Case Studies Session
18 August, Thursday - Perak Room - 10:45am - 12:30pm

Chair : Prof. Rolf Gubner, Curtin University​

Mitigating Corrosion under Insulation in a Gas processing facility 10 years on

18 August, Thursday - Perak Room - 10:50am - 11:20am

Bio of Speaker


As is often the case when developing new technologies the first adopters are those who have a specific problem for which they are seeking a solution.
This was the case in 2005 with a new, at the time, high temperature protective coating designed for use beneath insulation and in highly aggressive cyclic temperature environments between 40°C (104°F) to 260°C (500°F). The facility in question is a gas processing plan in South Australia and they had significant issues with corrosion on their propane treater units. This paper will review the circumstances of the application in 2005, detailing the corrosion mechanisms at work and the justification behind the selection
of the largely unproven new coating technology. It will then review the performance of the material over the course of its ten year service life concluding with a detailed review of its current condition. The paper will then move to the wider topic of coating development and specification, referencing this experience and posing the question 'how can new coating technologies be successfully developed and launched into a such a conservative market?', especially given the importance placed by customers around long term proof of in service performance.

ICCP based repair of Webb Dock Berth 4 &5, Melbourne.

18 August, Thursday - Perak Room - 11:25am - 11:55am

Bio of Speaker


Name:  Ian Godson
Title / Position:  Managing Director
Company:  Infracorr Consulting PL (Melbourne)
Ian Godson is the Managing Director and Principal Consultant of Infracorr Consulting Pty Ltd, a specialist engineering company based in Melbourne Australia operating in the field of structure repair and durability. Ian, who originally trained as a civil engineer, has over 25 years experience in all aspects of remedial engineering including condition assessment, remedial design and cathodic protection design and installation. Ian’s experience with cathodic protection of reinforced concrete structures dates back to 1989 when, following training in Europe, he completed the first design & installation of concrete cathodic protection with titanium MMO anodes in Australia. Ian has since been involved with Australia’s largest and most complex CP based repair projects including Sydney Opera House substructure and many major wharf and bridge projects.
As well as his extensive experience with Cathodic Protection and condition assessment, Ian has a long history of involvement in Design for Durability. Most recently he has been involved in the Port Capacity Project (Webb Dock), however other projects include the Sydney Opera House Substructure, and the City Link Bridge Structures.
Ian has a strong industry connection and has published a number of papers relating to condition assessment and cathodic protection design. A regular presenter at both Eurocorr and Australasian Corrosion Association annual conferences, Ian’s commitment to being at the forefront of remediation technology is a strong driver in his ongoing success
The Webb Dock Berth 4&5 are 700m of container berths controlled by Port of Melbourne Corp. The 15m wide wharf structure was constructed in circa 1970 with steel piles, steel sheet piling and 135 reinforced concrete beams, each 15 m long.  The structure suffered from significant reinforcement corrosion to the beams resulting in approximately 45% of the beam soffits and 25% of the beam sides spalling.  In addition, the steel piles and sheet piles had corroded significantly due to the likely effects of Accelerated Low Water Corrosion (ALWC) and required significant investigation and repair. The port required a 30 plus year life extension for the structure.
The investigation of the structure included 100% delamination and concrete repair quantity assessment, half cell potential, corrosion rate and analytical testing. The steel element testing included over 20,000 UTS thickness tests both above and below water to all elements.
The ICCP based repair design included a 3000Amp ICCP water anode system, incorporating distributed rectifiers with 90 zones and  approximately 200 Tubular titanium anodes.  The concrete ICCP to the 135 beams incorporated approximately 540 zones and  170 amp incorporating over 20,000 discrete titanium MMO anodes. 
The investigation and design was completed in 2014, with repair and installation of the A$40m repair project completed from January 2015 to May 2016.

Case Study of Impressed Current Cathodic Protection for Jetty Piles.

17 August, Wednesday - Perak Room - 12:00pm - 12:30pm

Bio of Speaker


Name: Shailesh D. Javia
Title / Position:  Division Head – (C.P. Division) 
Company:  SGB Scaffolding and Industrial Services Private Limited
An Electronics Engineer who has spent 24 years focused solely on corrosion Engineering and Cathodic Protection.  Mr. Shailesh has developed a strong expertise in the application of turnkey cathodic Protection and technical sales. In his career, he has developed a diverse portfolio designing CP systems and managing turnkey CP Projects for Cross country pipelines, Plants like Refineries, Fertilizers, Petrochemicals, Power etc. Tank bottoms, Tank and vessel internal CP, City gas pipelines, Post commissioning Survey works and handled complex interference problems on cross country pipelines.

Mr. Shailesh has been certified as NACE Cathodic Protection Technologist and successfully completed NACE Direct Assessment Course and has presented several papers at NACE and ASME conferences.

Mr. Shailesh has presented papers in India, Spain, Kuwait, Thailand, Abu Dhabi and Bahrain.

Mr. Shailesh Graduated from Amravati University in India with BE in Electronics Engineering
Ever since Sir Humphry Davy first applied cathodic protection to protect the British Navy’s ships of war from corrosion, the benefits of cathodic protection in marine applications have been adopted in a wide range of applications.  One of the areas where cathodic protection of marine structures is commonly applied is to protect steel piling systems on jetties and piers.  This paper discusses the various anode systems used for jetty piles in marine applications.
This paper discusses the design and implementation of cathodic protection on a new construction jetty in Indonesia. Impressed Current, Mixed Metal Oxide Sea-Bottom Anode is a complete, ready to install marine anode sled including the anode cable and protective housing. The Sea-Bottom Anode is quick and easy to install for cathodic protection of docks, piers, pilings and other marine structures in all types of water.
Every CP design effort begins with a basic decision of whether to use galvanic anodes that operate on the natural potential difference between the anode and the structure or impressed current anodes with an external power supply.