Course Overview:
- 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.
What are the Goals?
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).
Who Should Attend?
- 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.
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:
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.
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
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