Take an Up Close Look at the New Atlas

of Microstructures

Page 3

Duplex Stainless

Steel

A M a t e r i a l s T e c h n o l o g y I n s t i t u t e P u b l i c a t i o n

COMMUNICATIONS “Maximizing resources through a global network of materials specialists” | SUMMER 2014

http:/ /www.mti-global.org

2. RBI Training in China

6. New Member: SES 7. New

Member: ITRI

8. AsiaTAC Highlights

Inside this Issue10. EuroTAC

Highlights11. New EuroTAC

Chair

16. Refiners Roundtable

SUMMER 2014 | 2

Dow Corning Applies MTI RBI Training in China

About this Publication:MTI Communications is published by the Materials Technology Institute, Inc. (MTI). MTI is a unique, cooperative research and development organization representing private industry. Its objective is to conduct generic, non-proprietary studies of a practical nature on the selection, design, fabrication, testing, inspection, and performance of materials and equipment used in the process industries.

Copyright © 2014 Materials TechnologyInstitute, Inc. All rights reserved.

Contact:Submit all correspondence regardingMTI Communications to:Materials Technology Institute, Inc.1215 Fern Ridge Parkway, Suite 206St. Louis, MO 63141-44081-314-576-7712 (telephone)1-314-576-6078 (fax)mtiadmin@mti-global.org

MTI Communications Editorial Board:Michael Anderson, SyncrudeDavid Barber, The Dow Chemical CompanyEileen Chant, Becht EngineeringDebby Ehret, MTIGene Liening, The Dow Chemical CompanyJohn Aller, MTISteve Springer, DuPontHeather Stine, MTIMichael Turner, AkzoNobelBill Watkins, MTI

Editor: Kirk Richardson, MTI

Subscriptions:For a free subscription, write to MTI orcontact mtiadmin@mti-global.org

Calendar:AmeriTAC 114 June 16-19, 2014 Denver, CO

AsiaTAC Fall Meeting September 25-26, 2014 Shanghai, China

AmeriTAC 115 October 20-23, 2014 Columbus, OH

AmeriTAC 116 February 23-26, 2015 Miramar Beach, FL

EuroTAC Spring 2015 Dates: TBD Düsseldorf, Germany

Please contact us at 314-576-7712 or mtiadmin@mti-global.org for more information or to find out how your company can become a member.

Web Site:http://www.mti-global.org

Many Processing Industry companies depend on Risk Based Inspection (RBI) to

manage the risks associated with their process-containing equipment and minimize costly upsets, shut-downs, and turnarounds. RBI is a systematic approach to the manage-ment of inspection programs by prioritizing equipment inspection activities. The approach consists of a detailed analysis of prior inspec-tions, corrosion, materials of con-struction, process, plant operations, and consequence to identify the risk associated with the operation of the equipment. The analysis pro-vides the basis to make informed decisions on inspection frequen-cies, level of detail, and methods of nondestructive evaluations. RBI methodology was written into regulation in China in 2009, and today, a comprehensive inspec-tion program for pressure vessels used in operating the country’s CPI plants is required. To comply with the new regulations, Dow Corn-ing built a special team, consisting of mechanical integrity engineers, process engineers and process safety

engineers, aligning it with a local certified inspection authority, and initiated its own RBI project. In October 2012, MTI conduct-ed a two-day RBI training course in Shanghai, China prior to its An-nual AsiaTAC Meeting. Peiwu Sun, Mechanical Integrity Team Leader at Dow Corning (ZJG) Co., Ltd. in Jiangsu, China, led the Project Team that planned and organized the seminar. John Aller, MTI’s new Executive Director and an inter-nationally recognized RBI expert, taught the well-attended session. “It was very helpful to learn the RBI Program,” according to Sun. Dow Corning has already put the information to good use. The company’s China-based ZJG plants include nearly 500 pressure vessels. The RBI program has enabled Dow Corning to understand potential failure modes as well as accurately assess the likelihood of failure (LOF) and consequence of failure (COF) of the equipment using modeling software purchased from DNV.

> CONTINUED ON PAGE 4

Cover: Graphic artist Steve O’Neal was instrumental in designing MTI’s new book, Duplex Stainless Steel Atlas of Microstructures.

New Atlas of Microstructures Takes an Up Close Look at Duplex SS

SUMMER 2014 | 3

MTI will fill another void in the materials engineering world this summer when

it publishes the Duplex Stainless Steel Atlas of Microstructures. According to Co-Champion and Metallurgist Hira Ahluwalia (representing Nickel Institute), the book was prepared to meet the industry’s need for an atlas with high quality, instructive images of duplex stainless steel microstructures. This one-of-a-kind atlas fills a gap in knowledge, according to Ahulwalia. He adds that the 30 member companies who partici-pated points to the need for this kind of resource in industry. “We wanted this atlas to be a teaching tool and not just a bunch of pho-tomicrographs,” notes Ahulwalia. Making the leap from a coffee-table picture book to a useful metallurgi-cal guide and failure analysis tool required considerable attention to detail. Co-Champion and fellow Metal-lurgist Jim Fritz (representing Outokumpu) believes that the new atlas could help industry members avoid costly problems. “With the duplex family of stainless steels, it is important to maintain an appro- priate aus- tenite/ferrite phase ratio and avoid undesirable secondary phases, such as sigma and chi,” according to Fritz.  “Hence,

the microstructure is important in determining the properties of a du-plex stainless steel, particularly the toughness and corrosion resistance. “The value of the atlas is that it shows the reader both good and bad microstructures. The atlas also shows the microstructures for all the product forms, including plate, sheet, pipe, tube, bar, forgings, castings, and weldments. This is important because the microstruc-tures of different product forms can look quite different. The atlas will be a useful QA tool for screen-ing duplex products, evaluating weld procedures, and performing failure analyses.” “Duplex stainless steels in gener-al are being used to a greater extent than they had been before,” reports Ahluwalia. “They are replacing 304 and 316 stainless steels for many applications in the Chemical Indus-try. More people are dealing with these alloys, but at the same time, they aren’t familiar with the metallurgy of these alloys. It’s impor- tant for them to know what the mi- crostructures look like (good or bad),

so that they can make informed decisions for their application. Some of the intermetallic phases in these alloys are very brittle. Failures can be catastrophic!” According to Fritz, findings came out of the project that have not been previously reported, in-cluding:

• Thesuperiorityofthe Pellegrino’s etchant for prepar-ing samples for identification of secondary phases

• Thedifferenceinresolution of carbides and nitrides with backscatter versus secondary electron images and how this can help in identifying phases

• Thetendencyoftheoxalicacidetchant to selectively leach the secondary austenite phase

Making these and other discover-ies was no easy task considering the veritable obstacle course that the leadership trio faced along the

> CONTINUED ON PAGE 5

Through September of 2013, Dow Corning applied RBI model-ing to 347 vessels, determining that only 40 needed to be opened for inspection, and avoiding more than $1 million in associated maintenance costs in the process. “Inspection man-hours are a small cost savings,” reports Sun. “The bigger cost saving from the RBI pro-gram is that the vessels don’t need to be cleaned (purged and washed out) for internal inspection. That means that more wastewater is avoided to be dealt with at a high cost.” Additionally, Dow Corning was able to avoid costs associated with the construction scaffolding, insulation removal and replace-ment, and internal inspection for more than 300 vessels. “We also understand the impact of thermal damage in the future,” adds Sun. “Based on the RBI model, we can limit the location of inspections.” This is an ongoing process for Sun and his Mechanical Integrity Team. “We focus on preventive maintenance of existing, fixed equipment (pressure piping, pres-sure vessels, rupture disks, relief valves, etc.),” he explains. Every year, inspectors monitor shell thickness and conduct external visual inspection of the vessels. Sun adds that a small number of vessels are opened and inspected during scheduled shutdowns, adding: “All the available data we get will be input into RBI software for periodic re-assessment.” Risk Based Inspection helps engineers understand potential failure modes. “Various process conditions involve different potential failure mechanisms,” explains Sun. “RBI provides failure models to analyze possible failure mechanisms due to the process conditions.” Dow Corning engineers con-

tinue to work with JSSIE (China Jiangsu Province Special Equip-

ment Safety Supervision Inspection Institute), a certified inspection organization. JSSIE uploads the equipment and process data into the RBI software, analyzes the information, identifies the damage mechanisms, and together with Dow Corning’s Mechanical Integ-rity Team, plans the RBI inspection strategy. Project Champion Sun is pleased that the MTI RBI training course proved beneficial and hopes to hear other stories of its successful application by Chinese member companies. MTI regularly provides its members with tailored training sessions on a variety of technical topics in North America, Europe, and Asia.

RBI DEFINEDRisk-Based Inspection (RBI) technology has revolutionized the process industry and its approach to managing the inspection of pro-cess plants. It is a unique technol-ogy that can provide improvements in safety and production while reducing costs. A traditional definition de-scribes risk as the product of the likelihood and consequence of fail-ure. For the purposes of Risk-Based Inspection, the pertinent risks are the inspectable risks. Inspectable risks are those that are caused by equipment deterioration that can be identified by plant inspections. The likelihood of failure is driven by those factors causing the structural component to deterio-rate, offsetting the factors allowing the component to withstand the damage. The key drivers that affect the likelihood of failure are the material damage mechanisms, their rate of progression, the tolerance of the equipment to damage, and the amount and type of inspection activities that have been performed in the past. The consequence of failure is an analysis of the outcome or effect of

the failure. The consequence of a failure is a function of what fluid might be released because of the failure and what impact that fluid would have in the uncontained state. For example, a large release of compressed gasses will have an overpressure effect associated with the energy release. A release of a hydrocarbon might have one of sev-eral flammable effects, such as a liq-uid pool fire or vapor cloud explo-sion. A toxic release will result in a health hazard in the affected area. Other non-safety related events might have the consequence mea-sured by the maintenance costs, lost production, product quality, or reputational consequences. The benefits of RBI are quan-tifiable. In an existing operating company, the simplest way to create value is to improve the utilization of resources. In a plant implement-ing RBI, measurable value can be created by minimizing the risk of equipment failure or reducing inspection and maintenance costs. In general, the cost of inspection and maintenance can be reduced by extending turnaround intervals, shortening turnaround duration, lowering the number and fre-quency of internal inspections, the quantity of thickness monitoring locations, and the frequency of re-lief device maintenance. Improved uptime can be a byproduct of reducing maintenance and inspec-tion events. This is particularly valuable when working in a regu-lated environment requiring short plant turnaround intervals that can be extended by incorporating a risk based inspection program. Today, Processing Industry companies apply these principles in their worldwide operations and realize benefits from improved production resulting in a better bottom line. MTI has been involved with RBI technology for nearly 20 years, publishing Implementing and Evergreening RBI in Process

SUMMER 2014 | 4

Dow Corning Applies MTI RBI Training in China> CONTINUED FROM PAGE 2

Plants (available at mti-global.org) in 2005. In the nine years since that book was written, the tech- nology has continued to develop, and adoption of RBI continues to expand to world-class process- ing industry companies, like Dow Corning.

ABOUT DOW CORNING AND ITS ZJG SITEDow Corning (dowcorning.com) provides performance-enhancing solutions to serve the diverse needs of more than 25,000 customers worldwide. A global leader in sili-cones, silicon-based technology and innovation, Dow Corning offers more than 7,000 products and ser-vices via the company’s Dow Corn-ing® and XIAMETER® brands. Dow Corning is equally owned by The Dow Chemical Company and Corning, Incorporated. More than half of Dow Corning’s annual sales are outside the United States. Dow Corning Zhangjiagang (ZJG) site is one of the largest integrated silicone manufacturing sites in the world. It consists of four production plants, including a siloxane plant and a fumed silica plant, both of which are jointly managed by Dow Corning and its joint venture partner, as well as finished silicone production plants, which are owned and operated independently by each company in full competition. Dow Corning is fully committed to sustainable production in China. Like their other facilities across the world, Dow Corning’s manufactur-ing sites in China actively imple-ment the concept of sustainable development. Its environmental, health, safety and security (EHSS) management system accords with Responsible Care® initiative, a stringent set of international stan-dards designed to advance the safe and secure management of chemi-cal products and processes. n

SUMMER 2014 | 5

way. “From my perspective there were two big hurdles,” recalls Fritz. “The sheer number of product forms, etchants, and heat treat conditions made it difficult to select the best images and conditions to include in the final draft without the atlas growing to an unruly size. The second hurdle was to identify and describe the many microstructures using the acquired images. Typically you would identify phases in the microstructure while the sample is on the optical microscope or in the scanning electron micro-scope.” Since that didn’t happen, Fritz and Ahluwalia had to pains-takingly re-examine and write descriptions for each and every image that appears in the book. Ahluwalia enjoyed working with a Co-Champion. “I think it kind of helps by not putting all of the burden on one person,” he observes. “We did a nice job of interacting with membership, keeping them in the loop, and also being able to interact with our vendors. I like the Co-Champion model, especially if you get people

from different industries and backgrounds working together, because it makes the project even stronger. But I also believe the more you give to MTI projects, the more you get out of them.” Stine shares credit for the success story, starting with MTI member companies. “This Du-plex Atlas project beautifully illustrates the strength of the MTI organization and member collab-orative efforts,” she concludes. “A large project team consisting of representatives from over 30 dif-ferent member companies de-signed the scope and objectives of the project, and then donated the alloy samples, including perform-ing a variety of different welds, to bring it together. The project Co-Champions then took on the task of completing the project to the highest standards, resulting in a work that will be very valu-able to the industry. This type of project would never have been produced if it were not for the combined efforts of MTI member companies.” n

New Atlas of Microstructures> CONTINUED FROM PAGE 3

A Super Duplex stainless steel plate sample isothermally aged at 982°C (1800°F) for one

hour shows widespread precipitation of intermetallic compounds (brown colored precipi-

tates) throughout the cross section of the plate. The thermal treatment is well within the

intermetallic temperature range for this 255/Uranus 52N+ dual certified super duplex

stainless steel. NaOH etchant, 750X.

SUMMER 2014 | 6

Immediately after Derrick Rogers presented The Development of Industry Standards for Composite

Repair Systems at AmeriTAC 112 in Savannah, Georgia last October, he was the one who was sold. Rog-ers, who is Business Development Leader/Staff Consultant at Stress Engineering Services (SES), was impressed enough with the MTI model that he was already planning on coming to future meetings, but as a member company representa-tive. Of course, Rogers knew that he would have support back in Houston from new hire Brian Fitzgerald, a fixture at TAC meetings when he was a Materials Engineer with ExxonMobil. Rogers was right. SES recently joined MTI and is already active in helping plan a Refiners Roundtable forum for October 2014 (see ar-ticle on page 16). But SES hopes to add much more value as it becomes involved in projects, forum discus-sions, seminars, and meetings. The company’s insights on aging plant issues, such as reliability, could prove valuable to member companies who are focusing on identifying potential problems and possible solutions. “SES is a specialty engineering company that utilizes an exten-sive knowledge base from across a wide range of industries to provide innovative solutions that meet all code and industry guidelines,” ex-plains Rogers. “Our team of highly skilled engineers and technicians use a multi-disciplinary approach, advanced engineering tools, and technology to provide cost-effective solutions that improve perfor-mance, reliability, quality, and safety. “SES is a unique organization with a combined suite of capabili-

ties, expertise, and resources. We

specialize in performing full scale testing, material characterization, and analysis for solving complex problems where the consequence of failure is catastrophic.” The company’s broad range of capabilities includes Life Assess-ments; Fitness for Service Evalu-ations; Failure Analysis; Acoustic Emission Testing; Field Instrumen-tation/Monitoring; Fracture and Defect Assessment; High Tem-

perature Pressure Part Assessment; B31.1 Covered Piping System Compliance; Vibration Analysis and Remediation (FIV); Compu-tational Fluid Dynamics; and Full Scale Testing. “SES provides value to our customers by having all of those resources under one roof,” points out Rogers. “This enables a seamless integration between testing and analysis, allowing us to solve complex problems.” There are plenty of organiza-tions that include the participation of oil & gas and CPI producer com-panies, but SES zeroed in on MTI’s

> CONTINUED ON PAGE 12

SES Brings New Capabilities, Connections, and Perspectives to MTI

Stress Engineering Services’ facilities in Mason, Ohio (top). Full scale testing, materials

characterization , and other capabilities in SES’ Houston, Texas headquarters include a load

frame with 6.5-million-pound capacity used to test threaded and welded connections for

OCTG piping (bottom).

SUMMER 2014 | 7

Everything in the world is mov-ing at an accelerated pace and that includes the period of

time it takes a new member to have a positive impact on the organiza-tion. Since joining MTI in January 2014, the Industrial Technology Research Institute (ITRI) has al-ready been a focal point in planning a major AsiaTAC FFS Training ses-sion as well as the Spring AsiaTAC Meeting in Taiwan (see article on page 8). MTI Associate Director Jesse Chen took advantage of a great opportunity, asking ITRI’s new TAC Representative T. P. Cheng to join the AsiaTAC Steer-ing Committee. Cheng was instru-mental in landing Co-Sponsors CPC Corporation and Formosa Plastics and helping organize the successful meeting. Although ITRI conducts its own research, it was attracted to MTI’s breadth of knowledge and unique projects. “Serving the industry is one of the main missions of ITRI and can be performed well only with the assistance of capable and experienced researchers and engi-neers,” notes Cheng. “So the contin-ued training, learning, and self-im-proving are an important and vital task. MTI as an organization has a huge knowledge-base, database and forum, established during the past 30 or more years and still growing, that meets the needs of ITRI.” One topic of great interest to ITRI is corrosion under insulation (CUI). The reason is quite simple and straightforward, according to Cheng: “Taiwan’s geographic loca-tion is in the subtropical region of the Pacific Rim in which the marine atmosphere causes a consid-erable corrosion loss to CUI every year,” he explains. “Therefore, CUI inspection and its mitigation were proposed as the highly interesting

topic by local CPI engineers. One warning and preventive system was presented and discussed during the AsiaTAC meeting and might be considered in the near future as a potential project worthy of an in-depth study and field trial.” ITRI brings its own experience and resources that will be benefi-cial to MTI and may help expand its network in Asia. “Networking with Taiwan’s and the Asia Pacific’s industries is one of the valuable as-sets,” he continues. “ITRI can help MTI promote and maximize the as-set performance of CPI companies in this region.” Cheng foresees a future where MTI can be an even more valuable technical resource in the region. “As more and more joint-venture businesses are being expanded in the Asia Pacific region, including Southeastern Asian countries, MTI’s already built database and ability will be very useful to help new startup companies to solve material application and corrosion problems and to train the inexpe-rienced engineers,” he predicts.

Until then, Cheng will continue to participate in AsiaTAC meetings and look for possible collaborative projects that could benefit ITRI and potential member companies in the region. MTI welcomes ITRI to its worldwide materials engineer-ing community.

ABOUT ITRIITRI is one of the world’s leading technology R&D institutions aiming to innovate a better future for society. Since its inception, ITRI has been dedicated to help-ing industries stay competitive and sustainable with the mission of expediting the development of in-dustrial innovation, facilitating the process of industrial upgrades,and creating value-added applica-tions for industrial technologies. Through multi-disciplinary in-tegration of resources and talents, ITRI keeps building its R&D capac-ity and strengthening industrial services. It is also keen on develop-ing smart technology and green solutions that can improve quality of life and protect the environ-ment. Headquartered in Taiwan, ITRI has five branch offices in Silicon Valley, Tokyo, Berlin, Moscow, and Eindhoven to extend its reach across the globe. n

New Member ITRI Opening Doors in Southeast Asia

New MTI Member ITRI Co-hosted the AsiaTAC Taiwan Meeting in May. TAC Representative

TP Cheng of ITRI (shown here) was a member of the Spring AsiaTAC Planning Committee.

SUMMER 2014 | 8

The AsiaTAC Steering Com-mittee started looking at Taiwan as a future meeting

site more than a year ago. Since that idea surfaced, a lot of planning went into the effort. The Commit-tee’s considerable effort paid off in a successful Fitness for Service (FFS) Training session and MTI’s second successful Spring AsiaTAC Meeting, held May 15-16 in Chia Yi City, Taiwan. AsiaTAC Chair Henry Ye, DuPont, called it an excellent conference. “MTI AsiaTAC just made a new landmark type of achievement,” emphasizes Ye. “Almost all major Taiwan petrochemical and chemical companies were included.” According to Jesse Chen, MTI Associate Director, more than 60 people attended the FFS Training seminar and AsiaTAC proceedings. Themes that concentrated on CPI Corrosion Issues (first day) and Cor-rosion Under Insulation (second day) generated plenty of interest and conversation. “Not surprisingly, many plants in this region share the same need of getting this issue un-der better control by understand-ing it better,” Chen says of CUI. “Many organizations have started to work independently of each other

or are attempting to cooperate. MTI is the organization that can help them in leveraging the team and resource-sharing approach, leading to better solutions to this prob-lem. We received a lot of positive feedback from the people that we talked to in this meeting.” Like Ye, Chen was very pleased with the mix of MTI member com-panies and prospective members attending AsiaTAC. “With a well-organized technical program under the leadership of Dr. T.P Cheng of ITRI, we were able to attract many long time MTI member companies that operate in Taiwan and in the region, such as DuPont, Dow, Air Products, BP, Outokumpu, Rath Gibson, Asahi-Kasei and Mitsui Chemicals,” reports Chen. “MTI’s newest member, ITRI, and several non-member major Taiwan com-panies, such as CPC Corporation, Formosa Plastics and China Steel, were also very well represented along with many smaller Taiwanese companies.” That broad range of experience and perspectives added value to the interactive exchanges. “Promi-nent Professors Wen-Ta Tsai from National Cheng Kung University, Taiwan, and Masatoshi Kubouchi from Tokyo Technology Institute,

FFS Training Session Highlights AsiaTAC Taiwan Meeting

(Top Left) Participants at AsiaTAC

Taiwan 2014, (Top Right) FFS

Training Session Presenter John

Young, DuPont, (Bottom Left)

Professor Wen-Ta Tsai of National

Cheng Kung University of Taiwan

(Bottom Right) Jesse Chen, MTI,

with Keynote Speaker Professor

Tsai, National Cheng Kung

University of Taiwan

SUMMER 2014 | 9

Japan, also presented papers,” continues Chen. “Finally, we also had participation from Taiwan government bodies in both the FFS Training and the AsiaTAC Meeting, which will improve the mutual un-derstanding between the governing bodies and the operating companies in Taiwan. We had a wide spectrum of organizations that all got togeth-er for the first time discussing key common material and processing issues facing the industry.” Ye applauded CPC Corporation for its hospitality and enjoyed the opportunity to explore its fascinat-ing facilities . “It was like a history tour,” he remarks. “Because CPC is one of the largest companies in Tai-wan, it goes up and down as Taiwan goes. During World War II, nearly all facilities were bombed down. But it has still been able to develop

itself back into a large and success-ful company, which was amazing.” Chen points out that the tour and technical program were the result of resource sharing and teamwork stretching beyond member companies. “MTI is fortunate to have many valuable partners namely, ITRI, The Corro-sion Association of the Republic of China, and Co-Sponsors CPC Corporation and Formosa Plastics,” he concludes. “Without our local partners, this meeting would not have been possible.”

AsiaTAC ANNUAL MEETING ON THE CALENDARAfter holding a successful meeting in Taiwan, the AsiaTAC Steering Committee is already busy plan-ning the AsiaTAC Annual Fall Meeting. That interactive forum

will take place in Shanghai, China, September 25-26, 2014. MTI plans to offer a special one-day training seminar on Reliability Technol-ogy in conjunction with the Fall AsiaTAC meeting. “Another day may be devoted to a training session on polymeric materials,” reports Associate Director Jesse Chen, a member of the Organizing Com-mittee. “Our first steering team planning meeting for this event will be held early June, so more details will follow.” Chen encourages members who want to be involved and present technical information at AsiaTAC to contact him at jchen@mti-global.org. Further details, including the name of the host hotel and reservation links, will be posted on the MTI web site as they become available. n

EuroTAC 2014 participants gather at TNO’s research facilities in Eindhoven, The Netherlands.

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A lot can be accomplished in a very short time when you bring the right people

together. Such was the case at the Spring 2014 EuroTAC Meeting, held March 25-26 at TNO’s headquarters in Eindhoven, The Netherlands. An insightful tour of the science-focused facility was followed by a variety of technical presentations and valuable discussions. “TNO gave the EuroTAC membership two tours of facilities showing state of the art materi-als engineering research projects,” reports MTI Associate Direc- tor Heather Stine. “They have a tribology lab and creep rupture apparatus that may be helpful resources for future MTI projects and demonstrated new techno-logical research, such as fiber optic sensors that may have future MTI applications as well. Being aware of the depth and breadth of their capabilities will be valuable for MTI member companies as well

as for being considered as a

potential contractor for future MTI projects.”   Minds filled with new ideas and possibilities, Stine, fellow MTI Associate Director Emory Ford, and Executive Director John Aller joined members and guests for a variety of technical presenta-tions. Thirty four people attended the spring meeting, representing 16 member companies, and one prospective member, Sonomatic. EuroTAC featured presentations on FRP Global Standards, Inspection Techniques, Guided Wave for Tank Bottoms, Accelerated Testing to De-termine Remaining Lifetime, Heat Resistant Cast Alloys, MTI Flange Project and Polymer Permeability Book Updates, and A Technique for the Evaluation of Toughness of Carbon Steel. “The talks were informative and the questions and answers and discussions after each one were engaged and showed great inter-est,” reports Stine. “Natalie Gelder also hosted a Special Case Studies session, where members brought

current engineering problems to the group and received helpful, pertinent feedback and input on the problems they presented. The level of participation and support was encouraging.” Future support and participa-tion could flow into an internation-al project. “The EuroTAC member-ship supports participating in a project on CUI (Corrosion Under Insulation) that has been proposed by a Japanese member company,” according to Stine. “It has not yet been formulated into a formal proj-ect, but EuroTAC, AmeriTAC and AsiaTAC will all likely collaborate in providing data to develop strate-gies in best solving this universal problem that all chemical process-ing plants experience.” In the annual business meeting, the group elected a new EuroTAC Chair, Dietlinde Jakobi of Schmidt + Clemens (see article on page 11). Natalie Gelder of BASF will remain as the Vice Chair. “Jakobi has been an active participant and presenter

> CONTINUED ON PAGE 12

EuroTAC 2014 Yields New Ideas, Plans, and Leadership

Dr. Dietlinde Jakobi, who has been a very active par-ticipant at MTI’s technical

meetings in Europe, was named EuroTAC Chair at the group’s most recent meeting in Eindhoven, The Netherlands. Member company representatives were unanimous in selecting Jakobi, who has been a regular presenter at previous meetings. It’s easy to see why Jakobi’s MTI peers selected her to lead the Euro-TAC. “In my role as R&D Director for the Schmidt + Clemens Group, my responsibilities cover five manu-facturing sites worldwide and the coordination of a team of 20 highly qualified researchers and techni-cians, currently working on 30 different R&D projects,” reports Jakobi. “These are carried out in close cooperation with part-ners, customers from different industries like the petrochemical industry, chemical plants, on- and off-shore industry, and power technology. This large number of research projects necessitates an ex-cellent research network, including experts from different institutes, organizations and associations.” That is where a strong connection to MTI is helpful. “The MTI community offers an excellent opportunity to network, to share the experiences and knowl-edge with professionals and to meet members during MTI meetings,” she notes. “I have always been very impressed and inspired by the work of MTI.” Jakobi is already thinking ahead, considering potential projects and seeking members’ input. “As the new EuroTAC Chair, I will make every effort necessary to sustain the earlier success of EuroTAC, under the lead of Michael Turner

(AkzoNobel), and to additionally expand the research activities in Europe by evaluating the specific requests of the European market,” she says. “I am convinced that we can successfully increase MTI European member engagement, and I very much hope that we will also increase the number of MTI members in Europe.” Members will have a big op- portunity to engage when MTI introduces its first Aging Plants Conference & Expo with industry partner KCI in March 2015 (refer to ad on page 13). In fact Jakobi and EuroTAC participants helped establish the initial agenda at TNO in Eindhoven. She believes that the event will

be an extremely valuable meet-ing for MTI’s European members. “Many chemical, petrochemical plants and refineries currently op-erating in Europe face the problem that they have reached or surpassed their life expectancies and still need to remain very productive,” observes Jakobi. “Plant managers must guarantee that the plants can be kept profitable and safe as well as economically sustainable, even though present day regulations and norms are quite different from the standards in place when the plants were originally built.” She is ready to contribute to the discussion when the conference launches next spring. In the meantime, Jakobi is already working with Vice Chair Natalie Gelder and Associate Direc-tor Heather Stine to strengthen MTI’s technical community in Europe. The leadership team has a variety of plans, including potential new projects and a second meet-ing in Europe. “This opportunity should be used to improve the MTI member network and to introduce new members to MTI EuroTAC,” she says of a possible Fall session. There are no shortages of opportu-nities for those willing to lead, and Jakobi will undoubtedly make the most of them. n

Schmidt + Clemens’ Jakobi Steps Up to Chair EuroTAC

Dietlinde Jakobi, MTI EuroTAC Chair

SUMMER 2014 | 11

SUMMER 2014 | 12

at EuroTAC for several years,” points out Ford. “We have a nice leadership team in place.” Jakobi’s background makes her a great choice for her new role at MTI. She is R&D Director for member company Schmidt + Clemens Group, where her responsibilities encompass five manufacturing sites worldwide and coordination of a team of 20 researchers and technicians work-ing on 30 R&D projects. Moving forward, the new EuroTAC Chair says that she hopes to expand MTI’s research activities and projects in Europe by evaluating the specific requests of the European market. Following the election, Jakobi, Gelder, and member company representatives discussed plans for future EuroTAC Meetings, includ-ing the potential for a Fall session. “This will increase momentum and

strengthen networking opportuni-ties among the membership and is an important step in increasing the value of MTI for European mem-bers,” notes Stine. That isn’t all that MTI has planned for EuroTAC. Fast-forward a year, when the next Spring Meet-ing will include a special twist. Aller and John Butterfield of KCI (producers of Stainless Steel World) announced the Aging Plants Conference, a brand new industry event co-hosted by the two Process-ing Industry-focused organizations, slated for March 2015 in Düssel-dorf, Germany (see ad on page 13). The presenters encouraged mem-ber companies and guests to help plan and participate in this event that will address one of the hottest topics in the CPI and associated industries. “We see regulations spreading

throughout the world that are put-ting much stronger requirements on operating companies to properly manage their aging infrastructure,” according to Aller. “More and more facilities are running beyond their original design intent. There is a big gap in our knowledge base to pro-vide assurance that those plants can continue to run safely once they’re beyond their original design life criteria.” Aller adds that a recent survey of MTI member producer company stakeholders demonstrat-ed that they are constantly looking for valuable/useful information on plant integrity and reliability issues, which is exactly what Managing Aging Plants is focused on delivering. Watch for conference and project updates, EuroTAC Meeting information, and other important news at mti-global.org. n

collaborative, project-oriented model. “What attracted SES to MTI is the ability to meet with all of the petrochemical industry plant owner /operators in one forum to hear their issues,” con-tinues Rogers. “We currently do business with a large number of chemical plant owner /operators, and we have an appreciation for the problems we are exposed to by those customers. In an effort to better assist our customers we like to be on the forefront of identi-fying problems and developing solutions. By participating in the development of those solutions, SES will have a better vision for our future investment strategies and the ability to acquire resources to better serve the industry and our customers. We embrace the collab-orative model as it enables the best and brightest to have input when

solving problems.”

Rogers notes that he and his colleagues are interested in many MTI projects and hot topics, including Prediction of Material Degradation; Polymers; Integrity and Condition Assessment; and Metals. But it will take time to identify all of the opportunities of interest. “When we look into the future, we hope to gain a deeper understanding of the problems the petrochemical industry is facing, and be a part of develop-ing solutions that can be lever-aged throughout the industry,” he says. “During the course of participating in the PDCs and projects, we look forward to meeting individuals, learning more about the companies they represent, and determining how SES’ expertise and resources can assist. “As a first step, we would like

to participate in more PDCs and gain a better understanding of MTI’s current events. We would like to be integral in building bridges with the other indus-try organizations. SES will be celebrating its 42nd anniversary this year, and we would like to leverage the relationships and expertise we have developed.” The “bridge building” is already underway. “SES is currently serving customers in the energy (oil & gas, power generation, and petrochemical), consumer products, and medi-cal industries,” explains Rogers. “SES would like to take a more active role in helping in the cross pollination of technology and information and speeding up the process of innovation.” In MTI, SES found the right environment to help make that happen. n

SES Brings New Capabilities, Connections, and Perspectives to MTI> CONTINUED FROM PAGE 6

EuroTAC 2014 Yields New Ideas, Plans, and Leadership> CONTINUED FROM PAGE 10

• Acceptablerisk/risk-basedinspection• Agingphenomenathatoccurlateinlife• Deterioratingequipment• Europeanmulti-nationals’bestpractices• Europeanregulations• Inadequate/outdateddesign• Insuringagingplants

TheMaterialsTechnologyInstitute(MTI)incooperationwithKCIPublishingisorganizingatwo-dayConference&Expodevotedtothetopicof“ManagingAgingPlants”,3–4March,2015,attheMesseDüsseldorfCongressCenterinDüsseldorf,Germany.

Conference Program at a GlanceTheconferencewillcoverthefollowingtopicsandmore:

If you are interested in presenting a paper, contact John Butterfield, KCI, at j.butterfield@kci-world.com or tel.: +31 575 585 294 for more information.

• Lackofeffectivemanagementsystems• Lossofexperience/competenceintheindustry• Materials/fabricationquality• PlanningforthefutureandIndustry4.0• Positivematerialsidentification(PMI)• Trackingtheincidenceoffailure

Preserving Industry in Europe with Safe & Sustainable Operations for the Future

http://www.mti-global.org

Future Looks Bright for 2014 MTI Scholarship Winners

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MTI recently awarded its 2014 Bert Krisher Me-morial Scholarships to

Zackary Lerch and David Waligor-ski, both seniors studying Materials Engineering at the University of Akron. Paul Manning (Haynes International) and John Aller (MTI) presented the awards at the NACE Annual Conference in San Antonio, Texas in March. NACE received 16 applications for MTI’s two $5000 awards. Se-lecting the winners from that talent pool of tomorrow’s CPI profession-als wasn’t an easy task. Committee Members Dale Heffner (Electro Chemical Engineering and Manu-facturing), Robert Sinko (Eastman Chemical), Manning, Kirk Richard-son (MTI) and Committee Chair Srini Kesavan (FMC) reviewed many worthy candidates, several of whom displayed both outstand-ing classroom performance as well as relevant materials engineering background and co-op work. Overall, Kesavan noted that he was very pleased with the universi-ties’ participation this year, with applications submitted from as far as Australia and with an impres-sive level of participation from the University of Akron. The schol-arship is creating value for MTI member companies by connecting them with the next generation of engineering talent and their new ideas. “The Scholarship Program is achieving the objectives of promot-ing awareness of MTI among stu-dents and CPI Materials Engineer-ing as a career choice,” he observes. It has certainly made an impact on this year’s winners. Lerch and Waligorski won the two awards based on their academ-ic excellence and pertinent work with materials. It helped that both

of them are passionate about

their studies and chosen career paths. “What’s not to be fascinated about within the realm of materials science?” asks Waligorski. “Every-thing we deal with in this world is made of materials, and these materials all have various proper-ties that allow them to perform certain tasks. “As an engineer, I have the op-portunity to orchestrate a beauti-ful system of these materials to solve problems – problems such as transportation (airplanes and auto-mobiles), technology (computers and circuits), energy (oil refineries and power plants), and structures (buildings and bridges). As society progresses, our material demands will only increase. We will need ma-terials that are cheaper, last longer, and can perform in more extreme environments. Because of this, I expect that the job market will be quite good in the future, which gives me comfort in choosing it as a career. Perhaps more importantly,

there will be many challenges and problems to solve in this arena going forward, which makes it an interesting and important topic to work on.” He is taking all of the necessary steps to prepare for the eventual opportunity. “The degree I am working towards, a Bachelor’s Degree in Corrosion Engineering, is a mix-ture of Chemical Engineering and Materials Science, which is a very unique combination,” says Waligor-ski. “The main goal of the program is to develop knowledge about how to prevent a system from degrad-ing, and thus last longer. From a materials standpoint, this can in-clude things such as materials and coating selection. From a chemical engineering standpoint, this may involve selecting corrosion inhibi-tors to inject into the system, or process redesign to better suit avail-able materials. An understanding of both materials and the chemical processes that these materials are

2014 MTI Scholarship Winners (David Waligorski, center-left, and Zackary Lerch,

center, right) receive their awards at NACE’s Annual Conference in March.

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expected to contain is paramount in properly developing a solution. This is what makes the University of Akron’s program unique. And since many of the large chemical processing facilities, such as refiner-ies, are very old, there is no shortage of these problems to solve. Much research is being done on these topics, and unfortunately failures of pipelines and other systems are becoming more common. For these reasons, finding and developing solutions to these problems is an important and challenging task, but also an interesting and worthwhile one, and that is why I am studying it.” Waligorski recalls that his first project involved testing coatings for the Air Force, research that he pre-sented at NACE in 2012. He has also participated in cathodic pro-tection, materials characterization, and coatings degradation modeling projects as well as corrosion inhibi-tor testing, research, modeling, and development. “The corrosion in-hibitor research has been the most extensive, and we actually filed for a patent based on my findings a few weeks ago,” he reports. Lerch has been dreaming about a future in science since boyhood. “Ever since I have been little, I have been fascinated by technology, especially military aircraft and cut-ting-edge advancements,” he recalls. “Material engineering interests me because without materials engi-neering, the advancement of tech-nology such as aerospace, chemical production, oil and gas exploration, and infrastructure would not have been possible.” Waligorski notes that he would love to move expeditiously up the ranks at a corporation and be re-vered for his accomplishments, but doesn’t expect that to happen with-

in the next five years. “I still have one year left before I graduate with my Bachelor’s degree,” he explains. “I’m still uncertain as to whether I will pursue graduate school after obtaining my Bachelor’s or if I will go straight to work. But I do intend to continue working in the Chemi-cal Process Industry, whether it is related to research or actual indus-try experience. This is because the Corrosion Engineering degree I am working toward is a combina-tion of Chemical Engineering and Materials Science, which makes the CPI an excellent fit for my skill set. Beyond that, both of these areas interest me greatly, which is why I decided to pursue this degree in the first place.” As for his plans, Lerch has his mind set on becoming a corrosion engineer working on corrosion mitigation and failure analysis within the oil and gas industry. He is a step closer to making that dream a reality. “Fortunately, my hard work and dedication to become a corrosion engineer has resulted in being a recipient of the MTI Bert Krisher Memorial, which will allow me to focus more on my educational goals rather than the financial burden upon graduation,” explains the ultra-busy student. “I am truly grateful, and words will never convey how thankful I am to be a recipient of this scholarship.” “Without scholarships such as these, I wouldn’t be able to focus on school and research as I have, and that is why I am very appreciative of such support,” adds Waligorski. “My thanks go out to everyone that made this possible.” The future certainly looks bright for Lerch, Waligorski, and the Chemical Processing Industry, and MTI continues to lead the way. n

Bridget Egan and Chis LaBelle of Oregon

State University presented on web-based

eLearning opportunities at AmeriTAC 113

AmeriTAC 113 Recap

MTI’s winter meetings are usually among its busiest, and AmeriTAC 113 was

no exception. In all 88 people rep-resenting 39 companies attended the Project Team, PDC, and Ameri-TAC sessions February 24-27 in Fort Worth, Texas. New member Stress Engineering Services (fea-tured on page 6) attended as well as pending members Huntsman and ITRI (both have since joined MTI). Presentation highlights included a comparison between four different international design codes for FRP vessels by Adriano Urena of OLLEARIS and a Final Report on the Investigation of Technologies Common to Other Industries by Steve Springer of DuPont. For further details about the meeting, including a full list of presentations, projects approved, and other valuable information, visit mti-global.org.

NEW DRs AND TAC REPSMTI welcomes the following new DRs and TAC Representatives.• JanvandeWetering

(AkzoNobel) – EuroTAC  • Sunila“Nina”Young

(Huntsman) – Designated Representative, AmeriTAC

• TPCheng(ITRI)–DesignatedRepresentative, AmeriTAC, AsiaTAC, EuroTAC

• JustinMuscarella(TITAN Metal Fabricators) – Designated Representative

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Refiners Roundtable Slated for October

Corrosion and other material challenges aren’t particular about what kind of process-

ing plant they vex. On October 20, MTI will bring together some of the best minds in the industry to discuss materials issues during a Refiners Roundtable. The one-day session will be held in conjunction with MTI’s Fall Project Team Meet-ings and AmeriTAC 115, October 20-22 in Columbus, Ohio. All MTI member companies, whether or not they operate refineries, are invited to participate. In addition, other major refiners will be invited to participate as guests. John Aller, MTI Executive Director, explains that the Refin-ers Roundtable is a way for MTI to identify the materials-related issues in the refining sector and formu-late a way to deliver value to its current and potential members in this sector. The meeting itself will provide members and guests with rapid access to critical technical information. It will include techni-cal presentations and a roundtable forum as well as discussions on longer term refinery-related poten-tial projects. “MTI is unlike other industry organizations because we have funds waiting for good proj-ects to get formulated, rather than good ideas looking for funding,” according to Aller. “The participat-ing companies have immediate

access to the knowledge that is be-ing developed by the project team.” Kevin Ganschow, a Materials Engineer at Chevron Energy Technology Company, adds that MTI is very agile and able to move quickly on the kinds of projects that he and colleagues at refineries would be interested in participat-ing in, including corrosion under insulation. Ganschow is looking forward to the roundtable session and discussion of MTI’s refinery-relevant past, current, and poten-tial projects. There will be plenty of chances to identify research opportunities, starting with a tour of the nearby Edison Welding Institute. EWI develops and applies manufactur-ing technology innovation within the manufacturing industry. The institute is noted for helping manu-facturers optimize the fabrication, operation, maintenance, and repair of complex refinery equipment. Following the tour, MTI will host a lunch presentation and roundtable session. Technical presentations will include:• MTIProjectsofSpecialInterest

to Refining• InherentlySaferDesign• StressCorrosionCracking

Concerns in Refining• FireDamageAssessment• OtherSpecialPresentationsand

Topics of Interest to Refiners

In addition, each refinery or producer company in attendance will receive a free copy of MTI’s book, “Damage Assessment: Investigating Fires, Explosion and Storm Damage in Chemical Plants” (an $850 value). The event will conclude with a reception on Monday evening, but refiners are invited to stay and attend MTI Project Team Meetings and AmeriTAC 115. This event is free of charge, but space is limited to member companies and select guests. Contact Kirk Richardson (krichardson@mti-global.org), Emory Ford (eford@mti-global.org), or the MTI Office at 314-576-7712 for more information and to request an invitation.

PRSRT. STD.U.S. POSTAGE• • • PAID • • •

PERMIT NO. 751SALEM, OREGON

1215 Fern Ridge Parkway, Suite 206St. Louis, MO 63141-4408http://www.mti-global.org

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