Mr. Gouranga Charan Rout
Sr. Vice Presiden
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Topic
Advanced Sustainable Material Technologies: Challenges and Opportunities
Affiliation
Sr. Vice President, Electrotherm (India) Limited
Abstract
Meeting needs of present without compromising the needs of future. Sustainability is no longer about doing less harm.- It’s about doing better.
Corrosion damages the structural integrity of steel, thus challenging the sustainability of infrastructure. The International Zinc Association (IZA) estimates that India loses 5–7% of its GDP each year due to corrosion. Fusion bonded epoxy coating on the TMT bars used in Infrastructures is a corrosion resistant; which increases the life span of an infrasture resulting in less steel consumption and more enhanced life and loss to the economy as well. This is an innovative material Strategy and sustainable resilient infrastructure.
Carbon footprint is the total amount of greenhouse gases (GHGs) released into the atmosphere due to human activities. Manufacturing Process of ET is driven by EIF & LRF refining process technology.
We have a 45 MW Captive Power Plant powered by WHRB and solar.
0.1% Vanadium addition lowers steel consumption by 10-15% and reduces carbon footprint. Uniform Vanadium distribution during rolling minimizes rolling loads. Emerging Steel Grades; Fe 650, Fe 700; •Vanadium micro alloyed steel.
Biography
With over three decades of expertise in the steel industry, Mr. Rout brings an exceptional background in Iron Making, Steel Making, and Rolling Technology. He holds an M. Tech in Mechanical & Material Science, an M.B.A. in Finance, and M.Sc. in Total Quality Management, showcasing his dedication to both technical excellence and managerial insight. Recognized early on with the prestigious Best Graduate Award from Rotary International Club in 1996, Mr. Rout has since built an impressive career, having contributed to renowned organizations like IISCO Burnpur, NISCO, TATA Sponge Iron Ltd, and Adhunik Metaliks. Currently, he serves as the Sr. Vice President of Integrated Steel Unit (ISU) at Electrotherm (India) Ltd, where his experience continues to shape the industry. As a Lifetime Member of the Indian Institute of Metals and with connections to the World Steel University in Belgium, he remains committed to advancing material science and engineering within the steel sector. His wealth of knowledge and practical insights make him a valuable contributor and sought-after speaker on the evolution and innovations in steel manufacturing.
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Christopher Do
Founder & Chairman
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Topic
Digital Applications in Corrosion Control: Transforming Corrosion Management from Periodic Inspection to Continuous Integrity Intelligence
Affiliation
Founder & Chairman,
IEV Group & Technisur Engineering Pvt Ltd
Abstract
Digitalisation is transforming corrosion control by enabling continuous monitoring, data-driven assessment, and informed integrity decisions. Traditionally, corrosion management has relied on periodic inspections, manual measurements, historical records, and engineering judgement. While essential, these practices provide limited visibility between inspections and may require scaffolding, insulation removal, shutdowns, or personnel exposure. This paper examines proven digital applications that convert selected corrosion threats into continuously monitored integrity workflows. These include remote Corrosion Under Insulation (CUI) monitoring using corrosion and moisture sensors, guided-wave monitoring for offshore risers and inaccessible pipelines, embedded or wireless ultrasonic thickness sensors for wall-loss trending, cathodic protection monitoring for tanks and marine structures, corrosion-rate sensors, concrete crack monitoring, and IoT-enabled integrity dashboards.
Digitalisation enables earlier detection of active corrosion, improved corrosion-rate trending, targeted inspection, and efficient maintenance planning. Digital platforms can integrate sensor data, inspection records, alarms, photographs, asset information, and risk rankings into a common decision environment. The paper reviews applications in CUI, pipeline integrity, cathodic protection, tank internals, and concrete structures, while discussing data quality, alarm thresholds, cybersecurity, interpretation, and RBI integration. Digitalisation strengthens corrosion engineering by reducing uncertainty between inspections and improving safety, reliability, efficiency, and asset integrity.
Keywords: Digital corrosion control, CUI monitoring, PIMS, CP monitoring, IoT corrosion sensors, RBI, asset integrity.
Biography
Christopher Nghia Do is a seasoned industry leader with over 38 years of experience, including more than 3 decades dedicated to asset integrity management (AIM) for oil and gas facilities. As the Founder and Chairman of IEV Group, he has played a pivotal role in pioneering AIM solutions across the Asia-Pacific, particularly in corrosion control, ocean-powered marine growth control, structural health monitoring, pipeline health management, and condition-based maintenance for offshore and onshore assets.
Throughout his career, Christopher has successfully led two IPOs, built multi-national strategic alliances, and expanded operations across Malaysia, Vietnam, India, Indonesia, and Australia. His extensive hands-on experience in the energy sector underpins his leadership in new ventures, where he integrates disruptive technologies with market demands. Renowned for bridging deep science with real-world application, he has transformed emerging technologies into scalable, market-ready solutions that drive both business growth and societal impact.
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Prof. Kallol Mondal
PhD Professor
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Topic
Value added by-products from recycled secondary Zn dross
Affiliation
PhD Professor Department of Materials Science and Engineering, IIT Kanpur
Abstract
The galvanizing industry consumes a significant proportion of global zinc production and generates substantial quantities of zinc dross as a waste by-product. Primary zinc dross, which is rich in zinc, is commonly used by local galvanizers for non-standard coating applications. These processes subsequently generate secondary zinc dross, creating an additional waste stream. This study presents an innovative approach for the treatment and recycling of secondary zinc dross into several high-value-added products. The recovered material was utilized to produce sacrificial secondary zinc anodes, zinc sulphate heptahydrate, zinc powder, zinc-coated hybrid refill graphite anodes, and steel-reinforced bars.
The developed products were characterized for chemical composition, microstructure, and electrochemical performance in 3.5 wt% NaCl solution. The performance of secondary zinc anodes was further evaluated in artificial seawater and compared with reference zinc anodes ad anodes produced from primary dross. The recovered-material anodes demonstrated satisfactory performance for industrial applications. Zinc powder and zinc sulphate heptahydrate also offer potential for diverse applications, demonstrating a promising route for the sustainable utilization of secondary zinc dross.
Biography
Dr. Kallol Mondal is a Professor at the Indian Institute of Technology (IIT) Kanpur, specializing in Metallurgical and Materials Engineering, with expertise in corrosion, materials degradation, surface engineering, metallic glasses, advanced steels, coatings, and materials processing. He holds a B.E. in Metallurgy from Bengal Engineering College (1995), M.Tech. from IIT Kharagpur (1998), and Ph.D. from IIT Kharagpur (2005).
His professional career includes industrial experience at Lakshmi Precision Screws Ltd. and TELCO, Jamshedpur, followed by research at IIT Kharagpur and NIMS, Japan, where he worked on stress corrosion and metallic glasses. He joined IIT Kanpur as Assistant Professor in 2007 and became Professor in 2016. He has also served as Visiting Associate Professor at the University of British Columbia, Canada. His teaching and research encompass corrosion and oxidation, materials degradation, heat treatment, surface modification, thermodynamics, and non-equilibrium processing. He has supervised numerous B.Tech., M.Tech., and Ph.D. students.
Dr. Mondal has 160 publications and several patents covering corrosion-resistant coatings, sacrificial anodes, nanoporous materials, multilayered steels, and advanced alloys. He has also contributed extensively to knowledge dissemination through NPTEL courses and video lectures.
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Rohan Patel
Founder & CEO
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Topic
From Inspection Data to Engineering Decisions: Asset Integrity in the Digital Age
Affiliation
Founder & CEO
Abstract
Industrial operators generate enormous volumes of inspection data, yet much of it never translates into timely engineering decisions. This keynote examines how risk-based inspection is being reshaped by the convergence of field mobility, predictive analytics, and enterprise integration.
Drawing on three decades of building mechanical and asset integrity software for oil & gas, petrochemical, specialty chemical, pharmaceutical, and semiconductor operators, the talk explores how encoding standards such as API 580/581, API 579-1/ASME FFS-1, ISO 14224, and IEC 61511 directly into auditable, configurable software closes the gap between what inspectors capture in the field and what engineers decide at the desk. It covers real-time image-based damage detection, the role of AI in prioritizing finite inspection budgets, and how synchronizing field data with enterprise systems (SAP APM/EAM) produces an end-to-end view of asset condition, performance, and lifecycle.
The session closes with a pragmatic roadmap for operators moving from periodic, reactive inspection toward predictive, decision-led integrity management.
Biography
Rohan Patel is the Founder and CEO of AsInt, Inc., a technology company delivering asset integrity solutions for the energy and engineering sectors under the banner of "a higher form of asset intelligence." Over a career spanning more than two decades, he has conceptualized and delivered software that improves performance, mitigates risk, and optimizes operations for owner/operators worldwide across oil & gas upstream, midstream, and downstream, petrochemical, specialty chemical, pharmaceutical, and semiconductor industries.
His expertise spans risk-based inspection program implementation, mechanical and reliability integrity, digital transformation, strategic business planning, and entrepreneurship. Under his leadership AsInt has launched IntelliSuite - a mobile inspection platform with predictive image damage detection and native integration to the SAP Business Technology Platform - alongside the CORE family of inspection and engineering tools. He is a frequent speaker at industry forums including the AMPP Annual Conference + Expo.
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Kamlesh Chandra
Professor
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Topic
Materials selection for acid process streams relevant to nuclear and chemical industries
Affiliation
Scientific Officer-H, Bhabha Atomic Research Centre and Professor, Homi Bhabha National Institute
Abstract
Various acid streams are essential in the extraction, processing and manufacture of metals and minerals. These acidic environments are inherently corrosive to structural materials or components handling them. Acidic environments are classified based on various criteria such as by strong or weak acids based on pH levels, and by oxidizing or reducing acids based on oxidizing power. For example, nitric acid, hydrochloric acid and sulphuric acid are classified as strong acids, but HNO3 is highly oxidizing, while HCl is highly reducing, and H2SO4 is intermediate. Both Hydrofluoric acid (HF) and phosphoric acid (H3PO4) are classified as weak acids, yet HF is highly corrosive, and only a limited materials can sustain such a corrosive environment. In contrast, H3PO4 is only mildly corrosive. However, if impurities are present in H3PO4, e.g., during phosphoric acid production, the metallic equipment may experience enhanced corrosion and undergo failure. In nuclear spent fuel reprocessing plants, the structural materials are exposed to concentrated nitric acid in boiling condition. Critical components made of austenitic stainless steel (SS) 304L, even in non-sensitized condition, are prone to intergranular corrosion in this environment. This presentation will provide guidelines for materials selection in these environments to minimize corrosion and avoid failures.
Biography
?B.E. in Metallurgy from B.I.T. Sindri in 2001
?Joined BARC in Materials Group in 2002
?Ph.D. from IIT Bombay in 2012
?Post-doctoral research at Federal Institute for Materials Research and Testing, Berlin for 2 years under Adolf Martens Fellowship in 2013
?AMPP Fellow, Student award for the best Ph.D. thesis for year 2012 by NACE, India, S.K. Seshadri Memorial Mascot National Award 2012, by The Electrochemical Society of India, DAE Award – Young Applied Scientist and Technologist Award 2009, Homi Bhabha Gold Medal Award (2002) in Metallurgical Engineering discipline.
?Has about 80 publications including journal papers, conference proceedings/presentations and book chapters
?Specializes in corrosion and its protection, aging degradation of materials and its control, high temperature corrosion and failure analysis.
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Pankaj Panchal
CEO
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Topic
Enhancing Quality and Reliability in Cathodic Protection Systems
Affiliation
CEO- - Corrosion Protection Specialist Pvt. Ltd.
Abstract
The reliability of Cathodic Protection (CP) and Alternating Current (AC) mitigation systems depends on accurate site surveys, sound engineering design, quality materials, proper installation, and effective commissioning. Gaps between design assumptions and actual field conditions can compromise corrosion protection and pipeline integrity.
Site Survey and Design: Accurate soil resistivity measurements are essential for reliable CP design. Unsuitable instruments, inadequate procedures, and unrealistic assumptions can produce ineffective designs. Site-specific data, applicable standards, engineering judgment, and commissioning feedback should guide design decisions. Differences between specified and measured anode-bed resistance highlight the need for field validation.
Materials and Installation: Counterfeit, underrated, and substandard materials can undermine system performance. Quality assurance should cover specifications, manufacturing inspections, delivery verification, installation supervision, Site Acceptance Testing (SAT), and commissioning.
AC Mitigation: Effective mitigation requires reliable field data, realistic modelling, and consideration of seasonal soil resistivity variations and changing power-line conditions. Solid-State Decoupler (SSD) quality and authenticity are essential to minimize AC corrosion risks and excessive pipeline AC voltage.
The principal contribution of this paper is a lifecycle-based approach integrating data accuracy, design verification, material quality, installation control, and field validation. It emphasizes that design compliance alone cannot guarantee performance without systematic verification under actual site conditions. These practices can improve corrosion control, pipeline safety, system reliability, and long-term asset integrity.
Keywords: Cathodic Protection (CP), AC Mitigation, Soil Resistivity, Quality Assurance, Testing and Commissioning
Biography
Mr. Pankaj Panchal is Director & CEO of Corrosion Protection Specialist Pvt. Ltd. since 2016. An Electrical Engineer with 30+ years of experience in corrosion assessment and cathodic protection (CP) systems, he worked with Abdulla Fouad Impalloy Ltd. Co, Saudi Arabia from 2001 to 2016 as General Manager (UAE) and Engineering Manager, and earlier in India’s CP industry from 1993 to 2000.
Mr. Panchal is an AMPP Certified Corrosion Specialist and Cathodic Protection Specialist, and an AMPP Lead Instructor for CP Levels 1–4 since 2014. He received the “Excellence in Corrosion Science and Technology” award in 2018 and a Meritorious Contribution award from AMPP India Section.
He has published 12+ international technical papers and designed CP systems for over 5,500 well casings and 10,000 km of pipelines with AC/DC interference mitigation. He pioneered the multiple well casing CP concept with Saudi Aramco in 2002, a global first in the industry.
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Gunnar Ackx
Founder/Chief Vision Officer
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Topic
Preparing for Coating Projects – From Risks to Requirements
Affiliation
The Coating Network: Founder/Chief Vision Officer
SCICON worldwide: Managing Director
SSPC: Past President (2016-2017)
Abstract
Protective coating work often represents only a small part of a project budget, yet premature coating failure can create repair, access, operational, legal and reputational costs that are disproportionately large. The central management problem is therefore not whether quality control is desirable, but how much quality assurance and quality control a specific project requires, and how that decision can be converted into practical instructions for execution. This paper combines two complementary tools. The first is the ICoPF risk-based approach, which evaluates the probability and potential consequences of coating failure to support a proportionate decision on the required intensity and competence of QA/QC. The second is the Inspection and Test Plan (ITP), which consolidates project quality requirements into a concise working document containing inspection parameters, standards, frequencies, acceptance criteria, responsibilities, inspection points and documentation requirements. Used together during project preparation, the tools form a continuous line from risk to requirements: ICoPF determines the level of control justified by the risk, while the ITP defines how that control will be implemented and evidenced. The combined approach improves early alignment, identifies missing or conflicting requirements, directs resources toward the most consequential risks and reduces the likelihood of rework, disputes, delays and premature failure.
Keywords: protective coatings; risk-based inspection; ICoPF; Inspection and Test Plan; ITP; QA/QC; project preparation; cost reduction; quality management.
Biography
Gunnar Ackx is a second-generation coatings inspector, consultant, and industry leader with more than 30 years of international experience in protective coatings, corrosion mitigation, asset integrity, and quality management. He has spent his career supporting major industrial, marine, offshore, infrastructure, and energy projects worldwide through inspection, consulting, training, auditing, and expert advisory services.
As Managing Director of SCICON worldwide, Gunnar continues to provide independent coating inspection, technical consultancy and failure analysis services to clients across multiple continents, helping all coating project stakeholders reduce costs and mitigate risks involved with corrosion.
Gunnar is an AMPP Senior Certified Coatings Inspector and AMPP Protective Coatings Specialist (PCS). He has been an active volunteer leader within the coatings industry for many years, including 9 years on the SSPC Board of Governors and service as SSPC President (2016-2017). Today, he remains actively involved in AMPP committees and initiatives that support industry standards, certification programs, governance, and professional development.
As the founder of The Coating Network, Gunnar channels three decades of knowledge and experience into a next-generation digital platform created to connect asset owners, contractors, inspectors, suppliers, and subject matter experts, with the goal of improving coating quality, knowledge sharing, and corrosion management across the industry.
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Sumit Srivastava
General Manager
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Topic
Direct Assessment Journey for Natural Gas and LPG Pipelines
Affiliation
General Manager – CIMG GAIL India Ltd.
Abstract
Direct Assessment (DA) is a structured methodology for evaluating the integrity of underground pipelines that cannot be inspected using In-Line Inspection (ILI) tools or hydrostatic pressure testing. It is recognized under US regulations, PNGRB IMS Regulations-2012, and ASME B31.8S as an integrity assessment method.
DA integrates historical data, pipeline characteristics, operating history, indirect inspections, targeted excavations, and post-assessment analysis to identify threats such as external corrosion (EC), internal corrosion (IC), and stress corrosion cracking (SCC). It also helps determine remedial actions and reassessment intervals.
Methodology: As per AMPP/NACE SP0502, Direct Assessment involves four steps:
1.Pre-Assessment: Reviewing pipeline design, construction records, operating history, and soil conditions.
2.Indirect Inspection: Identifying potential corrosion locations using techniques such as Close Interval Survey (CIS) and Direct Current Voltage Gradient (DCVG).
3.Direct Examination: Excavating selected locations to inspect pipe surfaces, coatings, and corrosion damage, followed by necessary repairs.
4.Post-Assessment: Evaluating findings, remaining pipeline strength, and reassessment intervals.
Implementation in GAIL: DA was introduced in 2011–12 for three unpiggable pipelines: Vijaipur–NFL, ONGC–Hazira, and Dibiyapur–NTPC. Since then, GAIL has adopted DA and other approved assessment techniques for pipelines where conventional inspection methods are impractical. Integrity assessments are generally conducted every 10 years, while pipelines beyond their 25-year design life require assessment at least once every eight years, subject to applicable requirements.
Biography
Mr. Sumit Srivastava an Electrical Engineering graduate and Business Management from IIT Delhi and currently serve as General Manager, Corporate O&M, GAIL, Noida.
I bring with me over 25 years of experience in the Oil & Gas sector, during which I have had the opportunity to witness first-hand the critical role our industry plays in India’s economic development, energy security and nation-building.
Over the course of my career, I have developed extensive experience across technical operations, project management, asset integrity and operations & maintenance, with a strong focus on safety, reliability, operational excellence and stakeholder management.
This journey has given me not only deep technical expertise, but also a broader understanding of how people, technology, projects and operations must come together to create sustainable and reliable energy infrastructure.
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