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In some companies senior management has developed a policy of zero failures or no failures. In translating this management directive into reality, engineers and other operational experts manage corrosion using a combination of well-established strategies, innovative approaches and , if necessary, experimental trials, e.g. by applying smart & advanced corrosion testing or monitoring methodology to ensure plant reliability & prevent failures. The course is intended to provide an overview about corrosion, an often underestimated topic with relevance and potential to significantly improve plant performance per senior management’s expectations from several perspectives: guarantee plant safety to employees and the neighborhood in order to keep the license to operate & handle chemicals, fluids and gases, assure plant reliability & availability for optimal operations/production as part of Asset Integrity Management and contribute to minimize cost of ownership.

Based upon some scientific fundamentals the course provides insights why corrosion occurs, what matters in complex corrosions systems in order to ideally predict what would be happening and when if the wrong material of construction or corrosion protection & control would have been selected. Furthermore, the course presents commonly used method and tools, is illustrated by number of examples and authentic case histories and provides exercises & opportunities to apply the new knowledge & how to apply it in the day-to-day engineer or operator’s life.

By the end of this course delegates will learn about:

• Corrosion & corrosion control matters in the chemical & hydrocarbon industry
• The key parameters which determine corrosion occurrence and corrosion rate
• How to establish a framework for a Corrosion Management System (CMS) for your Company
• The key requisites for CMS implementation & what are prerequisites for success
• How can one predict corrosion processes relating to changes in process conditions
• What Corrosion Control & Protection Measures do plant engineers have to manage corrosion adequately?
• How you learn from the past and avoid reoccurring of failures RCFA as a systematic methodology to identify the cause of failures and implement counter measures & what standards, codes or consultants can help
• Managing corrosion inspection
• An overview about the importance & basic´s of corrosion with regard to Process Safety & Asset Integrity Management and Plant Reliability
• The key parameters which determine corrosion and how engineers can manage the corrosion with economical measures to meet the company’s objectives in various areas that really matter
• The methodologies available & relevant to tackle the subject of corrosion adequately

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

Fundamentals & Basics of Corrosion

• Cause for corrosion (thermodynamics, kinetics & electrochemistry
• Rate of electrochemical reactions
• Rate of corrosion
• Phenomenon Passivity
• Types of corrosion & its mechanism considering various materials of construction
• Corrosion in aqueous media & high temperature corrosion, e.g.: hot gases
• Industry related considerations (Hydrocarbon, Petroleum, Typical failure modes, etc.)
• Acids, cooling water, caustics, typical challenging media from the Oil, Gas & Petrochemical/Chemical industry, etc.
• Relevant API codes & recommended practices

Corrosion Management

• Objective: Ensure safe & reliable operation
• Definition of Corrosion Management Systems
• Planning & Implementation
• Definition of Corrosion Systems
• Corrosion Control & Protection Methodology

Corrosion Engineering

Definition & Importance of Corrosion

Basic Considerations

Fundamentals/Basics of Corrosion

Process & Media Specific Considerations

Corrosion Control

Protection Methodology

Method Assisting Materials & Corrosion Assessments

·     Fitness for Service Assessments

·     Microscopic Analysis for RCFA

·     Corrosion Testing

·     Standard & Advanced NDT Technology