Course Details
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Course Description
Maintaining the ageing of metallic structures such as underground pipelines, vessels, and storage tanks is a challenge to the oil and gas industry worldwide. Understanding why and how corrosion, and corrosion control techniques work or fail can help the operator formulate appropriate strategy in managing the corrosion problems. This corrosion course will also provide participants with an understanding of why and how corrosion occurs, the metallurgical and environmental factors influencing pipelines corrosion, and practical methods of corrosion control and failure prevention to manage the pipelines corrosion problems.
The Training Course Will Highlight ?
The course is particularly directed at inspection and maintenance engineers who are concerned with corrosion of the structures of petroleum production. This course covers both the fundamentals and practices in designing, operating and maintaining corrosion and corrosion control for petroleum metallic structures.
Training Objective
The course is particularly directed at inspection and maintenance engineers who are concerned with corrosion of the structures of petroleum production. This course covers both the fundamentals and practices in designing, operating and maintaining corrosion and corrosion control for petroleum metallic structures.
Target Audience
Corrosion Control Engineers & Personnel, Process Engineers, Metallurgists, Inspection Personnel, Mechanical Engineers, Material Selection Personnel, Plant Contractors, Operations Engineers, Team Leaders & Supervisors, Maintenance Supervisors, Senior Plant Supervisors, Mechanical Engineers, Corrosion Control & Monitoring Systems Personnel, Oil and Gas Production Facilities Personnel, Chemists, Chemical Engineers, Technicians and Supervisors, Personnel who are / will be responsible for detecting, inspecting, monitoring, controlling corrosion in oil and gas piping, pipelines used in production operations and Personnel responsible for metallurgy, corrosion or the prevention of failures in plant and equipment
Training Methods
This interactive Training will be highly interactive, with opportunities to advance your opinions and ideas and will include;
- Lectures
- Workshop & Work Presentation
- Case Studies and Practical Exercise
- Videos and General Discussions
Daily Agenda
Fundamentals of Corrosion
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- Why do metals corrode
- How do metals corrode
- General methods of corrosion control and prevention
Testing & Monitoring Techniques
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- What is corrosion monitoring?
- The aims of corrosion monitoring
- What are the corrosion monitoring methods?
- Corrosion test objectives
- Significance of corrosion rate values
- Corrosion monitoring location & technique
- Design of corrosion monitoring location
- Conventional techniques of on-line corrosion monitoring
- Probe insertion / retrieving on- line
- Intelligent pipeline pigging
Cathodic Protection
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- Introduction
- How it works
- Why it works
- How effective it is
Sacrificial Anode Cathodic Protection
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- Anode materials
- Anode design
Impressed Current Cathodic Protection
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- Consumable ICCP anodes
- Permanent ICCP anodes
- Power sources, cables and connections
Criteria for Cathodic Protection: Instrumentation for Cathodic Protection of Underground Pipelines
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- Reference potential devices
- Potential measuring instrument
- Soil resistivity test instruments
- Wall thickness and pit gages
- Current interrupters
- Test rectifiers
- Holiday detectors
Cathodic Protection of Underground Pipelines
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- Electrical resistivity
- Resistance of ground connection
- Non-uniform electrolyte
- Groundbed design
- Long pipelines and pipe insulating joints
Stray Current Corrosion and Methods of Prevention
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- Stray current corrosion and electrolysis
- Practical stray current problems
- Interference from other CP installations
Pipeline Coatings and the Effectiveness of Coatings
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- Specification
- Inspection
- Type of pipeline coatings
- Coating failures and analysis
Cathodic Protection and Coatings: Pipeline Inspection: Survey Methods and Evaluation Techniques
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- Survey methods for pipeline not under cathodic protection
- Survey methods for pipeline under cathodic protection
- Overview of NACE Standard on Pipeline External Corrosion Direct Assessment Methodology
Corrosion Principles
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- Introduction
- References and definitions
- References
- Definitions
- Why metals corrode
- Corrosion defined
- Metal ores
- Chemical free energy
-
- Nature of corrosion reaction
- Corrosion by water
- Voltage source
- Electrical circuits
- Polarization
- Nature of metals
- Inhomogeneities in metal surfaces
- Effect of electrolyte composition
- Conductivity
- Hydrogen ion Concentration (pH)
- Dissolved gases
- Oxygen
- Carbon dioxide
- Hydrogen sulphide
- Chloride ions
- Physical variables
- Temperature
- Pressure
- Velocity
- Forms of corrosion
- Uniform corrosion
- Pitting corrosion
- Bimetallic corrosion
- Flow enhanced corrosion (erosion corrosion)
- Cavitation corrosion
- Intergranular corrosion
- Hydrogen induced failures
- Sulphide stress cracking
- Stress corrosion cracking
- Corrosion fatigue
- Microbiologically influenced corrosion (MIC)
- Oxygen corrosion
-
- Sweet corrosion (CO2)
- Sour corrosion (H2S)
Attachments
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- Free energies of metal oxides
- Galvanic series in sea water
- Galvanic corrosion material selection guide
- Corrosion cell
- Zinc-copper corrosion cell
- Electromotive force series
- Polarization curve
- Corrosion rate of steel vs. pH
- Corrosion rate of steel vs. O2
- H2S service induced cracking of steels
- Qualitative categorization of coupon corrosion rates for oil production systems
- Corrosion rate of steel vs. CO2
Fundamentals of Corrosion Mechanisms
-
- Introduction
- Wet corrosion
- Electrochemical reactions
- Electrode potentials
- Polarization and corrosion rates
- Forms of wet corrosion
- Dry corrosion
- High-temperature oxidation
- Hydrogen sulfide corrosion
- Biological corrosion
- Influence of microorganisms
-
- Control of corrosion caused by microorganisms
- Influence of macroorganisms
- Glossary
- References
Corrosion Monitoring Techniques
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- Electrical resistance probes
- Electrochemical linear polarization method
- Corrosion test nipples (spools)
- Corrosion coupons
- Iron counts
- Corrosion products analysis
- Ultra sonic gauges for surface inspection
- Procedure for retrieving corrosion monitoring devices under pressure
- Identify and explain in detail the procedures and problems associated with coupons and probe retrieval and installation
Basics of Corrosion Prevention
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- What is corrosion
- The consequences of corrosion
- Chemistry of corrosion
- Factors that control the corrosion rate
- Corrosion prevention
- Conditioning the metal
- Coating the metal
- Alloying the metal
- Conditioning the corrosive environment
- Removal of oxygen
- Corrosion inhibitors
-
- Electrochemical control
- Cathodic protection
Fundamentals of Cathodic Protection
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- Contents
- Mechanism of corrosion
- Electrochemical concept of corrosion
- Fundamental corrosion reactions
- Corrosion cells
- Galvanic corrosion
- Mechanism of cathodic protection
- Corrosion cells and cathodic protection
- Basic electrical concept
- Types of cathodic protection systems
- Sacrificial anodes
- Impressed current system
- General considerations
- Polarization and current required for cathodic protection
- Metal surface area
- Effect of pH on current requirement
- Effect of temperature
- Effect of oxygen
- Effect of relative movement between the structure and electrolyte
- Effect of soil salinity
- Effect of time on polarized potential
- Criteria of cathodic protection
- Potential criterion
- Polarization shift criterion
- Secondary effects of cathodic protection
- Change in pH
- Calcareous coating
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- Electro-osmosis
- Cathodic interference
- Direct current (DC) interference
- Mitigation of DC interference
- Alternating current (AC) interference
- Mitigation of AC interference
- Communication interference
- Safety considerations
- Glossary
- References
CP Principles: CP for Special Applications
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- Cathodic protection of tank and vessel internals
- Introduction
- Design considerations
- Sacrificial systems
- Impressed current systems
- Monitoring CP performance
- CP design calculations
CP Attachments
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- Cathodic protection tasks
- Explain the criteria of potential level requirements for protecting a buried carbon steel pipeline
- Explain the objective of cathodic protection technique and where it is applied
- Explain the effect of over protection on the coating of a buried structure
- Demonstrate the ability to carry out maintenance of CP system unsupervised and capable of solving technical problems on his own
-
- Explain the various survey techniques, interpretation of measurements, suggesting corrective action required and reporting
- Get familiar with interference, stray current and can identify interference in the CP protected system
- Identify and explain in detail the hazards associated with cathodic protection
Accreditation
BTS attendance certificate will be issued to all attendees completing minimum of 80% of the total course duration
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