Introduction:

This intensive course is specially designed for DAR Petroleum company in South Sudan to give adequate information, discussion and solution for corrosion associated problems, corrosion control, monitoring of corrosion, monitoring of corrosion control practices, corrosion testing and inspection procedures. The course was designed based on the knowledge of the operation and corrosion problems in Dar Petroleum Operating Company which had been known through the previous training courses conducted to DAR petroleum employee.

The intensive course will cover from A to Z the main points of corrosion, control, Inspection, Testing and monitoring of both corrosion process and of control methods. The course will focus on practical oilfield information, skills, and procedures for corrosion control, monitoring, testing and inspections.

The enormous cost of corrosion to industry can be significantly reduced through effective corrosion testing and monitoring. This corrosion course aims to present to the technologists and engineers a common corrosion testing and monitoring techniques that can be used to solve many of their most tedious and persistent corrosion problems. The corrosion course will provide the participants with a thorough understanding of the basic principles and the practical applications of some simple yet powerful techniques in corrosion testing and monitoring. For each technique, a step by step guide for performing the corrosion measurements will be described. This course provides an excellent avenue for corrosion practitioners, researchers, designers, technical managers, inspection and maintenance engineers, quality control personnel and those involved in failure analysis to update their appreciation of modern techniques for corrosion testing and monitoring. 

Course Objectives:

By the end of this course, delegates will learn about:

• Basics of Corrosion science
• Basics of protection and control methods
• Corrosion Measurements
• Corrosion Testing and Monitoring Techniques
• Inspection
• Applications of Corrosion Testing and Monitoring Techniques

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, 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 

Course Outline:

Introduction, Corrosion and society

·        The need for corrosion testing and monitoring

·        The cost of corrosion

·        Direct and indirect corrosion cost

Basic Chemistry and Physics

·        Atoms and molecules

·        Chemical reactions

·        Electrochemical cells

Basic Metallurgy

·        The Structure of metals

·        Mechanical properties

·        Strengthening of metals

·        Metal testing

·        Welding effects

Basic of Corrosion

·        What is corrosion and corrosion rate?

·        Why metals corrode?

·        Galvanic series

Classification of Corrosion

·        Internal corrosion

·        External corrosion

·        Atmospheric corrosion

·        Corrosion and Electrochemistry

·        Corrosion cell

·        Anodic and Cathodic reactions

·        Polarization

·        Potential

·        Passivation

Corrosion Forms and Types

·        Uniform corrosion

·        Pitting corrosion

·        Differential corrosion cells

·        Microbial Induced corrosion (SRB corrosion)

·        Erosion corrosion

·        Environmental induced corrosion (SSC, SCC, etc.)

Factors Affecting Corrosion Rate

·        Dissolved gases (H2S, CO2  and O2)

·        PH

·        Temperature

·        Pressure

·        Velocity

·        Environment (water) properties

Corrosion Monitoring

·        Why use corrosion monitoring?

·        Direct methods of corrosion monitoring

·        On-line monitoring system components and functions

·        Principle corrosion monitoring methods

·        Where & when to use it, How much does it cost?

Corrosion Monitoring and Testing Techniques

·        Water analysis

·        Iron counting (corrosion rate calculation)

·        Soil resistivity measurements

·        weight loss coupons (preparation, installation, retrieval, handling and calculating of corrosion rate)

·        Electrical resistance ER

·        Linear polarization resistance LPR

·        Hydrogen probes

·        Bio-probes

·        Scale coupons (identification of scale and scale like-hood)

·        Inelegant pigging of pipelines

·        Steel structure to soil potential (pipe lines and tanks)

Corrosion Mitigation Methods: Material Selection and Design

·        Selection criteria

·        Carbon steel for sour system

Corrosion Inhibitors

·        Evaluation, testing and selection of corrosion inhibitors

·        Application and injection methods

·        Laboratory and field test

·        Chemical management and requisition procedures

Sulphate Reducing Bacteria Control

·        Testing, evaluation and selection of biocides

·        Application method

Coating and Painting

·        Types of paintings and coatings
Paint testing (thickness, holiday detection)

·        Coatings performance evaluation

·        Coating inspection and Testing

·        Coating defects and failure

·        Coating repair

Cathodic Protection (Galvanic and Impressed Current)

·        Basics of cathodic protection

·        Types of cathodic protection

·        Cathodic protection for internal of process vessels and tanks

·        Cathodic protection for underground pipelines and external of tanks

·        Cathodic protection criteria

·        Cathodic protection monitoring and testing

Inspection: Common NDT Methods

·        Visual

·        Liquid Penetrant

·        Magnetic

·        Ultrasonic

·        Eddy Current

·        X-ray

Selection and Application of Monitoring and Testing Points

·        Inspection and monitoring of process plants

·        Inspection and monitoring of pipelines

·        Inspection and monitoring of storage tanks

Data Recording and Failure Analysis

·        An overview of standards related to corrosion, material selection, monitoring and inspection of tanks, coatings and pipelines maintenance and repair

COURSE LOCATIONS