Corrosion Control and Prevention

Day 1

• Welcoming and introduction
• Pre – Test Introduction to Oil & Gas Production
• Introduction of Corrosion
  • Introduction to Metallurgy and steel
  • Theory for Corrosion and its application
• Factors affecting Corrosion Rate
• Ferrous Alloys
• Definitions and classifications and some uses of ferrous alloys including:
  • Carbon steels
  • Alloy steels
  • Stainless steels
  • Cast irons
• Fabrication of Metals
• A selection of metal fabrication methods, including:
  • Forming
  • Casting
  • Welding
• Testing and Mechanical Properties of Metals
  • Tensile tests
  • Impact tests
  • Hardness tests
• Compression of mechanical properties
• Softening of metals by annealing
• Comparison of Cold and Hot working of Metals
• Case study: Non-Similar Materials Corrosion Degradation

Day 2

• Heat Treatment
  • Hardening of carbon steel (by quenching)
  • Annealing
• Normalizing
  • Tempering
  • Surface treatments
  • Heat affected zone (HAZ) in welding
• Non-Ferrous Alloys
  • Nickel and cobalt
  • Titanium alloys
• Corrosion Damage
  • Definition of Corrosion
  • Corrosion Basics
  • Corrosion Fundamentals
  • Factors Influencing Corrosion
  • Basic Corrosion Control in Gas, Oil & Water
  • Forms of Corrosion
  • Corrosion Monitoring in Plant and Facilities
  • Corrosion Failure & Root Cause analysis
  • Differentiate between Corrosion due to Dissolved Oxygen, Microbiological, CO2 H2S,
• Case study : Microbiological Induced Corrosion Accident

Day 3

• Cost of Corrosion
• Cause of Corrosion
• Types of Corrosion
• Uniform Corrosion and Local Corrosion
• Pitting
• Stress Corrosion Cracking (SCC)
• Hydrogen damage (Embrittlement / Blistering)
• Galvanic Corrosion
• Crevice Corrosion
• Hydrogen Embrittlement.
• Case study :  Thermal Chock Failure

Day 4

• Corrosion Control Technique
• Material selection
  • Effect of dissolved gases
  • Stream Velocity 
  • Fiberglass Type
  • Under Ground GRP Material
  • Limitation of Non-Metallic Material
  • Cost of material
• Improved Design
  • Examples of Impingement Corrosion
  • Examples of avoiding crevice corrosion by design
  • Incorporation of corrosion allowance
• Chemical treatment 
  • pH Control
  • Removal of Dissolved Gases
  • Application of Corrosion Inhibitor
  • Biocides role in corrosion control
  • Control of Microbial Corrosion
• Advantages of Corrosion Monitoring
• Corrosion Coupons
• Electrical Resistance (ER)
• On-Line Wall Thickness ( UT ) Measurements
• Forms of Corrosion (General)
• Forms of Corrosion (Localized)
• Forms of Corrosion (Stress Induced)
• Forms of Corrosion (Biological)
• Case study : High temperature Painting Failure

Day 5

• Types of Coatings
• Wrapping
• Protective Coatings
• Heat-Shrinkable Sleeves
• Wrapping & Sleeves
• Surface Preparation
• Water jetting
• Abrasive blasting (provides surface roughness): Sand blasting and Grit blasting
• Surface Profile
• Paint Application Methods
• Climatic conditions during painting application
• Paint inspection
• Holiday detector test
• Cross Hatch Adhesion Test
• Dry film thickness (DFT)
• Cathodic Protection
  • Application of CP system
  • Sacrificial anode system
  • Impressed current system
  • Cathodic protection monitoring
  • Potential Measurement
  • Reference electrode
  • Installation of CP system
  • Types of ground beds
  • Typical Under-Tank Cathodic Protection System for New Tanks
  • Impressed Current Cathodic Protection for Tank Internals
  • ICCP for jackets
  • Isolating flange kits
  • Casings for Road Crossings
  • Test Posts for CP Monitoring
• Stray-current corrosion
• Galvanizing, etc.
• Inhibitors, Types and usage
• Nelson Curve
• Corrosion Resistance Material, Stainless Steel, Monel, Hastelloy
• Case study: Creep Damage

Upon the successful completion of this course, each participant will be able to:

• Apply systematic techniques in metallurgy, corrosion and prevention of failure for plant, equipment and pipelines including material selection and properties
• Reduce corrosion and prevent failure of plant and equipment at the design stage or during the operation of the facility
• Assess the state of damage in plant, equipment and pipelines and implement the relevant repair technique
• Acquire a good background knowledge on the metallurgy of ferrous metals, nonferrous alloys and stainless steels as well as recognize the classification and heat treatment of steels and explain passivity and passive films on stainless steels
• Develop a good understanding on physical and mechanical metallurgy including crystal structure, phase diagrams, diffusion, phase transformations, T-T-T diagrams and C-C-T diagrams
• Discuss the materials, metallurgy and the general characteristics and mechanical properties of metals and alloys and describe welding metallurgy, non-destructive examinations and electrochemical principles
• Discuss the fundamentals of corrosion and identify its different forms in varying circumstances including atmospheric corrosion and corrosion by water and steam
• Describe cathodic protection, protective coatings and inhibitors as well as discuss the various aspects of high temperature corrosion, the prediction and control thereof
• Identify the different damage and failure mechanisms and the methods of failure prevention & inspection as well as carryout preventative and predictive maintenance

• Recognize the OSHA requirements for mechanical integrity as well as the API and ASME codes and standards related to the in-service, construction and repair.