This course is designed to provide practitioners, engineers, all levels of management details on the control of corrosion. It is assumed that the participants will be conversant with principles of electrochemistry and the general forms of corrosion, such as crevice, pitting, dealloying and inter-granular corrosion. The course is an educational one in which the participants will be given information which can then be applied to their own specific problems. Due to the wide ranging topic, industry specific guidelines can only be discussed in general terms. However the students will be better prepared to understand why they have corrosion problems and how to approach an industry specific solution.
The course is delivered as a series of 10 - 60 minute modules across two days of instruction, with time between modules for assimilation and discussion of the content. The delivery is highly interactive, and participants are encouraged to ask questions.
This course is designed to help corrosion professionals understand better the root causes of many of the common corrosion problems. The course covers the electrochemistry of corrosion, looking at electrode kinetics and then applies this understanding to specific industry challenges, such as pipelines, corrosion under insulation, splash zone corrosion, sour service and concrete degradation. There are 10 modules in the course, delivered over two days. In each module the problem is described and causes discussed, as well as appropriate mitigation strategies which can be adopted.
Supplementary materials are also provided. It is expected that each student should bring one challenge that they face so that they can work on the development of a solution to their problem.
WHO SHOULD ATTEND???
This course is specifically designed to increase awareness in the control of corrosion for
following personals . Pipeline expertise - Managers, Engineers, Production, Projects & Maintenance, Asset Management, Project Reliability, R&D, EHS, Corrosion Engineers & Specialists, Inspection Engineers & specialists, Operations Engineers, Designers .
WHICH ARE THE INDUSTRY???
Oil and Gas (Upstream & Down stream), Refineries, Cement, Processing Industry, Chemical Plants,
Textile, Pharmaceutical & Fine chemicals, Paper Distilleries / Breweries, solvent Extraction plants,
Food processing steel, Engineering & Heavy Engineering, Sugar, Automobile Industry.
Corrosion is an never-ending challenge where prevention and control play a vital role. A different approach to corrosion management at the design stage, material control etc can make the job of the
operations corrosion engineer easier. Yet there are challenges well beyond control design life, life extension . Corrosion control, it means prediction and diagnostics, and early corrosion detection is the easiest way to avoid costly material damage and failures.
Here is an analysis corrosion that can account to 60% of all maintenance and repair costs, economic factors must be considered as the most important constraint affecting both prevention and control.
A right strategy adopted with real protection and prevention can definitely be solution to this on going process.
Corrosion is the chemical or electrochemical reaction between materials, usually a metal, and its environment that result in deterioration of the material and its properties. Corrosion is generally initiated when atmospheric moisture (humidity)settels in metals. This moisture will act as a conductor.
Enabling the flow of electrons between high-energy areas (Cathodes) and low-energy areas (anodes) on metal Surfaces.
This electrochemical process results in the visible oxidation referred to as rust (iron, steel) white rust (galvanized steel) and some terms of corrosion are tarnish, pitting, flaking and spalling.
WHAT WOULD YOU MISS IF NOT ATTENDING IT
- No understanding of why their structures fail.
- More failures.
- More shutdowns.
- Losses in expenses leading to a bad reputation.
- Case studies are many and varied used to illustrate each point in corrosion.
Review of electrochemistry and Evans diagrams
Since corrosion is electrochemical, it is vitally important that students get a good grounding in
the fundamentals. This module is a summary of the material covered in the basic corrosion course, and is primarily a refresher/ introduction to electrode kinetics, primarily the Evans Diagram.
Corrosion Measurement Techniques
How is the rate of corrosion determined? There are several techniques, such as the use of coupons
periodic inspection, linear polarization and pigging. These techniques are discussed in detail in this
Pipeline Corrosion Control
Pipelines are used extensively and face many different corrosive threats. In this module we
discuss pigging and how to control corrosion, both the internal and external threats, as well as advice
on pipeline design and how to remediate old pipelines
Splash Zone Corrosion
Marine structure shave many corrosive threats, primarily due to immersion service and chlorides,
yet the hardest to control is corrosion in the splash zone. We discuss the causes and remediation
techniques which can control this.
Day 1 Exercises
Illustrative examples and calculations to reinforce the day's activities
Acid Gas Corrosion
Some of the most difficult to control corrosion comes from the acid gases, carbon dioxide and
hydrogen sulphide. We look at CO Mesa corrosion 2 as well as the damage hydrogen sulphide can
cause, primarily the cracking of susceptible steels, a review of NACE MR0175 is included in this
Day - 2
Concrete reinforcement bars (rebar) provides tensile strength to concrete structures. However rebar is not immune to corrosion and a major determinant of the life of a concrete rebar structure is the specifications in the design phase. We show how simple corrosion control techniques can dramatically increase the design life of structures.
Corrosion Under Insulation
This is a very common problem, and yet once the mechanism is understood, you can make simple
changes to your system which will eliminate the problem completely.
One of the simplest ways of increasing asset life is by reducing corrosion rates such that the life of the remaining corrosion allowance in your structure can be dramatically extended. Inhibitors make this possible. In this module we discuss what inhibitors are, how they work and how you can implement them to your system
You can spend weeks understanding how cathodic protection works. In this module we discuss the
principles of how it works, as well as looking at the common problems it can cause.
It is estimated that 70% of the cost of corrosion is due to the costs associated with applying protective
coatings. In this module we discuss the different types of coatings, how coatings work and most
importantly how to ensure effective coatings systems.
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