/2013

Gregory Harrold

4061

19/04/2015

David Lepelaar

3356

11/06/2014

Peter Hatchard

4039

12/08/2015

Neil Alan Lewis

2598

30/05/2013

Darrin Hatton

3206

30/01/2014

Daniel Lillas

3597

30/11/2014

Rohan Healy

3184

18/01/2013

Peter Luke

3795

11/06/2014

Bronte Henning

178

31/10/2013

Jonathan Mace

4035

6/07/2016

Clayton Henry

1595

13/04/2012

Spencer Macsween

3170

18/01/2013

Don Herrigan

4033

12/08/2015

Willie Mandeno

1216

31/12/2017

Greg Hill

1434

30/11/2013

Bradley A Marsh

3232

18/07/2013

Shaun Hinks

3208

23/04/2014

Andrew Martin

545

4/05/2012

Frank Hiron

2888

30/05/2013

Craig Martin

2276

18/07/2013

Matt Hollywood

1744

31/05/2014

George Martin

669

2/07/2015

Paul Howe

3177

30/01/2014

Robert Wayne Mason

1076

30/05/2013

Anthony Huethorst

2297

13/04/2012

Garry Matthias

1481

30/04/2013

Paul Hunter

2988

13/04/2012

John May

2436

4/05/2012

Jeffrey Hurst

1746

30/05/2013

David McCormack

4352

6/07/2016

April 2012 www.corrosion.com.au p.31

ACA COATING INSPECTION CERTIFICATE

Brett Meredith

2218

30/11/2012

Gary Smith

2512

3/08/2014

Andrew Miles

1031

30/09/2014

Laurence Snook

1526

18/01/2013

John Mitchell

1042

31/01/2013

Vic Spunner

2272

18/07/2013

Wayne Mitchell

3357

2/07/2015

Michael Stacey

1864

30/05/2013

Colin Mogridge

2010

27/10/2013

Dragan Stevanovic

2960

15/07/2013

Vic Monarca

2053

6/07/2016

Steven Stock

3923

6/07/2016

Bryan Moore

462

23/04/2014

Lex Stolk

3216

31/10/2014

Wessel Mulder

2507

31/12/2017

Steve Storey

3176

30/01/2014

Peter Myatt

1907

11/06/2014

Raymond Street

3173

30/06/2012

Peter Nicholson

4086

12/08/2015

Peter Sutton

3183

18/01/2013

Steve Nixon

2256

13/04/2012

Brian Taylor

2967

4/05/2012

Charles O’brien

1827

13/04/2012

Adam Thomas

2087

27/10/2013

Dennis O’Loughlin

611

31/12/2017

Michael Thorne

1825

9/09/2013

Sean O’Sullivan

1933

9/09/2013

Junior Tiaiti

2991

3/08/2014

Mark O’Sullivan

4059

30/01/2014

Russell Tierney

2000

2/12/2014

Clifford Parkes

3607

2/07/2015

David Towns

2702

27/10/2013

Rick Pascoe

2605

23/04/2014

Andy Tyldesley

2817

13/04/2012

Stephen Pearce

2269

2/12/2014

David van Tricht

1082

30/05/2013

Darryl Penney

612

4/05/2012

Andy Vesco

3783

19/04/2015

Lorraine Pidgeon

1513

18/01/2013

Paul Vince

2700

31/12/2017

Graham Porten

2257

3/08/2014

Andrew Walker

2969

18/07/2013

David Power

2487

19/04/2015

David Walters

1910

11/06/2014

Brian Probert

235

31/07/2014

Troy Ward

2571

30/01/2014

John Puljak

3780

12/08/2015

Roy Warry

859

30/05/2013

Barry Punter

1843

31/10/2012

Mark Weston

883

31/12/2017

James Rebetzke

1862

11/06/2014

Paul Weston

2129

23/06/2014

Greg Reece

3508

19/04/2015

Charles Wheeler

3943

19/04/2015

Rick Roberts

1316

28/02/2013

Geoffrey White

31/10/2013

Dean Rowe

4200

2/07/2015

Peter Whitmore

681

30/05/2013

Stephen Sach

3013

30/01/2014

Greg Wiggins

2992

13/04/2012

Valentine Scriha

1896

12/08/2015

Craig Williams

4176

12/08/2015

Kevin Sellars

1649

31/12/2017

Geoff Woodman

1171

4/05/2012

Kevin Sharman

627

30/11/2012

Stephen Yates

1615

30/05/2013

Tracey Sherman

1829

9/09/2013

Douglas Shipley

2221

2/07/2015

John Simoni

3596

2/12/2014

p.32 CORROSION & MATERIALS

Please note: this list is current as at 19 March 2012

COATINGS GROUP MEMBER PROFILE

H2O Contractors Pty. Ltd. Q: I n what year was your company established?

Q: Is the business yard based, site based or both?

A: 1994

A: W e have our depot and offices in Thorndon and a range of mobile, office and storage assets which are site based during large projects. Some work can exceed six months on site.

Q: H ow many employees did you employ when you first started the business? A: F ive staff carried out mostly water blasting and painting work which expanded into drain clearing and CCTV as resources permitted. Q: H ow many do you currently employ? A: F ull time staff number 14 including administration. We also use temporary staff. Q: D o you operate from a number of locations in New Zealand? A: Y es, solidly Wellington based with a new sole operator branch based in Palmerston North. We do however carry out maintenance and refurbishment projects throughout the country. Q: W hat is your core business? A: A brasive blasting, industrial coatings, water blasting, drain clearing, CCTV inspection and logging, high and ultra-high pressure cleaning. Q: W hat markets do you cover with your products or services? A: O il and gas, marine, chemical process, tank lining, power generation, construction, transport infrastructure, reticulation, property maintenance, domestic maintenance, municipal infrastructure, engineering.

Q: What is your monthly capacity or tonnage that you can blast and prime? A: M onthly outputs tend to be dictated by weather and the specification. Typically our experienced staff using large volume compressors and airless spray plant incorporating latest tip technology can blast and prime perhaps 350 m2 of flat plate per day. Q: D o you offer any specialty services outside your core business? (eg. primary yard based but will do site touch up etc.) A: W e certainly do offer small job capacity based in our depot, our marine facility or on the client’s work site. All plant is very mobile. Q: W hat is the most satisfying project that you have completed in the past two years and why? A: BP Seaview new terminal complex. Four tanks internally lined and externally coated to client and coating manufacturers specifications. The key to the successful project (and all our successes) is having professionally trained blasting and coatings staff, proper equipment, working closely and at a professional level to standard/agreed specifications and quality assurance with the client and coatings manufacturers.

Q: What positive advice can you pass on to the Coatings Group from that satisfying project or job? A: Forward planning is essential to this type of contract involving; climate control for internal linings, availability of high calibre staff experienced in blasting and lining work, strong management of work outputs and client requirements, quality assurance standards that reflect the specifications and standards required on this project and on every job. Q: Do you have an internal training scheme or do you outsource training for your employees? A: While we have internal training and have been lucky enough to have taken on experienced or fast learning staff, every job poses its own challenges. Thus on-the-job learning is constant and effective supervision is essential. QA monitoring can highlight shortcomings in technique but this can mean expensive remediation. In addition, due to the nature of many of our projects site inductions are frequent. There are also constant re-certifications covering gas monitoring, heights, first aid, confined spaces, BA use access equipment etc... which must be outsourced.

Alistair Mackenzie – Managing Director Collin Gear – Coatings Manager Ph +64-4-4733124 Fax +64-4-4734625 Email: info@h2o.co.nz

April 2012 www.corrosion.com.au p.33

ARTICLE

Coating Inspector’s Equipment The following article is copyrighted by CoatingsPro Magazine. Written by Malcolm McNeil, the article was published in the magazine’s Inspector’s Corner in the November 2011 issue. Coating inspectors, whether they are working for an inspection company or are independent, require a vast array of instruments and other inspection aids to carry out their inspection responsibilities. Some of these include: Sling Psychrometer Hygrometer Surface Thermometer Psychrometric Tables VIS 1, VIS 3, VIS 4, etc. TesTex Tape Dial Gauge Depth Micrometer Profile Comparators Ultra Violet Light Transparent Tape Wet Film Thickness Gauge Dry Film Thickness Gauge Micrometer Holiday Detector Tooke Gauge pH Indicators Inspection Mirror Salt Test Kits Pit Gauge Microscopes Adhesion Testers Batteries Safety Gear (Harness, Lanyard, Hard Hat, Safety Glasses, Respirators, Steel-Toed Work Boots) Inspection Report Forms Standards

p.34 CORROSION & MATERIALS

The list goes on and on, depending on the specific project and the specifications for the project. The cost of all of these required tools can be substantial, and a fully equipped inspector will have a large investment, which may take months or years to recover. Having said this, it is obvious that the smart inspector will take all measures necessary to maintain all of his or her tools to ensure that they are in good operating condition and accurate. Many of the above mentioned gauges are quite sophisticated and require training and practice to learn how to use the gauge correctly. Any time an inspector buys a new gauge, he or she must become thoroughly familiar with the gauge and the proper operation of same to ensure accurate results. This not only requires reading the manufacturer’s instructions, but also extensive practice with the gauge until using it accurately becomes habit. One of the quickest ways for an inspector to lose credibility is to pull out a gauge on the job and fumble around, trying to figure out how to use it properly. The NACE Coating Inspector Program (CIP) provides the training needed to learn how to use the most commonly used tools to meet the coating inspector’s responsibilities on coating projects. Care and maintenance of the inspector’s equipment requires a dedicated effort by the owner of the equipment. Most of the instruments are battery-operated. Batteries should be removed from the gauges when they are going to be stored for any extended period. Leaking batteries will ruin an instrument quickly. The instruments should be handled with care. The electronic instruments have circuitry, which is delicate and can be damaged by rough treatment, such as dropping the gauge or throwing it around carelessly. Gauges should be kept clean and dry. Most gauges come with protective covers of some type, and it is a good idea to keep the gauges in these original protective covers. Most gauges come with lanyards that fit around the operator’s wrist to prevent dropping the gauge while climbing around on swing stages, scaffolding, spiders, etc. Dropping an electronic gauge 25 or 30 feet to the bottom of a steel tank will most often damage the gauge beyond

repair. It can cost a considerable sum to replace a gauge that was dropped because the operator did not like the lanyard around his or her wrist. It is a wise practice to carry insurance on at least your most expensive instruments. There are requirements for periodic calibration of many of the gauges an inspector uses for his or her inspection work. Actual calibration can only be performed by the manufacturer of the gauge or a certified laboratory. Calibration is not done in the field. Verification of the calibration of a gauge or verification of the accuracy of the gauge is what we do in the field. There are certified laboratories located in many cities around the country that can calibrate a variety of inspection instruments. It is advisable for the inspector to locate these laboratories and see that his or her instruments are calibrated periodically as required. If no lab is available locally for the inspector, the gauge can be returned to the manufacturer for calibration. A calibration history should be kept for all instruments that require periodic calibration. Taking Responsibility As inspectors on any coatings project, we are responsible for our own safety. This means that unless we are employed by an inspection company that furnishes our equipment, we are responsible for providing all required safety gear. This includes fall-arrest equipment, such as harnesses, lanyards, lines, etc. OSHA regulations state that fall-arrest equipment is required if we are working at a height of 6 feet (1.8 meters) or higher. OSHA regulations also require replacement of this equipment periodically, whether or not it has been used. If a person falls and his or her lanyard is deployed, it must be replaced. Inspectors should be aware of the regulations regarding their safety equipment so they can be in compliance and protect themselves when working on any coatings project. Often, we read of someone falling and being killed while working on a coatings project. When the event is investigated, it is often revealed that the individual was not using the required fall-arrest equipment. A while back, four painters working on a swing stage on a bridge spanning the Mississippi River fell when the cables on the swing stage broke. Three of the painters were wearing the required

ARTICLE

Inspection on Auckland Harbour Bridge

fall-arrest equipment and were rescued without harm. The fourth painter was not wearing the required fall-arrest equipment and fell into the river. His body was never recovered. This could happen to others working at heights if they ignore the regulations and do not protect themselves. Do not let this happen to you as an inspector. Follow the rules and live to work another

job. Numerous other safety items are required, and inspectors should make sure that they are fully equipped and protected on all projects on which they may be working. As inspectors, we must strive to keep up with all requirements, safety and otherwise, on coatings projects where we are doing quality assurance work.

Knowing how to use and maintain our inspection equipment is essential to our performing our tasks accurately and professionally. It is not an easy task to keep up with all these requirements, but it is one that, as responsible inspectors, we must be aware of, comply with, and on which we must stay current.

April 2012â&#x20AC;&#x192; www.corrosion.com.auâ&#x20AC;&#x192; p.35

INDUSTRY INSIGHT

Manufacturing Aluminium and Zinc Sacrificial Marine Anodes Introduction This article looks at the manufacturing of galvanic anodes for cathodic protection. It will explain some of the terms you might hear used in this industry and the processes involved. It is based on an article written by Russell Northey from Cathodic Diecasting Qld Pty Ltd who has worked there for over 10 years. Russell has Foundry Trade qualifications and in 1990 obtained an Associate Diploma in Applied Science – Metals Technology at the Sydney Institute of Technology. What Goes into Making the Anode Alloys Only certified primary ingots are used for manufacturing galvanic anodes. Secondary ingots, or scrap materials should never be used. Note: “Primary Ingot” refers to those made from high purity metals obtained directly from a continuous smelter. “Secondary Ingot” refers to those that have been made into “casting alloys”, by addition of other metals. Alloy Manufacture In order to make an “alloying addition”, one of two methods are used depending on the melting point of the element being added. 1. Add the metal in its pure form. Requires the element being added to have a lower melting point (MP) than the primary element) – e.g.: Zinc (MP = 419°C) can be added to molten Aluminium (MP = 660°C).

Aluminium Primary Ingots

p.36 CORROSION & MATERIALS

2. Use what is called a “master alloy” (A specially produced alloy material, usually in the form of small pugs, pellets, or waffle plate). This lowers the elements melting point to a suitable value for “going into solution”. Examples of these are Silicon and Titanium. Silicon’s Melting Point = 1412°C but for a master alloy of Al-12% Si = 577°C Titanium’s Melting Point = 1667°C but for Al-10% Ti it is towards 1000°C and in time it will go into solution. As a rule of thumb, master alloys need to be added to the charge early to ensure proper solution, whereas pure metals (of a lesser melting point) can readily go into solution when added towards the end of melting. The two main methods for making the Alloy(s) for galvanic anodes are: (1) Bulk Melting – Transfer – Alloying – Holding – Casting: This process is typical of a high output manufacturer, where ingots are continuously melted in a separate furnace. Liquid “base metal” is then transferred to another furnace where the “alloy” is made (mixed), tested (by chemical analysis), and cast. (2) Melting/Alloying/Casting: where each individual “heat” is melted, alloyed, tested, and cast from the same furnace. This is probably the more commonly used method.

Zinc Primary Ingots

Furnace Types There is a range of furnaces which can be used for melting ingots and making alloys for galvanic anodes. Some are better suited to some products and processes than others. Before discussing the furnaces, it should be noted that there are several different “styles” of casting employed in making sacrificial anodes which can dictate the type of furnace used. These include: asting the anode directly from the C furnace, usually employing the use of a chute or “launder”, then topping up and finishing from a smaller “by the side” furnace. These launders can be “swung” to pour a second and possibly a third cavity if required. apping the furnace into a pouring T ladle which is then used to cast the anode, then topping up and finishing from a smaller “by the side” furnace. It can also be employed to pour multiple cavities without the need for “the radius” that the launder requires. and Casting which is where a small H “refractory coated steel hand ladle” is used to individually pour many multiple dies. A manufacturer of galvanic anodes needs to be able to make hundreds, if not thousands, of small anodes at a time, as well as to cater for casting the larger “long life off-shore” sizes. Unlike a “normal foundry”, who produce many sand moulds in advance prior to “casting” a heat, a manufacturer of galvanic anodes

INDUSTRY INSIGHT

Casting an Aluminium anode using a launder – then “topping up” by hand.

Casting an Aluminium anode using a pouring ladle – then “topping up” by hand. repetition pressure die casting where thousands of small anodes may be cast from the one heat.

Hand Casting Zinc anodes. works somewhat differently. They use Cast Iron or Steel moulds in order to produce the fine “chill cast grain structure” in the “as-cast” condition which is desired by the end user. The tooling (dies) are designed for a general range of products what the market requires and the foundry also needs the ability to make up tooling for specific requests.

However a manufacturer does not need to have 100 dies to make 100 off a 600 x 100 x 150 Aluminium hull anode. They will cycle 5-10 dies in repetition, to achieve the order. This may be the contents of a “heat”, or several heats. Alternately, on the larger scale, they may cast only one 3000 x 300 x 300 off-shore anode. On the smaller end of the scale is the high

Whatever the process, the metal’s chemistry is checked prior to tapping and/or casting. All anodes are stamped upon solidification (as they are usually in open dies) for traceability and if certificates of analysis are required, corresponding chemical sample “buttons” are prepared and stored. (Note – most machine die cast components are not stamped for operational reasons, but they can be batch segregated if required). The furnace “process” for a particular casting method needs to be able to demonstrate it is capable of melting and heating the alloy into a homogenous liquid, and maintain that homogeneity throughout the time that “the heat” is being processed.

“Hard Stamped” identification on both the casting (anode) and the sample. If necessary these numbers can be recalled from computer records at a later date.

April 2012 www.corrosion.com.au p.37

INDUSTRY INSIGHT

Furnaces Furnaces used to melt the alloy are of various types, some having unique features. Their advantages and disadvantages are discussed below. Note: Aluminium anodes make up a large portion of galvanic anodes produced, partly because of their lower density. One tonne of Aluminium has the same volume as 2.5 tonnes of Zinc. The Reverberatory Furnace: This uses deflected heat so the ingots are not in direct contact with the fuel and is usually a primary ingot bulk melting facility, however these are also used for alloying (common in secondary ingot making), can produce the Aluminium anode alloys, and suit casting large anodes straight from the furnace and/or a pouring ladle. Pros: most efficient “fuel fired” melting, and large capacity furnaces are available. Cons: can be difficult for holding and casting long runs of small to medium anodes. The Induction Furnace: Is possibly the quickest of all the furnaces for melting Aluminium. Stirring and homogeneity is superior, and also suit casting large anodes straight from the furnace and/ or a pouring ladle. Pros: natural stirring, also less oxidation than the reverberatory furnace. No temperature “over-run”. Cons: higher initial set-up costs (infrastructure) and repairs and maintenance can be higher than a simple “fuel system”. Gas Fired Tilt: An old style design but still widely used as it is versatile and can

be a very economical unit. Suits large casting sizes straight from the furnace and/ or a pouring ladle, or transfers. Pros: lowest set up cost, and requires only fuel and 3 phase electrical supply. Fuels used include LPG, Natural Gas, Oil, Diesel, and can be wood fired. Cons: Utilises heel melting, and benefits from continuous use and a large capacity to be economic. Noise can be a concern for the operator. Electrical Resistance Bale Out: were usually only found in the automotive & light metals casting areas, as a holding furnace. With the advancement of high insulation “panels” which house the resistors (elements) and higher power factors they can also be used as a melting unit. Can produce “melt costs per Kg” similar to the others, especially when run continuously. Pros: can hold metal overnight to optimise work hours nearer to 100%. Almost silent operation. Cons: still regarded as a “stand and bale out.” Gas Fired Bale Out: The most common type as they give flexibility due to the different sizes available. They range from small 30kg “pot” furnaces, used for top up material, up to those that can handle tonnes of Aluminium. These are commonly used for Zinc (which has a much more uniform (horizontal) heating curve than Aluminium), and most Zinc anodes are hand cast. They also can be used for Magnesium, with the appropriate shielding gas, although Electrical Resistance furnaces are generally preferred for Magnesium due to their superior stability and control.

A “charge” of ingots in an induction furnace prior to melting.

p.38 CORROSION & MATERIALS

How To Test This Material For Correct Chemical Analysis – What Is OES? Optical Emission Spectroscopy (OES) is commonly used for any hot metal producing area. Whilst an OES is comparative (as opposed to quantitative) its advantage is its speed. In a foundry it is possible to sample a small amount of homogenous liquid, chill cast a sample to produce a homogeneous solid metallic disc, lathe the material for arc-spark analysis, and have a qualitative result within three minutes of sampling. A quantitative method can take very much longer. An anode manufacturer needs to be sure what is being cast is within specification which cannot be done by buying certified material and carefully weighing them, as galvanic anodes rely on major alloying elements and “micro-alloys” to function properly. A spectrometer must be capable of measuring their concentrations as low as 20 parts per million – up to levels of 6 percent – in a given “base” metal. The Casting “Processes” Pressure Die Casting: is the intricate end of the casting process where threaded pencil anodes can be produced, as well as rudder and shaft anodes with a high quality finish. Closed Die Gravity Casting: is employed for larger shaft and block anodes. This process is also intricate and used by only a few manufacturers. It uses a runner / riser system and the product is cast “in the traditional founder’s method” but uses a re-usable mould, which can be open and closed by mechanical operation. There’s no pressure – just gravity, in order to produce the desired “defect free” casting.

Ingot nearing the end of melting in an induction furnace.

INDUSTRY INSIGHT

2400mm length. The insert can inhibit the “contraction” inwards, as it has a grip on the outer “ends” of the anode (being the first area to solidify upon completion of casting), hence the anode tears itself in the centre, where the temperature is still much higher than the ends and this initiates a crack. Instead of the shape contracting inwards (ends to centre), due to the “grip” on the ends it has no choice than to reverse this direction and it contracts (centre to ends) causing what is called a “hot tear” in conventional casting terms. Aluminium ingot melting in an electrical resistance bale out furnace. A shrouded thermocouple resides permanently in the bath for optimum temperature control. Open Die Casting: is the oldest and most widely used process for making galvanic anodes, if measured by total tonnage produced. However if you measure by sheer numbers of repetition, pressure die casting becomes very important.

they build patterns for manufacturing castings. This is all taken care of whilst making engineering castings by use of closed moulds, metalo-static head pressure, and atmospheric pressure all ensure accurate finished shapes, and “soundness” are met.

Cast Iron Dies are preferred due the superior conductivity of the graphitic “grey” cast iron. Steel dies can also be used; however steel does not conduct the heat as efficiently as cast iron. This may be a concern when casting large Aluminium anodes for heavy duty applications.

Below is a table of properties of the anodic metals. As an example of volume change; if a 100 litre drum of solid Aluminium were heated, upon reaching “melting point” and heating the liquid through to 700 degrees, the drum would overflow 6.6%. As a consequence, the density also lowers as the volume increases.

Bench scales and crane scales are required for process control. Other controls can include load cells on furnaces where launders are employed. Blank rod and billets can be cast for machining blanks to be made into whatever shape anode one requires. Variations in Dimensions and Weight All metals experience a volume increase upon heating above their melting point or “liquidus” where they change from a crystalline phase and become homogenous liquid. They also “contract” upon cooling after solidification to ambient temperature. These two physical properties can be taken care of (in the traditional foundry) by use of “risers or feeders” to supply the additional liquid required by the volume loss, and also by patternmakers applying “contraction allowance” to the dimensions which

This “volume increase” is also a volume loss towards solidification – this is called liquid shrinkage. In large module (heavy section) anode castings “top up metal” is added to replace the volume loss. Also, if a die is 600 x 150, the casting will be (600 x 0.987) x (150 x 0.987) = 592 x 148. To counteract this effect, the die is made bigger (600 x 1.013) x (150 x 1.013) = 608 x 152. This “dimensional loss” occurs after the metal has solidified – this is called solid contraction.

The ratios of the insert cross-section versus the anode cross section versus length are important design factors. Whilst purchasers want anodes “free from cracks”, sometimes it is the design of an anode which makes it “prone” to cracking which should be discussed with the manufacturer. When designing a long, slender anode, it should be remembered that the “core” only has to hold (apart from being the reliable electrical connection) the anode to the structure. Another variable is the final insert length, especially hole centre distances of inserts, which can be difficult to control. The steel insert expands due to the mass of heat it has to absorb, and depending upon the “ratio” mentioned above, it may not fully return to its original dimension. Slotted holes are used to help with this variation that can’t be completely removed. In large offshore anodes, hole centres can be anything up to +- 15mm, an obvious headache to installers on site. In most cases it is not practical to punch these holes “after casting” the anodes. Any further discussion is welcomed by contacting the author at russell@cathodicdiecasting.com.au

When anodes are made, most (not all) are cast around an insert, which is usually steel. This steel insert does cause problems, dimensionally, and physically. The insert can inhibit long shaped anodes from contracting the 1.3% they would if they were cast without the steel insert, e.g. 31.2mm over a

Anodes waiting transport to the buyer.

Element

Symbol

Melting °

Boiling °

Density

Volume ↑

Contraction

Aluminium

660

2520

2.70

6.6

1.3

Magnesium

649

1090

1.74

4.2

1.3 – 1.4

Zinc

419

907

7.14

6.5

1.18

April 2012 www.corrosion.com.au p.39

TECHNICAL INTRODUCTION

Hot Dip Galvanizing – An Introduction The hot dip galvanizing process is relatively simple compared to most other corrosion protection systems and it is this simplicity that makes it an economically efficient and technically effective corrosion protection system for both small items and structural steel applications. The galvanizing process utilizes zinc, one of the most widely used metals, to provide a protective coating to steel. Most hot dip galvanizing that is specified in Australia and New Zealand is performed to AS/NZS 4680 Hot-Dip Galvanized (Zinc) Coatings on Fabricated Ferrous Articles. The process to be discussed here is after-fabrication batch hot dip galvanizing. There are other forms of galvanizing or closely related processes: in-line, or continuous, galvanizing, spun products (for fasteners and other small items) and electroplating. These will be discussed in later issues. Galvanized steel uses zinc for corrosion protection. Coatings utilizing zinc make up the largest use of the world’s zinc production. This includes galvanizing and other applications, such as electroplating, zinc thermal spray, and paints. Zinc is an ideal corrosion protection material for steel because it corrodes at a much slower rate than steel when exposed in most conditions. This can vary from a corrosion rate of approximately one twentieth that of steel in inland or benign environments to up to one eightieth in coastal and marine situations. The Galvanizing Process Galvanizing is conducted in varied ways depending on the type of plant, but in general most plants follow similar procedures. It should be noted, that galvanizing relies on the iron content of steel for the process to occur. Thus, it is not possible to “galvanize” nonferrous metals, for example, copper or aluminium. The preparation process for steel prior to galvanizing involves the removal of scale, rust, oil paint and other surface contaminants. This is usually achieved through cleaning in a caustic solution followed by immersion in an acid bath. The steel is then rinsed in water prior to its immersion in a warm flux tank, usually made up of a 30% zinc

p.40 CORROSION & MATERIALS

ammonium chloride solution. The flux solution removes the oxide film that forms on the surface of the steel after the acid clean and also prevents further oxidation prior to the actual galvanizing process. The galvanizing bath is made up of molten zinc in a steel kettle and some trace alloys such as aluminium. Other alloys can be added to achieve slight modifications to the coating and the process, for example, nickel, but these are usually used in very small amounts. Zinc has a melting point of approximately 420°C so the kettle temperature is normally maintained in the range of 445°C to 465°C. If the temperature is too low, then the reaction may not occur satisfactorily and if it too high, then energy usage, kettle wear and ash production is increased. On immersion in the galvanizing bath, the surface of the work is completely covered and the molten zinc reacts with the steel to form a series of zinc-iron alloy layers. The coating continues to form until the steel has reached the temperature of the molten zinc and the reaction is complete. The time required for the complete reaction is influenced by a number of factors including the temperature of the molten zinc, the size and weight of the article, and the type of steel being galvanized. The article is then withdrawn from the bath and an outer layer of molten zinc is carried with it. Much of this runs off the article and into the zinc bath, however, some if it solidifies to form the predominately pure outer zinc coating familiar to most users. The item is then usually cooled and passivated in a sodium dichromate bath. The passivation process assists in protecting the galvanized steel during its initial storage, transportation and installation. Depending on the client’s requirements and at the galvanizer’s discretion as to possible issues with distortion, the item may be air cooled instead. Further information can be found at the Galvanizers Association of Australia website and in the references at the end of this article.

Figure 1: Galvanized steel being withdrawn from a zinc bath (Industrial Galvanizers) Key Physical Properties of Galvanized Steel The metallurgical alloying process of galvanizing provides galvanized steel with a number of unique properties. All surfaces of the work are completely covered, both externally and internally. This means that corners, edges, holes, welding seams and any recesses are completely covered and protected. This generally produces a uniform coating of zinc and zinciron alloy layers over the complete article, no matter how complex the configuration, and specifically in areas that are potentially “corrosion hot spots” for other coating systems. Hollow steel sections are particularly suited to galvanizing since they are protected both externally and internally without the need for additional specialized requirements. Also, because the zinc and zinc-iron alloy layer thickness is determined primarily by steel thickness, a standard minimum coating thickness is automatically applied to all areas regardless of orientation, access and applicator technique. Corners and narrow edges will produce a slightly thicker galvanized coating, thus providing greater protection on the areas most likely to suffer from impact damage and subsequent corrosion. This contrasts with other coating systems, such as paint, which thin out in these critical areas and require careful design and application modifications to improve their thickness and performance on such surfaces. The base of a layer of galvanizing has more iron while the most outer layer or surface of the galvanized coating

TECHNICAL INTRODUCTION

Eta layer 70 DPN hardness Zeta layer 179 DPN hardness Delta layer 244 DPN hardness Base Steel 159 DPN hardness

Figure 4: Galvanizing alloy hardness (AGA)

Figure 2: Micrograph of galvanizing on edge of steel (GA UK) (q) Insufficient edge preparation prior to painting (sharp edge) Protective paint

Steel

Structural members generally

Hot Dip Galvanizing: Corrosion Protection Mechanisms In addition to the extra mechanical protection afforded by the zinciron alloy layers, galvanized steel is protected from corrosion via a number of different mechanisms.

Galvanizing provides barrier protection in two ways. The galvanized layer of zinc-iron alloys provides a protective physical envelope around Protective paint the steel, shielding it from the environment. Secondly, the galvanized system layer also develops a protective patina d on its surface upon exposure to the Steel environment. This is made up of zinc Good oxides, hydroxides, carbonates and basic zinc salts depending on the d = 1 mm Chamferred edge nature of the environment.

Chamfer or round edges prior to painting

Protective paint system Better

Steel

r = 2 mm Rounded edge

Figure 3: AS/NZS 2312 suggested requirements for edge corrosion protection for paint systems. Note extra engineering design required (Standards Australia) is 100% zinc. The intermediate layers have varying ratios of zinc and iron progressing from ~25% Fe/ 75% zinc to 6% Fe/ 94% zinc, and finally pure zinc. This is known as the “free zinc” coating. It is not strictly part of the galvanized coating, but provides extra protection and the “silvery” appearance associated with most galvanzing. Coatings are measured in either the thickness of the coating micro-metres (μm), or by the weight per unit area, g/m2. The lower alloy layers are up to 50% harder than the base steel. This provides galvanized steel with much greater resistance to abrasion and mechanical damage, thus protecting the base steel from exposure to the atmosphere. The advantage of this is not only seen in service, but also during transportation, handling and erection.

Free flowing air O2

1 Zinc Oxide ZnO

Moisture from rain (dew) H2O

2 Zinc Hydroxide Zn(OH)2 Free flowing air O2 + CO2

3 Zinc Carbonate 2ZnCO3 • Zn(OH)2

Figure 5: The stages of development of galvanized steel’s protective patina (AGA) progress past the soluble stage and the galvanized steel continues to corrode. Galvanizing is usually not recommended for such applications unless there is additional protection, for example, a suitable paint.

The patina forms in a staged manner upon the exposure of the galvanized steel to the environment. It is the carbonate form that provides the greatest protection to the steel, but its development follows the others so they are all important in the protection process. The patina can take anywhere from a few months to a few years to develop, hence the initial passivation of the galvanized steel with sodium dichromate. The initial stages are soluble, so to a certain extent galvanizing relies on favourable wetting/drying cycles to fully develop the protective patina. This is why galvanizing is generally unsuitable in areas that are constantly moist or subject to excessive spray, particularly if it is corrosive. It should be noted that the oxide and hydroxide coating are soluble and will dissipate under weathering and cleaning. The true protective layer, the zinc carbonate coating, is insoluble and more resistant to damage and removal. This layer is what gives galvanized steel its ultimate dull grey or “weathered” appearance. The speed of the final transformation will vary based on the corrosivity of the environment.

In the event of severe mechanical damage, galvanizing also provides cathodic protection to the base steel. The galvanizing performs in a similar way to other sacrificial protection systems, except in this case the sacrificial anode is distributed over the article to be protected and electrical continuity is assured.

As mentioned above, environments that are constantly moist inhibit the development of the protective patina since they don’t allow it to

It should be noted that much of the testing that is later attributed to galvanized steel is actually the testing of pure zinc. In many environments,

Durability of Hot Dip Galvanized Coatings There is a variety of data available from different sources on the durability of galvanized steel. Since the process has been utilised virtually unchanged since 1837, a large amount of empirical data has been recorded from case studies in a large number of operating situations, locations and corrosive environments. This history of use also assists maintenance engineers in planning for infrastructure life, maintenance and remediation. Engineers can choose to use empirical data from selected sources such as Porter (1991), Slunder & Boyd (1983), Porter (1994) and Zhang (1996) or refer to standards that address corrosion rates for various metals and corrosion protection systems such as ISO 9223 and AS/NZS 2312.

April 2012 www.corrosion.com.au p.41

TECHNICAL INTRODUCTION

the performance of the zinc-iron alloys is actually superior to pure zinc, so these figures need to be used with the realization that they will often be conservative. A discussion of the corrosion and durability performance of galvanized steel in different environments will follow in later articles in this series. One of the advantages of galvanizing is its ability to perform over a wide range of temperatures. It can operate at temperatures as high as 200°C and as low as -60°C. Galvanized steel has a further useful property under Australasian conditions since in that it is also immune to ultraviolet radiation. Many other corrosion protection coatings will degrade on exposure to solar radiation and it can be one of the key limiting factors to the performance of such coatings. Zinc is an amphoteric metal, which means it has a durability performance limit under both acidic and alkaline conditions. The accepted rule of thumb in the industry is that the pH of the environment should be in the region of 6 – 12 pH. For specialized applications that may fall outside this range, it is recommended that the designer consult with the galvanizer.

Figure 6: Galvanizing in sub-zero conditions in Victoria (Parks Victoria) The durability of hot dip galvanizing often raises the contentious question of warranties. The galvanizing industry does not have a consistent view on warranties and these need to be discussed on a case by case basis. Some companies offer them while others don’t. Most of the reluctance towards warranties is due to the fact that galvanizers usually do not have much input, if any, into the application of their products. Many items are galvanized and then it is only in hindsight that a warranty is requested. Galvanizers find this difficult to deal with since the durability of the steelwork is based on many different factors. Environment, design, thickness and many other variables

p.42 CORROSION & MATERIALS

Table 1: Corrosion Rate of Galvanizing on Vertical Surfaces in Various Environments ISO 9223 Corrosion Category

AS/NZS 2312 Corrosivity Description

Typical Environment

Average Zinc Corrosion Rate µM/year

Very Low

Few alpine areas, dry interiors

<0.1

Low

Arid/rural/ urban, Interiors – occasional condensation

0.1 – 0.7

Medium

Coastal High humidity interiors

0.7 – 2

High

Sea-shore (calm) Swimming Pools

2–4

Very High

Sea-shore (surf)/ offshore

4–8

(which are incidentally the same as for many other corrosion protection technologies) can affect the predicted durability of a galvanized article. However, if galvanizers are involved at the design stage, then it is possible that a valid warranty can be agreed on where it is required. Phillip Layton of Industrial Galvanizers says that, “There is independent information available that will accurately predict the life expectancy of the coating in various environments and in these instances some galvanizers will offer coating warranties on large projects.” He also mentions that the designer can access a large amount of information that is available from some galvanizers. “Large galvanizers would be able to provide technical information and design input to customers, either in person, via email or over the phone. It is common for galvanizers to receive requests for information on projects with the drawings being sent for comment, design input and pricing.” He points out that the Galvanizers Association of Australia (GAA) represents the Australian industry and they also have a wide variety of information on the subject. “The GAA also has a lot of information concerning potential problems and information regarding the correct specification of galvanizing. This can be accessed via their website or by contacting them directly.” Generally, if warranties and quality documentation are required for a specific project, then it is advised that the designer consult the galvanizers

as early as possible in the specification and design process. Conclusion Galvanizing is a proven technology with a long history of use, both in Australasia and around the world. It is virtually impossible to avoid galvanized steel in most situations in the built environment – electricity infrastructure, road furniture and items such as boat trailers are almost exclusively galvanized. Australasia is well serviced in most areas with galvanizing plants and this makes it a common solution to many corrosion problems. This has been a brief introduction to galvanizing and further articles discussing more specific issues such as appropriate design and durability are planned. References and Further Reading: AS/NZS 2312:2002 Guide to the protection of structural steel against atmospheric corrosion by the use of protective coatings AS/NZS 4680:2006 Hot-dip galvanized coatings (zinc) coatings on fabricated ferrous articles ISO 9223:1992 Corrosion of metals and alloys – Corrosivity of atmospheres – Classification Porter, F Zinc Handbook: Properties, Processing and Use in Design, Marcel Dekker, NY, 1991 Porter, F Corrosion Resistance of Zinc and Zinc Alloys, Marcel Dekker, NY, 1994 Slunder, C & Boyd, W, Zinc and Its Corrosion Resistance, ILZRO, NY, 2nd Ed. 1983 Zhan g, X Corrosion and Electrochemistry of Zinc, Plenum Press, NY, 1996 www.gaa.com.au www.galvanizing.org.nz www.ingal.com.au www.korvest.com.au

Emmanuel Pimentel

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April 2012 www.corrosion.com.au p.43

PROJECT PROFILE

Concrete Protection in Strong Chemical Conditions Metz Specialty Materials Pty. Ltd. manufacture and install products designed for highly corrosive environments. The following two projects illustrate the need to specify the right products to meet customer specifications. The two projects also show a wide range of material chemistries that are available to counter the wide range of chemical and physical conditions encountered in heavy industry. Project 1 was a sulphuric acid bund in an ammonium nitrate plant in central Queensland. Project 2 was a pickle line bund in Victoria.

Project 1: Sulphuric acid bund Specification A potassium silicate concrete was selected for the floor areas. Potassium silicates are resistant to all concentrations of sulphuric acid at high temperature, as well as all other acids, except those containing fluorine. The potassium silicate concrete can be laid like normal concrete, but reaches full cure within 48 hours at 20°C., thus minimising down time. It has the benefit of being able to be laid in varying thickness thus incorporating required falls. A special 100% solids epoxy novolac coating was selected for the wall areas. This epoxy novolac has excellent resistance to concentrated acids, including sulphuric acid. Viton® Caulk was selected for all movement joints. This fluoropolymer product has excellent resistant to many chemicals, including concentrated sulphuric acid and maintains flexibility over a wide temperature range.

p.44 CORROSION & MATERIALS

Gathering the following information was necessary in order to provide a correct specification for the two projects.

In both cases, the installations needed to be put back into service as soon as possible, so products with short curing times were selected.

Project 1 Area approx. 90m2

Project 2 Area approx. 250m2

Chemicalsconcentration and temperature

Sulphuric acid, 98% Ambient temperature (up to 50°C.)

Hydrochloric acid, 12% Temperature up to 60°C

Exposure

Intermittent leaks expected

Frequent spillages expected

Traffic

Foot traffic only

Non-traffic area after initial installation period.

Concrete substrate

Existing concrete with lining epoxy. Badly damaged.

New concrete, mostly 5 days old

Site conditions

Exterior ambient

Interior ambient

Surface Preparation Damaged topping and concrete substrate were removed by 10,000 psi high pressure water blasting. Grade 304 stainless steel anchors were fixed to the surface in diamond shaped pattern, with centerlines approximately 300 mm. apart. Special chemical resistant waterstop, manufactured from a proprietary rubber compound was fixed over concrete joints.

Viton® Caulk was applied to all movement joints using an air operated caulking gun. The bund was ready to go back into service after 1 week.

Installation All damaged concrete had to be replaced and falls incorporated into the acid resisting floor. (There were no falls in the original design –this fault would have most likely accelerated the failure of the original coating.) This meant that up to 90mm. of potassium silicate concrete had to be installed. A smoothing coat of an epoxy novolac plaster was to be applied to the wall surface prior to the installation of the coating to fill any holes or porous area. Two coats, each 250 microns of special epoxy novolac coating were then applied.

Sulphuric Acid Containment area – as found

PROJECT PROFILE

Sulphuric Acid Containment area – after water jetting

Project 2: Pickle line bund Specification As the concrete substrate would generally be only 5 days old, it was considered that laying any monolithic lining system would not be advisable. A ceramic tiling system was specified. Membrane: A rubber -modified bituminous membrane incorporating fabric reinforcement was selected. This product has been used extensively over green concrete. It provides an excellent bond between the concrete substrate and the tile bedding cement and accommodates differential movement between the substrate and tile system. Tile bedding mortar: A fast setting, 100% solids epoxy bedding mortar was selected. This product has excellent adhesion to both membrane and tile and also provides resistance to any acid that may penetrate the tiles and/ or joints. Tile jointing mortar: A special 100% solids epoxy novolac mortar was selected. This product has excellent resistance to concentrated acids at high temperatures. It also is fast curing, so that installations can be quickly put back into service.

Sulphuric Acid Containment area – after rectification works

solubility of much less than 1% and are ideally suited to acid environments. Surface Preparation New concrete surfaces were specified to have a wood-float finish. Pre-cast surfaces on pedestals were given a light grind. Installation Rubber-modified bituminous membrane was applied over concrete surfaces in 2 coats. A fabric reinforcement was incorporated into the first coat. Acid resistant ceramic tiles were cut to size where necessary and bedded in fast setting epoxy mortar. Average depth of bed was 3-4mm.

Pickle Line – Acid tiling system during installation

Tile joints were approximately 5 mm. wide and filled with epoxy novolac mortar. Movement joints were formed at all internal vertical corners, around pedestal bases and over all movement joints in the concrete substrate. Joints were filled with chemical resistant silicone rubber to a depth of 8 mm. Installation was completed in 8 days.

Pickle Line – Acid tiling complete

Movement jointing: A high chemical resistant silicone rubber was selected. This product has excellent resistance to medium strength acids at elevated temperatures and maintains flexibility over a wide temperature range. Ceramic tiles: Special acid resistant 240 x 115 x 18 mm tiles were selected. These tiles have a water absorption and acid Pickle Line – New concrete works prior to installation

Pickle Line installed

April 2012 www.corrosion.com.au p.45

PROJECT PROFILE

Fremantle Ports – Protecting the Unseen Introduction In May 1897 Fremantle Ports’ Inner Harbour was officially opened bringing increased trade into Western Australia. One hundred and fourteen years later in 2011, the Port saw 26 million mass tonnes of trade pass through its facilities at a value greater than $25 billion.

Busy times at Fremantle Ports Fremantle Ports is a harbour seemingly forever in expansion. With imports and exports increasing, 2011 alone saw Fremantle receive 1952 shipping visits. Vessel capability and size is increasing and capacity for container storage is at a premium. To ensure the Ports can meet the requirement to handle larger vessels, receive the increased container throughput and store the additional containers, means a continual improvement to Port facilities.

Lining them up – Berthing at Fremantle In 2009/10, Fremantle deepened the Inner Harbour and Entrance Channel to 14.7 metres and the Deepwater Channel to 16.5 metres, allowing larger vessels to enter the port fully loaded. The project also involved strengthening of the North Quay container berths to cater for the heavier loads the bigger ships impose on wharf infrastructure.

p.46 CORROSION & MATERIALS

Queen Mary 2012 Corrosion concerns Further to addressing improvements in Port throughput, Fremantle has been attacking (over many years) other less seen, and critical, issues occurring below deck level. Accelerated Low Water Corrosion (ALWC) and Microbially Influenced Corrosion (MIC) are the main corrosion morphologies identified at Fremantle Ports resulting in significant degradation to steel support piles. Substrate loss through ALWC was the first concern identified at the Port (both Inner and Outer Harbours) more than ten years ago and a dedicated petrolatum tape wrap system with HDPE overlay was implemented to assist with corrosion management. Pile wrap removals and inspections have identified great success in this system at the attack zone, predominantly at the splash zone and approximately 500mm below low water level. In 2004, the first reported case of MIC was observed on the submerged portion of the steel support piles and sheet-piling within the Fremantle Inner and Outer Harbours, identified by the presence of what has been described as the “Orange Bloom”. The presence

of this “Orange Bloom” has been directly linked to increases in corrosion rates of the underlying substrate. Further inspections and testing located substrate loss and pile perforations (in certain areas) below the level of the wrapping project and within the locations of identified “Orange Bloom”. As a result of an increase in identified corrosion to steel support piles outside the protected wrap zones, Fremantle Ports have undertaken a comprehensive Inner and Outer Harbours Cathodic Protection Management Plan incorporating both Impressed Current and Sacrificial Anode systems. Project Scope of Works Innovative Corrosion Management (ICM) commenced the design, supply and installation of the ICCP systems for the Inner Harbour in 2007. Fremantle Ports requested an ICCP system with a projected 30 year service life, with a specified protection potential of -900mV vs. Ag/AgCl reference cell, to allow for protection against MIC. Design works were first completed taking into consideration both immersed and embedded zones of steel support piles and with particular

PROJECT PROFILE

consideration to the difficulty of access, cable runs and anode and TR Unit placement. Design check and verification was provided by Mr John Grapiglia to ensure all aspects of the CP design were adequate to provide the final design requirements. Over a five year period working in with shipping schedules and project budget allocations, ICCP systems have been installed to Berths, 4, 5, 6, 7, 8, 9, 11 and 12 at Fremantle Ports. In total ICM have installed the following as part of system installation: 7 off 200 amp Transformer Rectifier 2 Units supplied by M Brodribb. All TR Units had to be installed below berth deck. ighty four (84) off Mixed E Metal Oxide anodes supplied by NMT electrodes. In excess of 3.5km of cabling. I CCP Remote monitoring units operating to provide system emails for real time notification of unit status (on/off). Project Considerations With a port facility operating on a 24hr 7 day basis, access to the steel support piles and berths was a major challenge to maximise man hours on site and reduce downtime due to shipping. With shipping taking precedence over installation works, constant contact with Fremantle Ports Operations to determine berthing status dictated which berths ICM could work on. Having several berths available under each contract

enabled movement around the berths depending on shipping, reducing project stand down time. The most difficult aspect of CP installation on this project was the access restrictions due to limited walkways below the berths and congestion with new and old steel support piles taking up considerable room below decks making manoeuvring and accessing locations at high tide almost impossible. In the end, rigging experience became one of the most valuable assets to CP installation, in particular at stages of manoeuvring and installing the TR Units below deck level, supported from the deck soffit. System Operations Prior to commissioning of the CP throughout the berths it was apparent that, ensuring continuity of the system and piles was going to be a significant consideration with the berths being of varying ages and construction methodologies. CP was not a consideration for bonding and continuity at the time of original construction, a practice that has changed with all new berth works implementing good bonding and continuity practices and provision for CP installation. On commissioning, piles that did not meet specified protection criteria were mechanically bonded and all piles are now achieving specification requirements. Fremantle Ports have also undertaken a dedicated monitoring and maintenance regime for the systems with ICM providing this service in accordance with the guidelines of AS 2832.3

In 2011, ICM worked with Fremantle Ports to increase awareness of the CP systems at the Port, with the biggest concern being CP Units being turned off for project works, and not being re-energised for extended periods. To this end, dedicated remote monitoring capabilities with real time email notification of TR Unit status (on/ off) have been installed which has eliminated unnecessary CP downtime. Fremantle Ports’ Viewpoint The installation of the various Cathodic Protection Systems within the Inner Harbour over the past few years, has been a total success and has totally met Fremantle Ports expectations. The 2000 or so tubular steel piles supporting the various wharfs are of vital importance to the Port to ensure that the berths continue to operate well into the future. All works were undertaken within project specifications, timeframe, budget and with no safety concerns or lost time injuries. In addition, and of particular note, is the amount of time and effort given by the contractor to details and of the technical support, expertise and advice provided over the years. Innovative Corrosion Management Pty Ltd Craig Hutchinson Fremantle Ports Dario Vallini

Typical Remote Monitoring Unit

Typical steel pile layout under wharf structure

Typical CP Transformer Rectifier Unit

April 2012 www.corrosion.com.au p.47

UNIVERSITY PROFILE

The University of Auckland The group Research on Corrosion and Protection at the University of Auckland (UoA), New Zealand currently has four academic staff including Prof Wei Gao as the leader, Dr Michael Hodgson, Dr. Michelle Dickinson and Dr. Tianping Zhu. There are also ~10 PhD students working on corrosion, protection, coatings and surface reactions. A few previous group members have made important contributions in the corrosion and oxidation areas, including Dr. Zhengwei Li (now with Building Res Assoc NZ), Prof Zhenyu Liu (Northeastern Uni China), and Prof Weiwei Chen (Beijing Inst of Tech). This group is a part of the Materials Research Cluster and Materials Accelerator at the University of Auckland, and has close relationships with the Research Centre for Surface and Materials Science (RCSMS), and Light Metal Research Centre (LMRC). The research group also established long-term international collaborations with overseas universities and institutes, including University of Science and Technology Beijing, and Shenyang Institute of Materials Research, Chinese Academy of Sciences. The group has carried out extensive research on high temperature oxidation, corrosion, protective coating and surface modification. Some examples are listed below. (1) The group studied the oxidation properties of nano-structured alloy coatings from 1996. A paper published in Acta Materialia in 1998 reported the strong effects of grain size on the high temperature oxidation resistance of Ni-Cr-Al coatings. When the grain size reduced to ~60 nm, Al content as low as 2 wt.% in Ni-20Cr-2Al coating can form a completely protective α-Al2O3 scale, while the same alloy with an “ordinary” grain size needs >6%Al to form a complete α-Al2O3 scale. A new model that considered the diffusion through both the lattice and grain boundaries was established to explain the mechanism. Based on the results of experiments and modeling, a “selective oxidation map” was established to describe the relations of grain size and oxidation products (Fig.1).

p.48 CORROSION & MATERIALS

(2) N ew high-temperature oxidationresistant Ti-based materials of Ti3Al(O)-Al2O3 composites were developed using in-situ mechanicalalloying and reaction-sintering techniques. These composites exhibited excellent oxidation behaviours. It can withstand high temperature at 850°C up to 500 h without scale spallation, while Ti and Ti3Al intermetallic alloys showed excessive scale spallation from 750°C (Fig.2). This composite has advantages of light-weight and easy fabrication from inexpensive materials. It can also be used as a coating material to improve the oxidation resistance of Ti based materials. (3) Reactive elements such as Y have been added into Ni and Fe aluminide coatings. Magnetron sputter technique is used to create micro-/nano- sized coating structures. The oxidation resistance, especially scale spallation resistance, has been improved significantly with the formation of α-Al2O3 scales at 1100-1200°C. Iron aluminides were tested as heat exchangers in a cement company plant with very good performance. (4) Hot corrosion behaviour of Ti-Al based intermetallics was studied in a salt mixture of 80 wt.% Na2SO4 + 20 wt.% NaCl (Tm=∼700°C). Different specimen exposure methods were tested to see their suitability. Ti3Al-TiC composites made by mechanical milling and HIPing were also tested. The composite sample exhibited superior scale spallation resistance. (5) Oxidation behavior of materials at extra-low oxygen partial pressure. An extra-low oxygen partial pressure testing system is developed in collaboration with Prof Yedong He of University of Sci & Tech Beijing (USTB), which can create pO2 as low as 10-23 atm. This system was used to study (i) oxidation kinetics when the reaction cannot be measured with mass changes, and (ii) early stage oxide nucleation and growth behaviours. Later this system has been used to produce

nano-structured semiconductor oxide thin films. (6) R esearch collaboration has been conducted with USTB on some basic oxidation theories including the transition from internal to external oxidation and P-B ratio for oxidation of alloys. (7) The group also studies the oxidation behaviors of metals under water vapor containing atmosphere. Nanowires, ribbons and various low-D structures can be obtained (Fig.3). Oxidation processes have been developed as a production method. More than 100 research papers have been published in highly impacting international journals, including Advanced Materials, Acta Materialia, Corrosion Science, Oxidation of Metals, Intermetallics, and Applied Physics Letters. Prof Wei Gao sits in the editorial committee of Oxidation of Metals, High Temperature Materials and Processes, and several other corrosion related journals. The research group has gained high reputation in this field. The group also has conducted extensive research on processing, property and applications of various coatings. We use both traditional and novel coating processes in our work, including magnetron sputter deposition, electro and electroless plating, sol-gel process, micro-arc deposition, and sol-enhanced electrochemical coatings. Here are several examples: (8) M icro-arc deposition directly transfers alloy coatings from the electrode to the substrate. The fast cooling and mechanical polishing make a nano-structured alloy layer that metallurgically adhered to the substrate. The coatings possess high hardness, wear, corrosion and oxidation resistance. This method can also be used for in-situ repairing of worn parts. (9) P lasma electrolytic oxidation (PEO) pre-treatment followed by electroless Ni plating has been developed to make pore-free coatings on Mg alloys. The coatings made with this technique are

UNIVERSITY PROFILE

pore-free, showing much better corrosion resistance compared to the traditional PEO coatings. An important advantage is the new technique does not use Cr+6 and HF in its pretreatment, therefore it is an environmentally friendly process.

The University and Faculty has facilities for corrosion, oxidation, and coating research, including CHI604D electrochemical analyzer, salt fog spray chamber, and various coating processing and testing facilities. Materials/surface characterization instruments include environmental SEM, XPS, EDX, XRD, XRF, AFM, TEM, Nano-Indentation System, DSC/ TGA are available in the Faculty and University Centres. The tests follow Industrial Standards and are suitable for corrosion mechanisms research. The group has served New Zealand and overseas companies extensively, including New Zealand Steel, Fisher & Paykel Appliances, Fisher & Paykel Healthcare, Rakon, Rigg, Methven Tapware, and Fonterra. We help the industries to develop their corrosion prevention technology, materials characterization and selection, failure analysis and cost reduction. The first contact point can be Prof Wei Gao w.gao@auckland.ac.nz.

Professor Wei Gao

Dr. Michael Hodgson

Dr. Balan Zhu

as-cast alloy

α-Al O 2 3 Cr2O3+Int. Al2O3

1e+3

l 2O 3 +α-A Cr 2O 3

1e+2

α-Al2O3

1e+1 0

micrograined coating

Grain size, nm

1e+4

Wallwork an d Hed

Cr2O3+NiCr2O4+Int. Al2O3

1e+5

Al2O3+NiC r

2 4

1e+6

4 6 8 Al content, wt. % Fig.1 “Selective Oxidation Map” showing the grain size has strong effect on the selective oxidation behaviour of Al containing Ni-Cr based coatings, Acta Mater., Vol.46, 1691. 4.0

Mass Gain (mg/cm2)

(10) One of our current focuses is the synthesis of nano-composite alloy coatings by combining sol-gel and electro/electroless plating techniques. Highly dispersed oxide nano-particle reinforced composite coatings have been produced on various substrates such as carbon steels, Cu, brass, stainless steels, Al and Mg alloys. The coating matrix can be Ni, Ni-P, Cu and Au. The hard particle reinforcement phases can be TiO2, ZrO2, and Al2O3. This method makes the nano-sized oxide particles dispersed uniformly in the alloy matrix, effectively avoiding their agglomeration. The volume percentages of the reinforcing phase are rather small (0.5-1.5%), but the improvement in hardness and wear resistance is significant (40-70%). We are exploring the wide applications of these new coating systems.

3.2

TiAl-Al2O3-TiC Isothermal TiAl-Al2O3-TiC Cyclic Ti-48Al-2Cr Isothermal Ti-48Al-2Cr Cyclic

2.4 1.6 0.8 0.0

0 80 160 240 320 400 480 560 640 720 800 880 960 Time/No. of 1h-Cycle Fig. 2 Oxidation kinetics of TiAl-Al2O3-TiC composite and TiAl at 800°C in air. Spallation does not occur on the composite.

Fig. 3 Wet oxidation turns Zn particles into ZnO nano-ribbons, 375-400°C/wet O2.

April 2012 www.corrosion.com.au p.49

TECHNICAL NOTE

Pipeline External Corrosion Analysis Using a 3D Laser Scanner Introduction Pipeline operators have to inspect their pipeline network directly or through NDT inspection service companies. In-line inspection (ILI) tools allow the identification of zones with critical external corrosion by magnetic flux leakage (MFL) or ultrasonic (UT) methods. The code specifies that a prove-up from the outside of the pipeline is required for critical zones, often requiring excavation. Various techniques can be used for external corrosion assessment to identify appropriate remediation. Each technique presents certain limitations which can be minimized or avoided with the latest 3D optical innovations coming from dimensional metrology and now applied to NDT applications. A manual measurement method using pit gauges makes the inspection operator dependant, brings variable results, a lengthy inspection process considering the high number of data points required, and limited report quality. UT methods require constant water coupling, which becomes difficult on rough surfaces due to water loss and probe misalignment. Precision is also limited by the front wall echo interface. UT probes must be positioned with a mechanical scanner complying with different pipe diameters, adding complexity while reducing portability. Furthermore, the small size of a UT probe for a full coverage C-Scan requires high speed displacement for reasonable inspection time. This method is more suited for internal corrosion considering a smooth external surface. Conventional one-line laser systems eliminate the need for water coupling and offer a much larger coverage. Unfortunately, they also bring other limitations in portability caused by the mechanical fixture to hold the system as it rotates around the pipe. We also need to consider the system sensitivity to laser lift-off and its incapacity to compensate for vibrations which quickly impact measurement accuracy.

p.50â&#x20AC;&#x192; CORROSION & MATERIALS

The latest innovations in 3D optical keep the advantages of the conventional laser method while solving most of its disadvantages. The EXAscan (1) shown on figure 1, patented and manufactured by Creaform (2), uses a dynamic referencing system which allows a light scanner design with small dimensions and a non-contact process. The 3D scan is perfectly scaled to be representative of the real geometry and allows easy external defect visualisation. The analysis software must be able to manage a large quantity of data to generate a report in minutes with comprehensive results to facilitate assessment. This document presents how these issues can be addressed using a portable 3D laser scanner and appropriate analysis software. The scanning procedure will be described, followed by the demonstration of enhanced results through data quality, scanning speed and finally, reproducible results.

Setup The first step is to prepare the pipeline surface for the scan and calibrate the unit. As with all other inspection techniques, a sandblasted surface clean of dust and dirt will yield better results. The 3D scanner requires the use of reflective targets that are typically 6 mm diameter stickers or magnets applied randomly on the pipeline. The spacing between targets will be approximately 10 cm but varies depending on the pipe diameter. Data Collection The second step is to acquire the corroded area of interest on the pipeline outside diameter. Once the acquisition software is ready, the inspector holds the scanner at approximately 25 cm from the pipe surface and pulls the trigger to start the acquisition. The scanner is manually moved along the pipe to paintbrush the area of interest. The inspector will look at the laptop screen to validate the scan coverage. The file is saved in .stl format.

Scanning Procedure with a 3D Laser Scanner Equipment It is fairly simple to use a 3D laser scanner. Required material includes the 1 kg 3D scanner, a laptop computer with software and a battery pack, all carried on-site with a special vest the inspector wears to perform the inspection. The equipment is shown in figure 2.

(1) E XAscan: Product trademark property of Creaform

Figure 1: Portable 3D laser scanner

Figure 2: On-site inspection with the 3D laser scanner solution

(2) C reaform: Registered company under Creaform Inc. in Canada

TECHNICAL NOTE

Analysis The third step is the data analysis. The scan file is imported into a corrosion analysis software where the inspector enters the pipeline parameters and analysis criteria. These parameters are useful for burst pressure calculation for instance. A report is auto-generated in Excel format, ready for assessment to determine pipe remediation

the ASME B31G and equivalent code were written based on single point measurements in a grid pattern. The numerical method must therefore reproduce the manual method to obtain comparable depth measurements. The proposed analysis software uses a virtual pit gauge to simulate the physical contact between the pit gauge and the pipeline.

Improved Data Quality Dynamic Referencing System Dynamic referencing represents one of the most important innovations for pipeline external corrosion inspection with laser. Ensuring in-situ laser acquisitions with constant accuracy within specifications is a challenge that can be easily overcome by positioning the scanner spatial referential directly on the pipe, as shown in figure 2 and 6. Since the pipe and the spatial referential are linked together, they both move in a synchronised manner which compensates the pipe and scanner movements. On the other hand, a static measurement system will only achieve comparable results in a controlled lab environment.

Depth measurement with laser requires a virtual reference surface to find the distance between the actual pipe topography and the nominal external surface. The construction of this pipe reference surface is essential to obtain meaningful results. One method consists in regressing a perfect cylinder feature aligned with the scanned pipe. However, this method does not compensate for any flatness, ovality or deformations affecting the real pipe geometry, as demonstrated by the light blue line across the scan on the left side of figure 3. The proposed method using a virtual pit gauge compensate for the pipe geometrical deviations with a bestfitted surface made from the unaffected areas around the corrosion, as shown on the right side of figure 3.

Virtual Pit Gauge Method The manual pit gauge inspection technique is the point of comparison for all other techniques developed for external corrosion analysis since

Figure 3: Cylindrical reference vs Virtual pit gauge reference surface method. The data collection and the analysis was performed 3 times by 3 different inspectors. The variations between the scans were kept within 50 microns, regardless of the inspector who performed the scan and analysis. Auto-Generated Reports Inspection results are available through an auto-generated report in Excel format shown in figure 4. Having a 3D representation of the corroded

Repeatable Results Corrosion depth measurements on a 8mm wall thickness pipe were taken using a virtual pit gauge analysis

Table 1: 3D Scanner Repeatability

Inspector 1

Position

Scan 1

Depth (in)

0.032

0.036

0.034

0.040

0.039

0.053

0.049

0.056

Scan 2

Depth (in)

0.032

0.037

0.035

0.040

0.039

0.054

0.048

0.056

Scan 3

Inspector 2

Depth (in)

0.032

0.033

0.035

0.033

0.039

0.038

0.055

0.049

0.055

Δ Depth

0.000

0.001

0.002

0.001

0.002

0.001

0.002

0.001

Scan 1

Depth (in)

0.032

0.038

0.035

0.033

0.038

0.039

0.051

0.046

0.053

Scan 2

Depth (in)

0.031

0.033

0.037

0.036

0.032

0.038

0.053

0.045

0.054

Scan 3

Inspector 3

Depth (in)

0.031

0.032

0.036

0.035

0.033

0.039

0.040

0.051

0.047

0.054

Δ Depth

0.001

0.002

0.001

0.002

0.001

Scan 1

Depth (in)

0.033

0.035

0.038

0.036

0.033

0.038

0.037

0.052

0.045

0.053

Scan 2

Depth (in)

0.034

0.037

0.038

0.035

0.038

0.037

0.052

0.045

0.055

Scan 3

Depth (in)

0.033

0.034

0.038

0.037

0.035

0.039

0.054

0.047

0.055

Δ Depth

0.001

0.002

0.001

0.002

Inspector 1

Max Depth

0.032

0.033

0.037

0.036

0.035

0.040

0.039

0.055

0.049

0.056

Inspector 2

Max Depth

0.032

0.033

0.038

0.036

0.033

0.039

0.040

0.053

0.047

0.054

Inspector 3

Max Depth

0.034

0.035

0.038

0.035

0.039

0.054

0.047

0.055

Δ Max Depth

0.002

0.001

0.002

0.001

0.002

April 2012 www.corrosion.com.au p.51

TECHNICAL NOTE

pipe ensures a clear visualization and understanding of the surface condition. A colour scale helps to quantify the variations in corrosion deeper than a specified percentage of the nominal wall thickness. The analysis software will automatically find the deepest points to retrieve the most probable path of failure on the corrosion zone and apply an overlay on the 3D view. Each corrosion zone is analysed separately, according to the selected interaction rules, to obtain its position, maximum depth and burst pressure.

Figure 5: Data collection in acquisition software 9 8

Scan Time (Hours)

7 6 5

3D Scanner

Pit Gauge

3 2

Figure 4: Auto-generated external corrosion report Inspection Speed With an acquisition rate of 25,000 points per second, the scanned surface is reconstructed in real-time to form a mesh file (.stl). The inspector can validate the data collection by looking at the laptop computer screen as shown in figure 5. It takes less than 10 minutes to scan 1mÂ˛ at a 1.5mm resolution. Running the complete analysis using a 12.5mm grid pattern will typically take less than 15 minutes. One person alone is able to carry the system on-site and perform both the scan and the analysis. Graph 1 shows a scanning speed comparison between the pit gauge technique and the 3D laser scanner solution using a 12.5mm grid pattern. This trial takes into consideration setup, scan and analysis time. The larger the scan, the more advantageous it becomes to use the 3D laser solution. Therefore, using the 3D laser method for a large corrosion zone can reduce the inspection time by a factor of 10 and more.

p.52â&#x20AC;&#x192; CORROSION & MATERIALS

1 0

0.33 m2

0.66 m2

1 m2

Graph 1: Scan speed comparison Repeatable Data Collection This section explains the importance of various scanner and software features to ensure repeatable results, regardless of the environment and operator. Positioning System Reflective targets must be positioned on the pipe so the scanner can reference itself by triangulation with its binocular vision. The reflective targets are randomly positioned on the pipeline to create a unique pattern and also facilitate the setup, as shown on figure 6. If the same pipe surface is scanned twice with different target positioning, both scans will be the same, again to eliminate the operator skill factor. Since data is not distorted from a scanner misalignment with the pipe, using 3D surface representation increases depth measurement accuracy. The 3D scanner allows scan angles

up to 45 degrees in any direction and scanner orientation. Focal Distance Another important scanner feature to consider is the focal distance, considering optimal inspection can only be achieved within a certain distance range between the scanner and the pipe. Using a proximity indicator on both the software scanning window and scanner using LED, the inspector is kept informed at all time during acquisition. However, the system will automatically stop the data acquisition if the scanner is out of focus. Surface Reconstruction During the acquisition with the 3D laser scanner, a mesh surface file is updated in real-time to avoid computing point clouds. When data points are not linked together, it leaves the possibility of overlapping multiple points on the same location creating

TECHNICAL NOTE

Figure 6: Reflective targets randomly positioned

Figure 7: Pipe parameters input table for data analysis

noise in the scan. Furthermore, merging point clouds generate deviations that can be avoided with a mesh file.

document is the logical evolution over traditional NDT techniques for pipeline external corrosion inspection.

Automated Analysis Data analysis follows the same approach to ensure repeatability with pre-programmed calculation and software operations. The inspector only needs to input the known pipeline parameters required for burst pressure calculation and interaction rules in the table shown in figure 7. The analysis is based on ASME B31G code to comply with code and ensure best practice.

2. The latest innovations in 3D laser scanning provide improved data quality using a unique dynamic referencing system and appropriate reference surface. 3. The inspection speed can be more than 10 times the pit gauge technique considering the time to setup, perform the inspection, and run the analysis to generate a report.

References 1) ASME B31G, Manual for Determining the Remaining Strength of Corroded Pipelines, American Society of Mechanical Engineers, 2009

Conclusions 1. The portable 3D laser scanner solution discussed in this

4. Repeatable results are ensured by the scanner design and the auto-

Pierre-Hugues Allard Creaform

generated reports within a 50 micron accuracy. 5. This inspection procedure proves to reproduce the manual pit gage technique and follows code regulation.

RFS NDT EQUIPMENT

3D Pipeline Laser Scanning Creaform’s portable Handyscan 3D laser scanner & Pipecheck data analysis software together provides a unique & effective solution to pipeline external corrosion assessment. Key functionalities include: – Automated interaction rules. – 3D colour mapping with river-bottom path overlay. – Worst case profile. – Estimated burst pressure calculations. – Corrosion depth measurement, dimensions & positions on the pipe. Contact Russell Fraser Sales Pty Ltd: Tel: +612 9545 4433 Fax: +612 9545 4218 Email: rfs@rfsales.com.au Web: www.rfsales.com.au

TECHNICAL NOTE

The Tiger Stripe Effect Observed When MIC Occurs at Welds of Stainless Steel Vessels Containing Stagnant Water It has been observed over years that an unusual surface morphology appears on stainless steel surfaces at circumferential welds in vessels (commonly austenitic grades 304 or 316) if microbiologically influenced corrosion (MIC) occurs due to contaminated water lying stagnant in the vessel for a period of time1. The unusual appearance of the MIC pattern has been described as tiger striping. There does not appear to be any satisfactory explanation in the literature as to why the tiger stripe phenomenon occurs. The tiger stripe effect has been associated (using microbiological techniques) with the presence of iron-oxidizing bacteria (IOB) such as the Gallionella and Siderocapsa strains in contaminated fresh water sourced from subterranean and ground water supplies. The water is often raw water or bore water with micro-organisms present. The water may be stored in a stainless steel (SS) vessel for use as cooling water, fire water, or for hydro-testing of newly fabricated stainless steel plant. A requirement for tiger striping to occur appears to be that the water lies stagnant inside the SS vessel for a period of time, at least days but sometimes weeks. The tiger striping appearance due to MIC occurring on the surface of a 304 SS vessel filled with contaminated stagnant water at circumferential welds is shown in Figure 1. Microbiological assay showed the presence of IOB strains associated with the localised corrosion at the circumferential weld.

vertical streaking does not appear to be associated with corrosion on the parent metal; the streaking occurs on SS welds. Tiger striping occurs only when MIC is also present on the circumferential SS welds. Another image of tiger striping on 304L SS, which is more advanced than in Figure 1, is shown in Figure 2.

Figure 2. Tiger striping occurring on SS welds in raw water at a potable water treatment plant. It can be observed in the two images that rainbow hues are present on the SS surface at the perimeters of the corrosion streaks2. The rainbow hue is likely due to interference fringes between light reflected from the stainless steel surface and the top layer of the iron corrosion products that are generated during corrosion. The interference pattern on the SS is similar to heat tinting that occurs on SS due to a thermal treatment, e.g. welding. However, thermal treatment of SS usually produces more dense darker coloured metal oxides than when tiger striping occurs.

Figure 1. MIC at welds in a 304L SS vessel that contained contaminated bore water for hydro-testing.

As is known from studies on the cause of heat tinting of SS weldments, the surface finish on the SS influences the heat discolouration that is produced. The thickness of the oxide film (chromium oxide) present on the SS surface after welding influences the surface discolouration that is observed. It is also noticed that the formation of a rainbow hue on a SS surface in food processing industries is an indication that a biofilm is forming on the SS during service. The rainbow coloured film on a SS surface must be removed immediately by cleaning to maintain essential food hygiene requirements.

It has been observed that localised corrosion damage (e.g. pitting corrosion) occurs at the horizontal welds in SS vessels where corrosion cells form and rust-coloured streaking (rainbow hues) occurs above and below a weld. The

Tiger striping due to hydro-testing of SS plant with contaminated water has been described in various publications over recent years3. A question that arises about tiger striping on SS surfaces is why the vertical streak pattern develops on SS

p.54 CORROSION & MATERIALS

welds - upwards and downwards of the centre of the weld where localised MIC occurs (i.e. pitting corrosion). A possible cause of the vertical streaking at circumferential welds in contact with stagnant contaminated water is convection currents developing in the water due to temperature variations of the stagnant water. The temperature variations are caused by differences in heating of the water in contact with the vessel walls compared to the water in the centre of the vessel. The downward striping pattern is due to the corrosion process producing iron corrosion products that descend due to gravity. The upward pattern is likely due to the effect of a thermal gradient existing in the vessel between the water at the vessel walls and a cooler central column of water. Because the water at the centre of the vessel is at a cooler temperature it descends while the water in contact with the vessel walls is hotter and therefore rises dragging the corrosion products upwards with the convection current. This effect produces the tiger stripe effect on the SS welds which occurs when IOB micro-organism are present in the contained water. The microbe population in the water assists the localised electrochemical corrosion mechanism to develop at a weld. But it appears that tiger striping is due to the corrosion mechanism producing iron corrosion products that in turn produce rainbow hues on the SS. Thus, tiger striping is due to the localised corrosion acting conjointly with convection currents in the contained stagnant water that then produces the vertical streaking pattern. L. H. Boulton, Nickel Institute Consultant, New Zealand Acknowledgement: A number of Nickel Institute Consultants and associates have contributed background information for this article. Thanks to P. Cutler and C. Powell (UK); R. Avery and S. Lamb (USA), L. Fassina and M. Ruini (Italy); G. Sussex and B. Hinton (Australia). References: 1 MIC of stainless steels by water used for cooling and hydrostatic testing; G. Kobrin, et al, NI Technical Series No.10085, 1998. MIC - Case Studies, L.H.Boulton, Proceedings of Symposium on MIC, ACA, Melbourne, Australia, August 2011.

Microbiologically Influenced Corrosion – a Practical Manual; J.G.Stoecker, Ed., Vol.2, NACE, Houston, USA, 2001.

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HEMPEL Australia

Remove poultice with scraper and collect waste into bucket. Wash off residue with low to high pressure water or wash and scrub clean with medium to hard brush. Removal of multi layers of paint may need repeat application. Before repainting, neutralise surface with an acid type of cleaner if necessary.

Leave for 30 minutes to an hour, test with scraper to determine if paint is sufficiently softened. Stripping time depends on number of paint layers, age and type. The product may be left on for 24 hours or even longer. Keep poultice moist. In dry conditions cover with gladwrap, plastic sheets or grease paper.

Apply thick coat of stripper (approx. 3mm) onto surface to be stripped. Application methods: sprayed on with hopper gun, trowled on or use soft brush.

Mix poultice thoroughly before use.

INSTRUCTIONS:

P 02 9438 2047 | info@letsclean.com.au | www.letsclean.com.au

We recommend all lead based paints be removed by professionals who are properly trained in the methods. Disposal must be in accordance with State Regulations.

captive water washing system

For additional information please ask at point of sale or ring HEIM TECHNOLOGIES.

Clean

1300 854 862 fax: 1300 554 862 sales@rmcoatingsupplies.com.au www.rmcoatingsupplies.com.au 2/16 Monterey Rd Dandenong Vic, 3175 PO Box 8239 Tarneit Vic, 3029

LEAD PAINT REMOVER

phone: email: web: office: postal:

HERITAGE No1

For all sales and general enquiries

NATURAL PAINT REMOVAL POULTICE

Telephone (02) 9438 2047 Facsimile (02) 9906 3328 www.letsclean.com.au

SALES OFFICE

Strip

First Aid: If contact with skin and eyes wash with running water. If swallowed do NOT induce vomiting. Material Safety Sata Sheet: Download from www.letsclean.com.au/heritage.html

pty ltd

FAX: 1-905-333-4313

www.Rustrol.com

A division of Let’s Clean Pty Ltd. ABN 68 003 272 811 3/93 Greenwich Road, Greenwich NSW 2065 or PO Box 36 Artarmon NSW 2064 Australia

Coating Supplies RM

TEL: 1-905-634-7751

Sydney | BriSBane | MelBourne | Perth

Original Bumax® Stainless Fasteners: » Bumax® 88 tensile strength to Class 8.8 » Unmatched Corrosion resistance Tel: (02) 8818 0222

www.hobson.com.au

April 2012 www.corrosion.com.au p.61

SUPPLIERS & CONSULTANTS

David Pocock

AIWC

MANAGER

Australasian Industrial Wrappings & Coatings Pty Ltd.

“Your one stop shop for the pipeline and construction industries” Roger McElhone - Managing Director Mob: 0419 242 638

22 Irvine Street Bayswater WA 6053 T: 08 9721 2265 F: 08 9271 2235 M: 0409 112 010 E: david@tfgpumpline.com.au www.pumpline.com.au

Ph: (02) 9608 8111 Fax: (02) 8783 7055 Web: www.aiwc.com.au Email: roger@aiwc.com.au

David Dawson National Sales & Operations Manager

10/7 Lyn Pde Prestons 2171 PO Box 40 Miller NSW 2168

Phone: 1800-RENT-DH (736 834) Mobile: 0450 008 259 Fax: (02) 8525 8850 ddawson@rentdh.com www.rentdh.com

DeHumidification Technologies PTY LTD 113 Bonds Road Riverwood NSW 2210 Australia

Strip paint and urethane remover

Clean

Specialist Infrastructure and durability consultants

low pressure • micro abrasive • vortex cleaning system

Protect

RustMasters complete corrosion control

Ph: 1300 763 319 | www.bcrc.com.au

P 02 9438 2047 | info@letsclean.com.au | www.letsclean.com.au

Russell Fraser Sales Pty Ltd SuPPLying inSPection & teSting equiPment www.letsclean.com.au

Pty Ltd

SYDNEY t: 02 9545 4433 F: 02 9545 4218 rfs@rfsales.com.au www.rfsales.com.au

E-Mail: info@letsclean.com.au Ph. 02 9438 2047 3/93 Greenwich Rd Greenwich NSW 2065 Sydney Australia

Ph.D, B.Sc (Hons), FIE Aust, CP Eng

• Ultrasonic Thickness Gauges • Holiday Detectors • Coating Thickness Gauges • Pit Gauges • Borescopes & Magnifiers • Surface Replication products

JOS Australia &

ABN 68 003 272 811

N I C H O L A S C O R R O S I O N P T Y LT D

Dr David Nicholas

References: Engineering Building, Sydney Uni; GPO, Sydney; Trades Hall, Sydney; Maclaurin Hall, Sydney; St. Paul’s Cathedral, Melbourne; Bonython Hall, Adelaide; Kings Cross Hotel, Sydney; St Mary Star Of The Sea Church, Melbourne; Macquarie Lighthouse, Sydney

Principal Consultant Tel: 02 4952 6593 Int: (+612) Mob: 0421 745 059 8 Bambara Close, Lambton, NSW 2299, Australia Email: david@nicholascorrosion.com.au

Materials and Corrosion Consultancy to the Water Industry

Silver Silver Chloride Reference Electrode

www.rustseeker.com Tel: +61 7 5476 9788 TM

DQ advert 60x40.indd 1

27/4/11 3:01:03 PM

A.B.N. 82 101 032 788 1300 723 924

www.industrialpainter.com.au

• Anti Grafﬁti • Sign Writing • Line Marking • Pressure Cleaning • PCCP/NACE Accredited • • Protective Coatings • All Related Services • Building Maintenance •

KURT RUSSELL Sales Representative

MR JUSTIN RIGBY

Abrasive Blast Media Supplier

Factory 5, 227 Wells Rd Chelsea Heights 3196 jrigby@industrialpainter.com.au • www.industrialpainter.com.au 1300 723 924 • Fax 9773 3522 • 0417 338 773

Exclusive Distributor for Australia & New Zealand

Business Development Manager

p.62 CORROSION & MATERIALS

SUPER GARNET www.mineralscorp.com

AU Free Phone 1800 309 734

sales@industrial-minerals.co.nz NZ Free Phone 0800 646 372

Manufacturers and Suppliers of: • Dessicant Dehumidifiers • HCU- Humidity Control Units • Temporary Humidity Control Systems For Applications in: • Surface preparation and coating • Condensation and corrosion prevention Munters Pty. Limited Sydney – Brisbane – Melbourne

Toll free: 1800 008 379 Fax: (02) 88431589 Email: dh.info@munters.com.au www.munters.com.au

SUPPLIERS & CONSULTANTS

D R MAY Inspections David May Welding Supervision Welding Inspection NDT Specialist Coating Inspection Inservice Inspection

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

Leading Suppliers of NDT Equipment for the Corrosion Industry Unit 23, 58 Box Rd Taren Point NSW 2229 Tel: 02 9524-0558 • Fax: 02 9524-0560 Email: ndt@ndt.com.au • Web: www.ndt.com.au

Cathodic Diecasting

Abelmet

Abel Metal Services Pty Ltd

• Mg & Alloy Ingots • Mg Anodes • Backfill Mail: PO Box 90, Moorebank, NSW, 2170 Phone: 02 9602 7740 Fax: 02 9602 7780 Email: mckimmie@abelmet.com.au Web: www.abelmet.com.au

Manufacturing anodes since 1984 Queensland (Head Office)

Phone: +61 7 5476 9788 Fax: +61 7 5476 8268

Melbourne

Phone: +61 3 9755 3770 Email: sales@cathodicdiecasting.com.au

ABN: 93 821 370 828

www.cathodicdiecasting.com.au

ANNOUNCEMENT

Cathodic Diecating - small advert 3-2-10.indd 1

3/3/10 10:51:21 AM

The new name andPROTECTION address for Ian Godson & Associates: CATHODIC

Infracorr Consulting PL.

Agent for:

LIDA® – Mixed Metal Oxide Anodes • Sacrificial Anodes • Silicon Iron Anodes • Transformer Rectifiers • Reference Electrodes

Prevent corrosion on your:-

D E NORA

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• Strip, Rod, Tubular, Ribbon, Disk and Wire

Infracorr

–Copper, Zinc and Silver

PIPELINES, TANKS, BRIDGES, WHARVES, OFFSHORE PLATFORMS

Tel: +61 (03) 94672520 or 0413 201562

Corrosion Durability Repair

Email: robertcox@pipecorr.com.au • www.pipecorr.com.au Committed to Professional Service, Competitive Pricing and Customer Satisfaction

ANNOUNCEMENT

The new name and address for Ian Godson & Associates:

Infracorr Consulting PL. �/�� Burwood Rd Hawthorn East VIC �� Ph: +�� (�)� �� www.infracorr.com

Infracorr

Front

Corrosion Durability Repair

Gareth van Loggerenberg Corrosion and Coating Failure Investigations Fitness for Purpose and Remnant Life Assessment Expert Witness and Litigation Support Corrosion, Materials & Mechanical Engineers Applied Scientists, Metallurgists, Coating Inspectors NDT Technicians Arthur.Austin@alsglobal.com Australia Wide +61 7 3718 0300

TITANUM ELECTRODE PRODUCTS

t: +61 (0) 8 9256 4499 f: +61 (0) 8 9256 4599 m: +61 (0) 408 931 072 e: gareth@telpro.com.au w: www.telpro.com.au Unit 2, 26 Baile Road Canning Vale Western Australia 6155

April 2012 www.corrosion.com.au p.63

Original Bumax® Stainless Fasteners:

Bumax® 88 & 109 tensile strength equivalent to Class 8.8 and Class 10.9

» Corrosion resistance superior to 316L stainless » Test certificates online