Course Details

Objective

From Corrosion Basics we learn all metal under a given environmental or operational conditions do not behave in the same manner and when the environment changes, the same metal’s behavior abruptly changes. From the excellent tools available now in Electrochemistry we are able to follow the failing patterns of metals; and from NDE methods we are able to assess what is going on. Metallurgical and optical tools as Microscopy, enable us to know what caused the damage This course blends all these modern technology and theory to get an inside out picture of the pains and aches of metals and materials which are subjected to high pressure, temperature and aggressive chemical situations that prevail in any oil field operation. The diagnosis is available on line and offline before or after failure and we get to know how to treat it.
This course is designed to create an understanding of the common corrosion forms, deteriorations mechanisms, corrosion control and corrosion monitoring principals used in oil, gas fields, and other industries in general.

Content

COURSE OUTLINE

Day 1 Why metals fail?

• Profile of the atom
• Crystal structure & grain boundaries
• C as impurity in Iron
• Environment that affects
• Corrosion basics

Day 2 Types of corrosion

• Macro the easy identifiable
• Galvanic
• Uniform
• Pitting
• Fretting and
• Filliform

Flow related

• Erosion
• Cavitations
• Impingement
• Selective leaching

Where they occur in oil field, their mechanism of failure and extent of damage and impact on reliability

Day 3 Chemical related problems

• CO2 corrosion
• Amine corrosion
• Chloride corrosion
• Acid corrosion
• Sour water corrosion
• Flue gas corrosion

What components are affected what is the pattern of failure, how to monitor and control?

• Other types of corrosion
  • Microbial induced
  • Hydrogen embrittlemnt
  • Corrosion under claddings
  • Stray current

Where do they occur in the plant and piping; how to monitor and control?

Day 4 Stress corrosion

• SCC in
  • Carbonate
  • Caustic
  • Naphthenic acid
  • Ammonia
  • Polythionic acids
  • Chlorides

Which are the metals affected and in which part of the plant?. Failure patterns cause and remedy

• Stress and fracture
  • Stress rupture
  • Creep rupture
  • Brittle fracture
  • Ductile fracture
  • Fatigue fracture
  • The many faces of wear

Patterns of fractography to indicate intergranular and intragranular failure mechanisms

Day 5 Temperature induced failures

• Oxidation
• Carburisation
• Decarburisation
• Sulphidisation
• Metal dusting
• Weld decay

Failures in selection of material

• Wrong selection
• Material composition impurities
• Rolling forming and extrusion defects
• Cold and residual stresses
• Fabrication and assembly stresses
• Welding heat affected zone/ crystal morphology

Each lecture has practical. A Manual for Practical with Sketch will be Provided

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

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.
All presentations are made in excellent colorful power point. Nearly a hundred graphics on failure would enable the participant to

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