Location

Date

Duration

Language

Discipline

Introduction

The annual losses due to corrosion and the cost of rectification run to several billion dollars in most of the countries.  High production under aggressive and extreme operational conditions necessitates the development of new materials which also have peculiar failure patterns. Thus, mankind is on continuous experimentation with products and processes. Yet material failure not only entails in loss of production but loss of life as well. Prediction of failure pattern, residual life measurements, preventive measures are all approaches in corrosion studies for safe and economic operation of plant and machinery

Objective

This course aims to provide the participants with an understanding of why and how corrosion occurs, and how the environment in the gas and oil installations is aggressive to iron and steel equipment, plant and structures. It is designed to give a practical approach to control corrosion and prevent failures. Presented are the basic concepts of corrosion, the metallurgy of iron and steel, and the mechanism of failure.  Participants learn the state of art of corrosion control and be able to apply it in day-to-day work, thereby ensuring safety, plant reliability and economy. It is an update of Corrosion problems which affect the oil and gas production and reduce the plant integrity. It necessitates an understanding that ageing plants can cause catastrophic failures and underlines the importance and methodology of inspection. This also imparts an awareness of the emerging technologies for corrosion control and failure prevention. Interactive discussions on photographs of plant failures and a working methodology of failure analysis reinforce the understanding of the theory taught.

Audience

Process Engineers, Inspection Personnel, Mechanical Engineers, Material Selection Personnel and Corrosion Personnel. For all technicians, supervisors and maintenance staff who are interested in knowing why some components fail more often than expected- A Corrosion awareness for all Plant Engineers who are interested in learning the fitness for service of plant  and equipment they are handling- For Safety Engineers who are interested in health safety and environment in case of unintended plant failure-for Finance Managers who are interested in knowing what affects production and asset management- and for all those who want to know more about inspection and monitoring.

Content

Day 1

The importance of the study

Introduction

Corrosion and society

What is corrosion?

Why is it important?

The social, economical and environmental impacts

Lessons from history

The liability due to corrosion

Interactive session on causes and possible avoidance

From the known to the unknown

The three classification of failures

Metallurgical

Mechanical

Electrochemical

What the metallurgists failed to see

Metallurgical

Thermodynamics- the energy transfer  principles

Why different metals react differently in same situation-Galvano’s experiments

The atoms and electrons that matters- Niels Bohr’s experiment

Live demo on corrosion in action

Describe one plant and machinery handled by you

What are the various auxiliaries connected to it  or what different metals are used in that fabrication.

Day 2 

Environment stronger than metals

Why metals fail often and more than in the past

Gas and oil installations- some process diagram

Steel-One metal in different aggressive environment

Gaseous environments- H2S, oxides of sulphur, carbon dioxide organo compounds, chlorine, ammonia

Liquid environments- crude, salt and seawater, wash water, effluents,bacteria

Solid environment- soils, sulphur, catalysts, trace metals

Pourbaix experiments and principles

Live demo on corrosion in action

 Learning to handle failures - Corrosion Basics

Definition of corrosion

Grouping the information from the photographs of failures

The eight forms of corrosion

Evolving a theory based on failure analysis – cause and effect

Relating to metallurgical, mechanical and electrochemical

One more finding-operational factors also influence corrosion

Velocity – impact on steel and stainless steel

Temperature- high temperature and oxidation , cryogenic

Pressure – pipeline systems, reaction towers  and storage vessels

Discussion on photographs showing failures due to stagnancy, erosion, cavitations, rupture, explosions - what factor was responsible for failure?

Write a process diagram ( indicate operational factors)

What are the input and output ( product impurities that affect plant performance)

Day 3  

First step to control

Measurement of loss (corrosion)

Faradays electric laws

Four components of corrosion cell

Tools that can be used in field- known simple NDT Techniques-UT, PT and RT

What do they tell us?

Mechanism of Corrosion

Tools  that are used in field and laboratory-microscopy, electrochemical analysis,

What do they tell us?

More sophisticated tools –just know about them

Some special corrosion problems related to oil and gas installations;

High temperature oxidation

Microbiologically induced corrosion

What are the operative conditions that affect production?

What are the failures noted in the past – by what tools?

Day 4

Step two- Preventive control

Mechanical aspects

Innovative Vs iterative Design

Fabricational issues

Metallurgical

Material selection vs environment

Galvanic effect

Flow and velocity effects

Temperature and creep effect

Stress

Chemical and electrochemical

Coating painting and lining

Deft definition

Classification and types for different environmental conditions

For atmospheric

Buried

Submerged

Internal

Importance of Surface preparation  & application

Why Coating defects occur and the causes of failure

Insulation  & Lining materials- high temperature appliances- furnaces, chimney

Under cladding issues- high temperature- energy losses and safety

Chemicals for fouling & corrosion control

Selection of inhibitors for

Production & recovery

Pipeline & tanks

Cooling water

Acid systems

Boiler water

Dosing methods

Economics and control

What are the type of maintenance/ preventive method used to measure avoid and control failure? What are the merits in each of them?

What do you know more than safety personnel?

Video on corrosion

Day 5

Ensuring reliability- Step three- Electrochemical and hi tech methods

 Cathodic Protection

Principles of CP

Galvanic and Impressed systems

Selection of material and design

Pitfalls and failure

Monitoring and control

Internal line Inspection

Planning for pigging of line

Various types of pigs

Data acquisition and study

Cost and limitations

Discussion

Corrosion awareness is important for operators/ inspection staff or maintenance staff?

Does corrosion awareness help in plant reliability, quality, productivity, and asset management.

Certificate

MAESTRO CONSULTANTS Certificate of Completion for delegates who attend and complete the training course

Methodology

Our courses are highly interactive, typically taking a case study approach that we have found to be an effective method of fostering discussions and transferring knowledge. Participants will learn by active participation during the program through the use of individual exercises, questionnaires, team exercises, training videos and discussions of “real life” issues in their organizations.
The material has been designed to enable delegates to apply all of the material with immediate effect back in the workplace.

Fees

$4000