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MP Corrosion Innovation Awards
Award Introduction View the Winners Program Details Nomination Guidelines
NACE International Home page Materials Performance Magazine

2014 MP Corrosion Innovation of the Year Awards Recipients

In July 2013, Materials Performance magazine invited those involved in the worldwide corrosion control industry-including individuals, companies, organizations, and governments-to submit nominations for its third annual Corrosion Innovation of the Year Awards.

The goal of the annual awards program is to provide a forum where NACE International members and customers can showcase their corrosion mitigation technologies-and be recognized for them.

The corrosion-control community nominated a total of 34 innovations from seven countries. These nominations represented groundbreaking advances in coatings and linings, cathodic protection, materials and design, instrumentation, testing, integrity assessment, chemical treatments, and other corrosion prevention and mitigation technologies.

This year, the corrosion-control innovations were rated by a panel of leading corrosion experts. It is our pleasure to announce the top 10 corrosion innovations selected by our panelists as the leaders in cutting-edge technology.

The award recipients are (in alphabetical order):

Innovation: 3D Structured Light

Corrosion Control Category: Integrity Assessment

Joseph Summa Dr. Matt Bellis
President President
Technical Toolboxes Seikowave, Inc.
Houston, Texas Lexington, Kentucky
United States United States

Web sites: www.technicaltoolboxes.com and www.seikowave.com

Phase measurement profilometry (PMP) (known as 3D Structured Light) is not a new technology, but it is new to the pipeline industry and is now being used as a method for gathering measurements of pipeline corrosion features and defects (corrosion pitting, dents, gouges, etc.). There is a need in the pipeline industry to assess the severity of a particular feature in a pipe or structure to determine whether or not repair or removal is required.

3D structured light is a scanning process that projects a series of patterns so that a camera is able to extract range information when the patterns are viewed from an angle. Depth resolution is controlled by the number of patterns projected, which increases the total time that the target object must remain still. By adding a second camera sensor, it becomes possible to achieve wrap-around scanning while reducing the number of patterns needed to achieve a certain degree of depth resolution. A second camera also makes it possible to reconstruct three-dimensional surfaces through stereo vision techniques and triangulation between the cameras, instead of between the cameras and the projectors.

Innovation: Bullhorn RM4150 Rectifier Monitor

Corrosion Control Category: Cathodic Protection

Jaco Botes
Director, Product Strategy
American Innovations
Austin, Texas
United States

Web site: www.aiworldwide.com/bullhorn

Created to monitor rectifiers used in cathodic protection systems, the RM4150 RMU has five analog channels and two digital channels to monitor rectifiers on pipelines, well casings, tanks, and other assets. The unit measures alternative current (AC) and direct current (DC) volts and amps, pipe-to-soil potential, shunts, instant off, line power presence, and more with 1% of reading accuracy. This allows high-resolution changes to be observed and monitored, as well as the measurement of very low mV readings to accommodate current shunt measurements. The digital channels provide an accumulator for metering applications and intrusion detection. It includes GPS-synchronized interruption for close interval, depolarization, and DCVG surveys.

The RM4150 features over-the-air configuration and firmware upgrades via the Bullhorn Asset Tracker (BAT™) Web site. The RM4150 also communicates measurement readings to AI’s Pipeline Compliance System (PCS™) via BAT to give operators the ability to further manage, analyze, and report on data collected in the field. By collecting and communicating rectifier measurements using GSM networks, operators can protect their pipelines and meet 49 CFR 192/195 regulations.

Innovation: CermaCladTM High-Speed Large-Area Metal Cladding

Corrosion Control Category: Coatings and Linings

MesoCoat, Inc.
Euclid, Ohio
United States

Web site: www.mesocoat.com

MesoCoat’s CermaCladTM technology utilizes a high-intensity arc lamp to rapidly fuse protective, proprietary cladding materials on steel pipes and tubes (both internal and external surfaces), plates, sheets, and bars. CermaClad high intensity arc lamp can rapidly heat a spot up to 1,000,000 °C, and there is no limitation in terms of the material or thickness that can be clad to the substrate without causing any damage to the substrate. The CermaClad combines high-speed fusion cladding equipment that is faster, better, and more cost-competitive than current processes with proprietary corrosion-resistant alloy (CRA) and wear-resistant alloy coating materials incorporating patented microstructural and compositional modifications that lead to industry-leading performance and life.

With the CermaClad technology, MesoCoat has been able to capture “sun” inside a reflector that melts and fuses any material onto the inside of pipe within seconds—the result is a clad pipe product that offers a seamless metallurgical bond, smoother surface, lower porosity, minimal dilution, very small heat affected zone, strength retention of substrate, amongst several other advantages. More importantly, these clad pipes, because of their metallurgical bond, are much easier to inspect, and install (bend, reel) irrespective of size and thickness of the base pipe.

In addition, by allowing application of thinner metallurgical cladding, CermaClad can significantly bring down the cost of cladding, enabling it to compete with epoxies and paints and expand the potential outreach of metal cladding in applications such as transmission pipeline coatings, shipbuilding, infrastructure, etc.

Innovation: In-Line Inspection for Water Pipelines

Corrosion Control Category: Integrity Assessment

Margaret Hannaford, P.E.
Division Manager
Hetch Hetchy Water and Power Division
San Francisco Public Utilities Commission
Moccasin, California
United States

Web site: www.sfwater.org

An advanced inline inspection (ILI) system was developed to assess the condition of large-diameter, cement mortar-lined steel pipelines for water conveyance. The project designed and built magnetic flux leakage (MFL) tools, a geometry (caliper) tool, and propulsion equipment to move the tools through pipelines ranging from 56 to 80 in (1.4 to 2 m) in diameter and lined with cement mortar with thicknesses of 0.05 in (12 mm) or more. A computer-based system for data handling and interpretation was also developed.

The inspection system accurately measures the depths and dimensions of metal loss areas and their locations on the pipeline. Features such as joints, connections, welds, and third-party damage also are identified. Wheels support the tool in the pipeline. Magnet and sensor arrays are housed in an orange circumferential band near the center of the tool. The blue frame holds electronics modules and is adjustable so the tool will fit various pipe diameters. All power and data storage are housed in the tool. Separate propulsion vehicles are used to move the tool through the pipeline, which is taken out of service and drained prior to inspection.

Innovation: In-Line Inspection for Water Pipelines

Corrosion Control Category: Integrity Assessment

Dr. Francois Ayello Dr. Swati Jain Shan Guan Vinod Khare Dr. Gerry Koch Narasi Sridhar
Principal Engineer Engineer Senior Engineer Engineer Senior Principal Engineer Director, Materials Program, Research & Innovation
Dublin, Ohio Dublin, Ohio Dublin, Ohio Dublin, Ohio Dublin, Ohio Dublin, Ohio
United States United States United States United States United States United States

Web site: www.dnvgl.com/marv

MARV is a suite of tools that predicts the risk to pipelines by analyzing all the complex cause-effect relationships through failure models and expert input. MARV incorporates internal and external corrosion and stress corrosion cracking models and, in the future, will include third-party damage and other failure mechanisms. MARV provides the risk information in an easy-to-use, touch-screen visual interface by combining geographical maps, models, and predictions so that the user can readily see how the system is modeled, and move along the virtual pipeline to see how the risk changes from one location to another and how risk at any location changes when moving back and forth in time.

The MARV platform provides a quantifiable and verifiable way to incorporate the effects of corrosion mitigation and monitoring activities on risk, which allows users to prioritize risk management actions. Using the same tool, the user also can assess the most probable failure cause if the failure is already known.

Innovation: N2-Blast®-Corrosion Inhibiting System

Corrosion Control Category: Materials Design

South-Tek Systems
Wilmington, North Carolina
United States

Web site: www.southteksystems.com

Internal corrosion of dry and preaction fire protection systems is an ever growing problem for building owners and operators. It often goes unnoticed until a pinhole leak occurs somewhere within the piping network, leading to potential inventory and property damage. Even worse, the buildup of scaling, tuberculation, and other debris can obstruct water from flowing to the sprinkler head in the event of an emergency. An ongoing study on the long-term exposure effects of both air and nitrogen supervision has revealed that the use of 98% nitrogen can reduce the corrosion penetration rate by 66% in black steel pipe and 93% in galvanized pipe. The use of 98% nitrogen will significantly increase pipe service life and ensure that the sprinkler system works properly to save lives.

The N2-Blast® nitrogen generation system is a turnkey solution for inhibiting corrosion with 98%+ supervisory nitrogen. The system is compact, wall mountable, and designed to require only quick and low-cost annual maintenance. The N2-Blast produces an infinite supply of nitrogen, thereby eliminating the potential for a supervisory gas run-out, which will occur with a high-pressure nitrogen cylinder. In addition, the N2-Blast has patent-pending technology that monitors the system’s nitrogen purity, runtime, and will notify the facility manager if the N2-Blast is inadvertently being bypassed by compressed air. Over the past few years, the N2-Blast has successfully inhibited sprinkler pipe corrosion in a great magnitude of facilities ranging from privately held organizations to Fortune 100 companies. Today, the system is gaining considerable traction in the fire protection industry as it proves to be the most effective technology available for inhibiting internal sprinkler pipe corrosion in dry and preaction fire protection systems.

Innovation: PosiTector Interchangeable Probes

Corrosion Control Category: Testing

DeFelsko Corporation
Ogdensburg, New York
United States

Web site: www.defelsko.com

The new PosiTector gage body accepts all coating thickness, environmental, surface profile, and ultrasonic thickness probes. Each probe contains unique calibration information enabling it to be attached and recognized by any gage body.

Additionally, WiFi has been added for simple communication with all WiFi-enabled devices, including laptops and smart phones. Instead of adding features to the gage, WiFi allows the use of features found on other smart devices such as cameras, keyboards, voice-to-text features, and more.


Innovation: PowerMag 1000

Corrosion Control Category: Cathodic Protection

John Bollinger
Chief Corrosion Engineer
Farwest Corrosion Control Company
Gardena, California
United States

Web site: www.farwestcorrosion.com

Farwest Corrosion has invented and patented a cathodic protection (CP) controller for steel water tank applications. Only the energy generated by magnesium anodes and an isolated copper electrode powers the controller, which will automatically regulate the tank-to-water voltage potential in a galvanic CP system. The controller then automatically adjusts anode current to maintain a constant "IR free" tank-to-water potential—all without the use or need of any type of external power or batteries.

Using the latest in electronic digital technology to create this 100% solid-state system, Farwest designed components that have a very low power requirement, allowing operation of the control circuit on as little as a 3-mA drain from the anode system. The PowerMag controller also includes a pulse width modulation current regulator and a sophisticated potential measuring system to monitor and control various functions. This technology provides the ability to regulate the potential of a sacrificial CP system and avoid “over voltage” issues. By regulating this CP system, the anodes can run at a lower current output, which results in longer anode life.

Innovation: Robotic Internal Inspection Machine

Corrosion Control Category: Integrity Assessment

Russ Langley Dale Davis David Paulley James Huggins Darrell Davis Michael O’Neill J. David Carter
Co-founder and Vice President Electronic Design Supervisor Retired, Co-founder and immediate Past President Software Engineering Supervisor Senior Principal Engineer Electrical Engineer Vice President and General Manager
CRTS, Inc. CRTS, Inc. CRTS, Inc. CRTS, Inc. CRTS, Inc. CRTS, Inc. CRTS, Inc.
Tulsa, Oklahoma Tulsa, Oklahoma Tulsa, Oklahoma Tulsa, Oklahoma Tulsa, Oklahoma Tulsa, Oklahoma Tulsa, Oklahoma
United States United States United States United States United States United States United States

Web site: www.coatingrobotics.com

The inspection machine is a robot-based electrical system with multiple inspection features and applications. It locates internal coating defects within new construction coated steel pipe. The Robotic Internal Inspection Machine facilitates visual inspection using an onboard camera, measures dry film thicknesses, and detects holidays after coating the internal field joint. This allows any necessary coating repairs to be made immediately on site, prior to product being introduced into the pipe.

The internal inspection may also be applied to the entire length of the factory-applied coating using a removable circumferential brush. The high-quality video feature can be used to display weld bead contours as well as detect faulty welding, faulty field-applied couplings, debris, parent coating damage, etc. Detection and repair prior to introducing product in the pipeline eliminates or greatly minimizes the chance of internal corrosion anywhere in the pipeline.

Innovation: Ultra High Strength CRA SM2535-140TM

Corrosion Control Category: Materials Design

Masayuki Sagara Hisashi Amaya Yohei Otome Masaaki Igarashi Naoki Sawawatari
Senior Researcher General Manager, Seamless Pipe Material R&D Lead Manager Fellow, Head of Advanced Technology Research Laboratories Senior Manager
Nippon Steel and Sumitomo Metal Corporation Nippon Steel and Sumitomo Metal Corporation Nippon Steel and Sumitomo Metal Corporation Nippon Steel and Sumitomo Metal Corporation Nippon Steel and Sumitomo Metal Corporation
Amagasaki, Hyogo Wakayama City, Wakayam Wakayama City, Wakayam Futtsu City, Chiba Amagasaki, Hyogo
Japan Japan Japan Japan Japan

Web site: www.tubular.nssmc.com

Exploration for extreme high-pressure, high-temperature (x-HPHT) hydrocarbon reserves with corrosive environments has been increasing. The development of these types of reservoirs requires the usage of high-value corrosion resistant alloy (CRA) seamless oil country tubular goods (OCTG) that contain large amounts of noble elements such as chromium and nickel. The industry needs more high-strength grades for x-HPHT corrosive deeper well applications. The higher nitrogen content enhances the strength in the austenitic alloy, especially after cold working, but this alloy doesn't perform as well after hot workability and is less corrosion resistant in harsh environments.

By raising the nitrogen content to strengthen the material, Nippon Steel & Sumitomo Metal Corporation (NSSMC) has developed the ultra-high-strength CRA OCTG (140ksi grade, SM2535-140) meant for high-pressure, high-temperature gas well development applications. In addition, NSSMC has resolved the mechanism of microalloying rare earth metal, which is the key technology breakthrough for consistency of strength, productivity, and corrosion resistance. The microalloying technology has resulted in enhanced corrosion resistance, as well as improved hot workability.

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