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This corrosion short course aims to provide the candidates with an understanding of why and how corrosion occurs, the metallurgical and environmental factors influencing corrosion, and practical methods of corrosion control and failure prevention. They will be able to grasp the basic concepts related to corrosion, metallurgy and failure analysis, and to apply the state of the art technology in their workplace.

By the end of this course delegates will be able to:

·       Understand the fundamentals of material failure at normal and plant operating condition and why different material behave differently - strategic maintenance methods

·       Understand how plant aging can cause catastrophic failures and the methodology of inspection

·       Importance of monitoring and modern methods

·       Understand corrosion in other structural materials as concrete fiberglass and nonmetals

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, New Petroleum Engineers, Asset Management Personnel, Design & Construction Engineers, Team Leaders & Coordinators, Construction Coordinators, Maintenance Engineers, Technologists,  Maintenance Team Leaders & Engineers, 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

Basic Concepts in Corrosion

·       Introduction: economic, social, political and environmental impacts

·       How to avoid liabilities due to corrosion, Basic concepts

·       Terminology and convention, Primer in chemistry and electrochemistry

·       Potential-pH diagram, Kinetics of corrosion, High temperature oxidation

Metallurgy & Corrosion

·       Introduction to Metallurgy, Extractive metallurgy, Mechanical metallurgy

·       Physical metallurgy, Metals in the melting pot, Defects in metals

·       Point defects, Line defects, Volume defects

·       The iron-carbon phase diagram

·       The microstructure of common metals/alloys

·       Different Forms of Corrosion: Mechanisms, Recognition & Prevention

·       Uniform corrosion, Galvanic corrosion, Dealloying and Graphitisation

·       Crevice corrosion, Pitting corrosion

·       Intergranular corrosion and weld decay, Exfoliation

·       Filiform corrosion, Microbiologically-influenced corrosion (MIC)

·       Environment-sensitive cracking, Hydrogen damages

·       Corrosion fatigue, Fretting, Stray current corrosion

·       Erosion corrosion, impingement attack and cavitation damage

Failure Analysis & Prevention

·       General approach to failure analysis, General methods of failure prevention

·       Corrosion Resistant Coatings, Cathodic & Anodic Protection

·       Corrosion Inhibitors, Corrosion Testing & Monitoring

Weldment Metallurgy & Corrosion

·       Weldment metallurgy and weldment corrosion

·       Factors affecting weldment corrosion, Methods of welding

·       Welding austenitic SS vs carbon steel

·       Residual stress and stress concentration, Weld defects

·       Weld metallurgy, Weld metal composition

·       Iron contamination: its effects & removal

·       Heat tint: its effects & removal, Summary of fabrication defects

·       Precipitation of intermetallics in stainless steels

·       Microstructural features in SS

·       Precipitation of delta ferrite and Schaeffler Diagram

·       Alpha prime phase and 475°C embrittlement

·       Precipitation of intermetallics: submicroscopic sigma, chi and Laves phases

·       Chemical compositions of various intermetallics and phases

·       Time-Temperature-Precipitation diagrams for  sigma, chi and Laves phases and carbides

·       Effect of chemical composition on sigma precipitation

·       Effect of Nitrogen on sigma precipitation

·       Effect of cold working on sigma precipitation

·       Invisible (submicroscopic) sigma/chi phases and their effects on corrosion

·       Time-temperature-precipitation curves for various austenitic stainless steels: precipitation of carbides, sigma, chi and Laves phases

·       Intergranular corrosion, weld decay and knifeline attack

·       Sensitization of austenitic stainless steels

·       Cr profile along the grain boundaries

·       Effect of carbon, molybdenum and nitrogen on time-temperature- precipitation diagrams

·       Effect of cold working and applied stress

·       Sensitization of Ferritic Stainless Steels

·       Sensitization of Duplex Stainless Steels

·       Effect sulfide inclusions in stainless steels

·       Ferritic and duplex stainless steels

·       Nickel-chromium alloys, Aluminum alloys

·       Weld decay and knifeline attack on austenitic stainless steels

·       Weldment corrosion of various alloy systems

·       Austenitic stainless steels, Ferritic stainless steels, Nickel alloys

·       Duplex stainless steels, Carbon steels, Aluminum

·       CO2 and H2S Corrosion of various steels and alloys

·       Corrosion under insulation

·       Corrosion in seawater systems

·       Corrosion in atmosphere