DEFINE | Management Consultancy & Training

CORROSION PREVENTION IN OIL & GAS INDUSTRY

Location

Dubai, UAE

Date

From Date: 04-Sep-2023
To Date: 08-Sep-2023

Duration

5 Days

Language

English

Discipline

Introduction

Ref No:   WC024
Title:     Corrosion Prevention In Oil & Gas Industry
Start Date: 04 September 2023  End Date: 08 Septmber 2023
Venue: Dubai, UAE
Fee:       $5,250

In any of the 5 star hotels. The exact venue will be informed once finalized.

The annual losses due to corrosion and the cost of rectification run to several billion dollars in most of the countries. High production under aggressive and extreme operational conditions necessitates the development of new materials which also have peculiar failure patterns. Thus mankind is on continuous experimentation with products and processes. Yet material failure not only entails in loss of production but loss of life as well. Prediction of failure pattern, residual life measurements, preventive measures are all approaches in corrosion studies for safe and economic operation of plant and machinery.

Objective

This course aims to provide the participants with an understanding of why and how corrosion occurs, and how the environment in the gas and oil installations is aggressive to iron and steel equipment, plant and structures. It is designed to give a practical approach to control corrosion, and prevent failures. Presented are the basic concepts of corrosion, the metallurgy of iron and steel, and the mechanism of failure. Participants learn the state of art of corrosion control and be able to apply it in day-to-day work, thereby ensuring safety, plant reliability and economy. It is an update of Corrosion problems which affect the oil and gas production and reduce the plant integrity. It necessitates an understanding that ageing plants can cause catastrophic failures and underlines the importance and methodology of inspection. This also imparts an awareness of the emerging technologies for corrosion control and failure prevention. Interactive discussions on photographs of plant failures and a working methodology of failure analysis reinforce the understanding of the theory taught.

Audience

Process Engineers, Inspection Personnel, Mechanical Engineers, Material Selection Personnel and Corrosion Personnel. For all technicians, supervisors and maintenance staff who are interested in knowing why some components fail more often than expected- A Corrosion awareness for all Plant Engineers who are interested in learning the fitness for service of plant and equipment they are handling- For Safety Engineers who are interested in health safety and environment in case of unintended plant failure-for Finance Managers who are interested in knowing what affects production and asset management- and for all those who want to know more about inspection and monitoring.

Content

DAILY OUTLINE

Day 1

The importance of the study

Introduction
Corrosion and society
What is corrosion?
Why is it important?
The social, economical and environmental impacts
Lessons from history
The liability due to corrosion
Interactive session on causes and possible avoidance
From the known to the unknown
The three classification of failures
Metallurgical
Mechanical
Electrochemical
What the metallurgists failed to see
Metallurgical
Thermodynamics- the energy transfer principles
Why different metals react differently in same situation-Galvano’s experiments
The atoms and electrons that matters- Niels Bohr’s experiment
Live demo on corrosion in action
Describe one plant and machinery handled by you
What are the various auxiliaries connected to it or what different metals are used in that fabrication

Day 2

Environment stronger than metals

Why metals fail often and more than in the past
Gas and oil installations- some process diagram
Steel-One metal in different aggressive environment
Gaseous environments- H2S, oxides of sulphur, carbon dioxide organo compounds, chlorine, ammonia
Liquid environments- crude, salt and seawater, wash water, effluents,bacteria
Solid environment- soils, sulphur, catalysts, trace metals
Pourbaix experiments and principles
Live demo on corrosion in action

Learning to handle failures - Corrosion Basics

Definition of corrosion
Grouping the information from the photographs of failures
The eight forms of corrosion
Evolving a theory based on failure analysis – cause and effect
Relating to metallurgical, mechanical and electrochemical
One more finding-operational factors also influence corrosion
Velocity – impact on steel and stainless steel
Temperature- high temperature and oxidation , cryogenic
Pressure – pipeline systems, reaction towers and storage vessels
Discussion on photographs showing failures due to stagnancy, erosion, cavitations, rupture, explosions - what factor was responsible for failure?
Write a process diagram ( indicate operational factors)
What are the input and output ( product impurities that affect plant performance)

Day 3

First step to control

Measurement of loss (corrosion)
Faradays electric laws
Four components of corrosion cell
Tools that can be used in field- known simple NDT Techniques-UT, PT and RT
What do they tell us?
Mechanism of Corrosion
Tools that are used in field and laboratory-microscopy, electrochemical analysis,
What do they tell us?
More sophisticated tools –just know about them
Some special corrosion problems related to oil and gas installations;
High temperature oxidation
Microbiologically induced corrosion
What are the operative conditions that affect production?
What are the failures noted in the past – by what tools?

Day 4

Step two- Preventive control

Mechanical aspects
Innovative Vs iterative Design
Fabricational issues
Metallurgical
Material selection vs environment
- Galvanic effect
- Flow and velocity effects
- Temperature and creep effect
- Stress
Chemical and electrochemical

Coating painting and lining

Deft definition
Classification and types for different environmental conditions
- For atmospheric
- Buried
- Submerged
- Internal
Importance of Surface preparation & application
Why Coating defects occur and the causes of failure
Insulation & Lining materials- high temperature appliances- furnaces, chimney
Under cladding issues- high temperature- energy losses and safety

Chemicals for fouling & corrosion control

Selection of inhibitors for
- Production & recovery
- Pipeline & tanks
- Cooling water
- Acid systems
- Boiler water
Dosing methods
Economics and control
What are the type of maintenance/ preventive method used to measure avoid and control failure? What are the merits in each of them?
What do you know more than safety personnel?
Video on corrosion

Day 5

Ensuring reliability- Step three- Electrochemical and hi tech methods

Cathodic Protection

Principles of CP
Galvanic and Impressed systems
Selection of material and design
Pitfalls and failure
Monitoring and control
Internal line Inspection
Planning for pigging of line
Various types of pigs
Data acquisition and study
Cost and limitations
Discussion

Corrosion awareness is important for operators/ inspection staff or maintenance staff?
Does corrosion awareness help in plant reliability, quality, productivity, and asset management.

NOTE:
Pre & Post Tests will be conducted
Case Studies, Group Exercises, Group Discussions, Last Day Review & Assessments will be carried out.

Certificate

Define Management Consultancy & Training Certificate of course completion will be issued to all attendees.

Methodology

A highly interactive combination of lectures and discussion sessions will be managed to maximize the amount and quality of information and knowledge transfer. The sessions will start by raising the most relevant questions, and motivate everybody find the right answers. You will also be encouraged to raise your own questions and to share in the development of the right answers using your own analysis and experiences. Tests of multiple-choice type will be made available on daily basis to examine the effectiveness of delivering the course.
Very useful Course Materials will be given.

30% Lectures
30% Workshops and work presentation
20% Group Work& Practical Exercises
20% Videos& General Discussions

Course Details