Program Objectives:
By end of the course, participants should become able to:
- Describe the different HC streams (HP, LP, CRU lean gas, CRU 1st Stage,
- X manifolds, export gas, customer networks, etc.).
- Interpret corrosion theory.
- Describe effect of Bacteria on oil, water and gas piping and equipment.
- Describe corrosion mechanism and chemical reactions.
- Describe corrosion prevention/ control techniques.
- Corrosion inhibitors used in oil and gas industries, their specs and work mechanism
Delivery Method:
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.
Course Outlines:
Basics of corrosion
- Theory of corrosion
- Corrosion cell
- Corrosion reaction
- Corrosion rate
- Cost of corrosion
- Forms of corrosion
- Uniform (general) corrosion
- localized corrosion
- Pitting and crevice corrosion
- Stress corrosion cracking
- Hydrogen damage ( embrittlement / blistering)
- Galvanic corrosion
- Galvanic series of metals
Problems
- Problems relating to input material crude complexity and corrosivity-
- Water related problems Produce water-Desalter wash water-Hydro treater waste-Other waste water-a high volume – low
- toxicity waste. -Water separation and transport- site preparation, pumping, treatment equipment,
- storage equipment, management of residuals and associated corrosion problems.
- All that contains in crude Solids- silt sand carbonates, corrosion products Liquids- oil, condensate, TDS in water,
- Gases- soluble and insoluble- Oxygen, H2S, CO2 Bacteria
- types Flow related problems.
- Problem related to Treatment Chemical, Hydrate Inhibitor-Water Vapor:Dehydrator- Scale Inhibitor-corrosion Inhibitor- Bactericide Emulsion, Breakers- Flocculants-problem of inhibitors
- Produced water separation and disposal problems-
- pH management and related problems- scale
- removal and problem of sulphates-waste water and solids disposal-Environmental issues-salinity , and aquatic toxicity
- Crude distillation-process related problems
- The effect of Chemicals added to crude and water entering desalter
- The role of oxygen in presence of chloride, H2S, and CO2
- Desalter and mixed crude problems
- Over head and heat exchanger problems
Corrosion control
- Materials selection
- Metallic materials
- Non-metallic materials
- Advantages of using non-metallic materials
- Cost of material
Improved design
- Examples of avoiding erosion Corrosion by Design
- Examples of Avoiding Crevice Corrosion by Design
- Examples of Avoiding Crevice Corrosion by Design
- Corrosion Allowance
- Avoiding contact between dissimilar metals
Chemical treatment
- pH control
- Chemical injection system
- Removal of dissolved gases
- Corrosion inhibitors
- Biocides
- Chemical injection points.
Corrosion monitoring:
- Corrosion coupons;
- corrosion spools;
- instrumented corrosion spools;
- linear polarization probes;
- electrical resistance probes;
- hydrogen probes;
- galvanic probes;
- bio probe
- ultrasonic controls;
- radiographic controls;
- chemical analysis;
- micro-biological analysis
Corrosion monitoring points locations:
- Oil field gathering system
- Gas and gas condensate field gathering systems
- Oil treatment plants
- Gas treatment plants with glycol
- Gas treatment plants with amines
- Water injection plant
- Cooling water circuits
- Fire-fighting circuit with sea water.
Protective coatings:
- Types of coatings
- Surface preparation
- Painting application
- Paint technical data sheet
- Paint safety data sheet
- Paint inspection
- Surface roughness tools
- Holiday detector
- Dry film thickness
- Wet film thickness
Cathodic Protection:
- Principles of cathodic protection
- Application of cp systems
- Types of cp systems
- Sacrificial anode system
- Impressed current system
- Common sacrificial anodes
- Applications of sacrificial cathodic protection system
- Basics of impressed current system
- Applications impressed current system
- Cathodic protection criteria
- Cathodic protection monitoring.