• Corrosion is a major threat to the oil and gas, petrochemical and other process-intensive industries and is responsible for countless of dollars in damage and maintenance costs.
• Additionally, ageing equipment becomes more susceptible to corrosion and loses its ability to withstand harsh operating environments (e.g. high temperature and pressure).
• The purpose of a strong corrosion monitoring program is to improve safety, reduce maintenance and inspection costs, and maximize efficiency.
• Corrosion monitoring plays a vital role throughout the equipment lifecycle.
• Inspection and monitoring strategies and techniques may change according to the age and condition of equipment. Therefore, inspection and monitoring strategies should be reviewed at specific intervals at the owner-operator’s discretion.
• The goal of this course is to provide interested persons with a basic overview of the theoretical and practical aspects of corrosion and its control.

By the end of the training, participants will be able to:

• Recognize the different inspection tools and techniques.
• Be able to evaluate how the cost of corrosion is.
• Have FOUNDATION Level understanding of how to Analyze annual inspection plans and reports.
• Be able determine which pipelines need to be inspected.
• Assesse the need for corrosion and repair as per asset criticality.
• Conduct (physical) investigations to identify causes of failure and suggest mitigation measures (root cause analysis).

• Inspection technicians and chemists responsible for inspection programs.
• Corrosion technicians responsible for corrosion monitoring and field measurement.
• Asset integrity engineers responsible for equipment health,
• Operating (field) personnel responsible for collecting samples.
• QC technicians responsible for field examination and non- destructive testing.

The course will be delivered through a combination of lectures, case studies, group discussions, and practical exercises. Participants will engage in interactive sessions to enhance learning and practical application of concepts

Day 1 :

The benefit of applying inspection program

The cost of Corrosion

Basics of Corrosion

The Corrosion Cell

• Driving Force for Corrosion
• Voltage
• Metal Driving Voltage and Activity
• Electrolyte

Corrosion Rate

• Faraday’s Law
• Voltage Difference
• Reference Electrodes (Half-Cells)
• Standard Hydrogen Electrode (SHE)
• Copper-Copper Sulfate Electrode (CSE)
• Other Reference Electrodes
• Polarity
• Conversion Between Reference Electrode Values.

Polarization

• IR Drop
• Factors Affecting Polarization
• Current (Charge Transfer)
• Anode/Cathode Ratio
• Temperature
• Electrolyte/Electrode Movement Effect
• Electrolyte Concentration Effect (Interface Area)
• Passivity

Day 2

Forms of Corrosion

• Uniform Corrosion
• Localized Corrosion
• Pitting
• Crevice Corrosion
• Mesa Corrosion
• Weld Zone Corrosion
• Environmentally Assisted Cracking (EAC
• Flow-Assisted Damage

Potentially Corrosive Species

• Carbon Dioxide (CO2)
• Hydrogen Sulfide (H2S)
•  
• Microbiologically Influenced Corrosion

Environmentally Assisted Cracking Mechanisms

• Hydrogen Damage
• Hydrogen Induced Cracking (HIC)
• Hydrogen Embrittlement (HE)
• Stress-Oriented Hydrogen Induced Cracking (SOHIC)
• Sulfide Stress Cracking (SSC)
• Stress Corrosion Cracking (SCC)
• Liquid Metal Embrittlement (LME

Corrosion Mechanisms

• Galvanic Corrosion
• Concentration Cells

Flow-Assisted Damage Mechanisms

• Erosion
• Impingement
• Erosion-Corrosion
• Cavitation

Day 3

Inspection Methods

• Selection of Representative Inspection Locations
• Visual Inspection
• Magnetic Flux Leakage
• Ultrasonic Testing (UT)
• Manual UT
• Automated UT (AUT)
• Guided Wave Ultrasonic Testing Technology (GWUT)
• Eddy Current (EC)
• Radiographic Testing (RT)

Inspection Method Selection

• Wall Thickness Measurements
• Screening Tool/Quick Inspection
• Detection of Internal Cracking
• Pipeline Replacement / Internal Surface Exposed

Concept of Cathodic Protection

Polarization of a Structure

• Current Requirement
• Surface Area
• Examples (Bare and Coated)
• Polarization
• Effect of Environment pH on CP Current Requirement
• Temperature Effect on CP Current Requirement
• Effect of Oxidizers on CP Current Requirement
• Effect of Relative Movement Between the Structure and Electrolyte on
• CP Current Requirements

Applied Current vs. Corrosion Rate

Criteria for Cathodic Protection

• SP0169 Criteria

Designing for Corrosion Prevention

• Design
• Materials Selection
• Modification of Environment
• Cathodic and Anodic Protection
• Protective Coatings