2019

Corrosion, Coatings and Certifications. Raising standards through education and training

About the ACA •  The ACA is a not-for-profit, membership Association which disseminates

information on corrosion and its prevention or control by providing training, seminars, conferences, publications and other activities”

LEARN & CONNECT TO PROTECT AGAINST CORROSION

•  This is what we do, but what does it really mean? And how does this benefit you our member, your business, your people and more broadly the community?

RESOURCES

KNOWLEDGE

COMMUNITY

RECOGNITION

Knowledge The ACA offers opportunities for professional development to help you & your staff advance your careers.

•  Our training pathway framework caters to many different levels and skill sets in different fields of corrosion mitigation by offering flexible, local and international qualifications

Knowledge

•  Face to Face Training – ACA, NACE & SSPC 1 – 6 Day training programs

Knowledge • Online / Home Training Education Corrosion Technology Certificate

Knowledge

• ‘In house training’ offers your company the opportunity to have your employees trained at your own facility whilst eliminating travel expenses and minimizing downtime.

• Gives you the flexibility to choose the ACA training that best fits the needs of your company with flexible scheduling options.

• You choose the date, location & course! Schedule a course when it is most convenient for your company.

Knowledge

•  The annual Corrosion & Prevention conference offers a technical program of industry and research presentations, social functions and an exhibition showcasing industry innovation, products and services

Knowledge

•  Our annual event schedule is packed with one day seminars, site visits, evening technical presentations, social functions, mini tradeshows, equipment demonstrations, young corrosion group activities and more.

RESOURCES

KNOWLEDGE

COMMUNITY

RECOGNITION

Resources

•  Receive Corrosion & Materials which is the official publication issued quarterly containing case studies, professional practice papers, new products, research papers, technical articles, member profiles, ACA news, industry news, etc.

The ACA composes, collects and stores a range of information to assist your business and career

Resources

•  Receive Corrosion Matters, a regular e-newsletter providing relevant information incorporating technical articles, recorded presentations from recent events, future event details, member profiles, industry news, etc

Resources

•  Login to the ACA website to access over 2,000 conference papers from past ACA conferences, videos of recorded presentations from ACA events, past issues of Corrosion & Materials, technical articles, case studies and more.

www.corrosion.com.au

Resources •  Take advantage of the ACA’s international relationships with

access to past conference papers from the European Federation of Corrosion (EFC) congress along with discounts to EFC & NACE International publications.

•  ACA Corrosion Control Directory, a valuable listing whereby ACA website enquiries can be directed to your business.

Resources

RESOURCES

KNOWLEDGE

COMMUNITY

RECOGNITION

Community

•  Network face to face and online with asset owners, researchers, suppliers, contractors and consultants to share ideas, ask questions and connect with one another

The ACA is determined to continually build an active, engaged and passionate membership.

Community •  Be heard - we are your voice. We represent your interests and

raise awareness through media campaigns on the importance of corrosion mitigation

Community •  Connect with members who offer products and services to

mitigate corrosion in our Corrosion Control Directory.

Community •  Be active and learn new skills by volunteering on local

committees through to the Board.

Branch Committees •  New South Wales •  Newcastle NSW •  Victoria •  Tasmania •  Queensland •  South Australia •  Western Australia •  New Zealand

Technical Groups •  Oil & Gas •  Applicators •  Defence •  Contractors •  Coatings •  Asset Owners •  Cathodic Protection •  Research •  Concrete Structures & Buildings •  Mining Industry •  Water & Water Treatment

RESOURCES

KNOWLEDGE

COMMUNITY

RECOGNITION

Recognition

•  Be rewarded for your excellence in corrosion mitigation or by your continued support of the ACA through our series of Awards

The ACA appreciates and values the members who support us.

Recognition

•  Travel the world or attend an ACA training course or conference with a Scholarship.

Recognition

•  Apply for ACA Certification and be rewarded for your extensive education and experience as a Corrosion Technologist or Corrosion Technician.

Recognition •  Use of the ACA logo or name to increase your

visibility and credibility as corrosion professionals

Recognition •  Establish and build your profile by presenting and publishing

through various ACA channels.

Training, Competency & Certification

Corrosion

•  US Defense Department’s, Office of Corrosion Policy and Oversight, revealed that the

* “US Navy’s number one foe isn’t a foreign country but oxidation itself!”

Cost of Corrosion INTERNATIONAL CORROSION COST FACTS

Detailed analysis, released in 2002 by NACE International, one of the world’s leading authorities on corrosion engineering and control, calculated that corrosion costs are 3.4% of GDP for a developed industrial economy.

The figures are based on US Government funded research that analysed a number of key sectors: • Infrastructure • Utilities • Government • Transport • Manufacturing

Australia GDP (2017): $1,704 billion AUD Annual cost of corrosion: $58 billion AUD

USA GDP (2016) $18,570 billion USD Annual cost of corrosion: $631 billion USD

Previous cost of corrosion studies indicated that between 15 and 35% of this cost of corrosion could be saved by using current available corrosion control practices; i.e., between $8.7B and $20.1B AUD for Australia

Cost of Corrosion

Corrosion Risks

• Economic

• Human Life & Safety

What is affected by these risks?

•  Durability

•  Integrity

•  Safety

Risk Consequences?

Mechanisms for dealing with risk

Mitigating corrosion risk

•  With so much economic risk associated with corrosion protection of assets why would we not look at improving processes to reduce this risk exposure?

•  Sure we can put warranties on products and applications, we can insure with professional indemnity policies for the engineering / specification but these are all sureties that apply when something has gone wrong.

•  Why not “insure” upfront with competency / certification of the people actually doing the work?

So where are the main risks associated with a coating project?

•  Specification •  Product •  Application •  Inspection (QA / QC)

Specification Product Application Inspection Durability

Specification risks

•  Wrong product / system – Durability •  Incorrect corrosivity category - Durability

•  Generally the specifiers of corrosion mitigation systems are experienced in specifying in this area so actual risk is quite low

•  ACA Course – Coating Selection & Specification

3. CERTIFICATION OF PERSONNEL •  Certifications for all inspectors and blasters/coating applicators shall be provided to the Company/Contractor for review and approval prior to work commencement The Company/Contractor reserves the right to request re-certification of inspectors and blasters/coating applicators.

3.1 Inspectors •  Inspectors shall be individually certified by an approved organization (ACQPA, FROSIO, NACE International minimum level II, etc.)

3.2 Blasters and coating applicators •  The Subcontractor/Module Fabricator/Vendor shall demonstrate competency of the

blasters and coating applicators. Suitable competency verification records shall be maintained.

Sample extract 1:

Specification Risk - Competency

Specification Risk - Competency

2.2 APPROVED APPLICATOR •  Surface preparation and coating application shall be undertaken by a painting contractor (Applicator). The Applicator

shall demonstrate that its personnel have the required industry certification, training, track records and equipment in applying the nominated product. Unless otherwise accepted by the Water Agency or Project Manager, the Applicator shall be accredited to a recognised protective coating application scheme to the class relevant to the work to be undertaken.

•  In addition, where the work involves the maintenance or removal of coatings containing lead compounds or other toxic substances, it shall be undertaken to the requirements of AS 4361.1.

2.5 COATING INSPECTOR •  Inspection and test shall be undertaken by certified coating Inspector(s). They shall be nominated by the Applicator

or Project Manager to carry out inspections and testing and to verify all works performed in accordance with this Manual.

•  The Inspector shall be certified by either: •  (a) Australasian Corrosion Association (ACA); •  (b) NACE International; or •  (c) Society for Protective Coatings (SSPC). •  The Inspector should not be the Applicator’s work supervisor, unless approved by the Water Agency. The Inspector

should be given adequate notice for carrying out inspection. The work supervisor, who should initially inspect all work and carry out any necessary rectification before calling in the Inspector. DR WSA 201—2017-2.1 18

•  COPYRIGHT •  For coatings over structures, other than concrete, in extreme and immersion exposure class conditions (Refer to

Table 5.1), the Inspector shall hold a ACA CIC, NACE CIP Level 2, SSPC PCI Level 2 or equivalent certification. •  For coatings over concrete in extreme exposure class conditions (Refer to Table 5.1), the Inspector shall hold a

SSPC CCI Level 2. For all other coatings applied to concrete the Inspector will hold SSPC CCI Level 1. •  For Hot Dip Galvanizing, the Inspector shall hold a Certified ACA Hot Dip Galvanizing Inspector accreditation for

Inspection of Hot Dip Galvanizing and its surface preparation for application of coatings.

Sample extract 2:

Product risks •  Generally the products (coatings) and

technology are well used and tested and the technology sound.?

•  AS 2312.1:2014 denotes generic types of products, (eg hi build epoxy) and recommended film builds in a specific corrosivity zone which can then be matched to a durability period.

•  Not much can go wrong with products sourced from the major suppliers

Training – Certification / Competency Company

Qualification / QA risks

•  Risk associated with using non quality assured contractors (ISO 9001. PCCP)

•  Risk associated with using non qualified inspection personnel (NACE CIP, ACA CI)

•  Industry is well serviced by certified / qualified inspectors so risk is relatively low that failure in this inspection phase would occur.

•  ACA Courses - (NACE CIP series, ACA /GAA HDG Inspector, SSPC CCI)

Application risks

•  So given the risks associated with applications what can we do about it?

•  Education •  Training •  Certification

Result = Competency

Training – Certification / Competency Application

Training - Individual

Corrosion theory and technology

Preparation and Application

Training - Individual

Specification & Inspection

Training - Individual

A look into the future - ACA Pathways

Conclusions / Summary

•  There are many risks associated with corrosion mitigation projects

•  Certification of Contractor helps reduce risk •  Certifications of Personnel helps reduce risk •  Specifications need to be strong and detail

competency / certification criteria of personnel – Applicator and Inspector

•  Education, Training and Certification benefits all stakeholders.

Thank you

Questions?