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Seminars

Corrosion Control, Monitoring & Prevention in Petroleum Industry



Introduction:


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 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. 

Course Objectives:


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

 

  • Know the basics of corrosion mechanism
  • Learn about the corrosion forms
  • Microbial corrosion and its control
  • Material selection, coating, and chemical inhibition
  • Cathodic protection by galvanic anodes, and its design
  • Cathodic protection by impressed current system
  • Identify measurements in cathodic protection
  • Cathodic protection, and interference problems
  • Cathodic protection troubleshooting
  • Understand testing & monitoring techniques
  • Know the definition of corrosion and its principles
  • Know about the eight forms of corrosion and best ways to prevent it
  • Learn how cathodic protection works
  • Understand the effectiveness of pipeline coatings
  • Know the different type of pipeline coatings
  • Carry out coating failures analysis
  • Identify and understand the sacrificial anode cathodic protection
  • Identify and understand the impressed current cathodic protection
  • Know well the criteria for cathodic protection
  • Gain deep knowledge on the instrumentation used for cathodic protection of underground pipelines
  • Understand the importance of regular inspection and maintenance
  • Conduct pipeline inspection using survey methods and evaluation techniques
  • Learn the NACE standard on pipeline external corrosion direct assessment methodology

Who Should Attend?


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 

Course Outline:


Fundamentals of Corrosion

  • Why do metals corrode
  • How do metals corrode
  • General methods of corrosion control and prevention

 

Testing & Monitoring Techniques

  • 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

  • Introduction
  • How it works
  • Why it works
  • How effective it is

 

Sacrificial Anode Cathodic Protection

  • Anode materials
  • Anode design

 

Impressed Current Cathodic Protection

  • Consumable ICCP anodes
  • Permanent ICCP anodes
  • Power sources, cables and connections

 

Criteria for Cathodic Protection: Instrumentation for Cathodic Protection of Underground Pipelines

  • 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

  • Electrical resistivity
  • Resistance of ground connection
  • Non-uniform electrolyte
  • Groundbed design
  • Long pipelines and pipe insulating joints

 

Stray Current Corrosion and Methods of Prevention

  • Stray current corrosion and electrolysis
  • Practical stray current problems
  • Interference from other CP installations

 

Pipeline Coatings and the Effectiveness of Coatings

  • Specification
  • Inspection
  • Type of pipeline coatings
  • Coating failures and analysis

 

Cathodic Protection and Coatings: Pipeline Inspection: Survey Methods and Evaluation Techniques

  • 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

  • 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

  • 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

  • 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

  • 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

  • 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
  • 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

  • Cathodic protection of tank and vessel internals
  • Introduction
  • Design considerations
  • Sacrificial systems
  • Impressed current systems
  • Monitoring CP performance
  • CP design calculations

 

CP Attachments

  • 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

COURSE LOCATIONS

Code From To City Fee
C&M41 06 Jan 2020 17 Jan 2020 Bangkok US$ 7500 Book
C&M41 15 Mar 2020 26 Mar 2020 Cairo US$ 6500 Book
C&M41 03 May 2020 14 May 2020 Dubai US$ 7000 Book
C&M41 27 Jul 2020 07 Aug 2020 London US$ 8000 Book
C&M41 07 Sep 2020 18 Sep 2020 Tokyo US$ 9000 Book
C&M41 23 Nov 2020 04 Dec 2020 Kuala Lumpur US$ 7500 Book


DUBAI OFFICE

Ittihad Deira Building,
Al Ittihad Rd, Deira
Dubai,
UAE

info@petrogas-training.com

USA OFFICE

642 E14 Street,
10009-13 Manhattan,
New York (NY)
USA

info@petrogas-training.com

EGYPT OFFICE

52 General Kamal Hejab Street,
Suez Bridge,
Cairo,
Egypt

info@petrogas-training.com
 

COURSE CERTIFICATE

Certificate of Completion will be provided to the candidate(s) who successfully attend and complete the course. Training hours attendance percentage of 75% is required.


TRAINING HOURS

Standard course hours: 8:30 A.M. to 3:30 P.M. Informal discussions: 4:30 P.M. to 5:30 P.M.


TRAINING METHODOLOGY

We use a blend of interactive and hands-on methods, active participation, a variety of instructional techniques, dynamic presentations, individual and group exercises, in depth discussion, DVD’s, role-plays, case studies, examples. All of the information, competencies, knowledge and skills acquired within our training programs, are 100% transferrable to the participants’ workplace.


ASSESSMENT & EVALUATION

Pre-Test and Post-Test Assessment are applied on 5-day and 10-day programs. Also, post course evaluation and candidate’s evaluation are applied to add another level of quality measurement. Candidates’ feedback is highly appreciated to elevate the training service quality.


ORGANIZATIONAL IMPACT

A- Have staff trained in the latest training and development approaches

B- Support nationalization and talent management initiatives

C- Have properly trained and informed people who will be able to add value

D- Gain relevant technical knowledge, skills and competencies


PERSONAL IMPACT

A- Develop job related skills

B- Develop personal skills in subject matter

C- Have a record of your growth and learning results

D- Bring proof of your progress back to your organization

F- Become competent, effective and productive

G- Be more able to make sound decisions

H- Be more effective in day to day work by mastering job-related processes

I- Create and develop competency to perform job well


FREQUENT NOMINATIONS SCHEME

A- 10% discount after 05 candidates’ registration.

B- 15% discount after 10 candidates’ registration.    

C- 20% discount after 20 candidates’ registration.

D- 25% discount after 25 candidates’ registration.

E- 30% discount after 30 candidates’ registration

F- Higher discount rates will be offered based on work volume with different clients.  


SEVERAL NOMINATIONS ON THE SAME COURSE SCHEME

A- One extra free seat is offered on 4 candidates on the same course and dates.

B- Two extra free seats are offered on 6 candidates on the same course and dates.

C- Three extra free seats are offered on 8 candidates on the same course and dates.

D- Four extra free seats are offered on 10 candidates on the same course and dates.

E- Five extra free seats are offered on 12 candidates on the same course and dates.


REGISTRATION POLICY

Nominations to our public courses are to be processed by the client’s Training and/or HR departments. A refund will be issued back to the client in the event of course cancellation or seat unavailability. A confirmation will be issued to the relevant department official(s). 


CANCELLATION POLICY

If a confirmed registration is cancelled less than 5 working days prior to the course start date, a substitute participant may be nominated to attend the same course or a 20% cancellation charge is applied. In case of a no-show, a 100% fee will be charged.


PAYMENT POLICY

Payment is due upon receiving the course confirmation, invoice and/or proforma invoice. However; the fee due can be wire transferred to our bank account directly after course completion. Our bank details are illustrated on the confirmation, invoice and proforma invoice, as well. The above documents can be communicated electronically, i.e., in a soft copy or/and in hard copy based on customer’s request.


COPYRIGHT

© 2017. Material published by PETROGAS shown here is copyrighted. © 2017. All rights reserved. Any unauthorized copying, distribution, use, dissemination, downloading, storing in any medium, transmission, reproduction or reliance in whole or any part of this course outline is prohibited and will constitute an infringement of copyright.