• 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).

• nspection 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)
  • Oxygen.
  • 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