Corrosion Control and Prevention
Sculpt Your Skills & Knowledge of Corrosion Control and Prevention from The Expert!
Level
Intermediate
Type
Facetoface
Trusted by Leading Companies
Our training programs are promoted to engineers, supervisors, and technical teams across the globe, supporting their continuous development and operational competency.
About Training
Corrosion: this section of the course focuses on the fundamentals of corrosion as well as the potential problems caused by corrosion. It provides a review of the causes of corrosion and the methods for identification, monitoring and control. An understanding of corrosion and its control is vital for any company hoping to avoid the high costs that can be directly or indirectly attributed to corrosion. This section of the course also presents fundamental principles of corrosion and assists participants in recognizing corrosion problems, determining their causes, and understanding and selecting control methods. Emphasis is on the practical applications of corrosion technology to solve industrial corrosion problems.
Prevention and Control of Corrosion failures: this section of the course is concerned with the prevention of failures, the assessment of the state of damage in plant and equipment, and the use of failure analyses, inspection data, and operating history in predicting safe operating life or determining necessary remedial measures. Maintenance requirements, risk-based inspection (RBI) procedures, and the fitness-for-service (FFS) approach will be discussed along with the various mechanisms leading to damage and potential failure, mechanisms of accumulation, and predictive methods.
Material: this section of the course discusses metals and the metallurgical characteristics of various metals. It provides an explanation of physical characteristics of metals, including the reason metals behave differently than non-metals. This section of the course also explains how and why different metals are selected for specific environmental purposes, including resistance to wear, corrosion, heat, cold, repeated stress, and impact. This is a lecture and problem-solving section that also deals with the metallurgical aspects of welding. Emphasis will be placed on mechanical metallurgy, materials selection, and the fundamentals of welding technology, welding metallurgy, inspection and quality of welds.
Training Objectives
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.
Audiences
This course is intended for those who use or supervise activities requiring the use of metal parts or structures.
Those with little or no prior formal background who function as:
- Supervisors
- Facility integrity engineers
- Corrosion Specialists.
- Metallurgy and corrosion engineers
- Materials engineers
- Inspection engineers
- Engineers
- Planners
- Inspectors
- Designers
- Purchasers
- Chemical Engineers
- Welding Engineer
- Inspection Engineers
- Researchers
- Investors
- Lab Personal
- Other Technical Staff
And who seek a basic understanding of the practical aspects of metallurgy should find this course valuable, senior engineers and managers will be able to develop their interpretive skills in data analysis. Furthermore, the course is ideal for all engineers and technical staff whose responsibilities include the reduction of corrosion and the prevention of failure either at the design stage or during operation of the facility.
Instructor
ME
M. El-Sayed Mahmoud Shama
Mohamed Shama is a senior inspection engineer with over 23 years of extensive experience within the petrochemical, refinery, utilities and oil and gas industries.
He conducted training for API Certification Preparatory, Corrosion and Prevention, National Board and ASMPE PCC-2, ASME VIII Division 1 & 2, ASME V, ASME IV, Lifting Equipment Courses, CSWIP 3.2 and 3.1 Welding Courses, Pressure Relief Valves, NDT Techniques Training Courses.
He has experiences and involve in many huge shutdowns in the oil and gas field including supervision of inspectors and technicians and performing internal inspection for all kind of Piping Systems, Pressure Vessels, Tanks, Boilers, Heat Exchangers, Filters, Towers, Coolers, Columns, Drums and Incinerators, Heaters, Driers, Air Vessels, MCHE, Hot Oil Waste Heat Recovery Units, Spheres, ISO-Containers, Bullets and all kind of refractory materials shaped and un-shaped.
Daily Aims
- 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
- 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
- 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
- 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
- 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
Training Schedule
Why Choose This Training
Credibility
Align with API/ASME standards. Trusted by major operators.
Expert Instructors
Led by industry veterans with real field experience.
Real Case Studies
Practical application of concepts through real world scenarios.
Practical Skills
Hands on calculations and decision making for FFS outcomes.
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Delivered to Aramco, ADNOC, SABIC, and other major operators.
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Recognized across major industries by PetroSync's proven approach.
Professional Training Aligned with Industry Standards
Practical, industry ready training designed for real work environments
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If PetroSync cancels, postpones, changes the trainer, or alters the training location (classroom/virtual) for any reason, and the delegate is unable or unwilling to attend on the rescheduled date, a 100% credit voucher of the paid contract fee will be issued. This credit voucher can be used for another PetroSync training program, subject to mutual agreement, within one year from the postponement date.
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