Course Details

Objective

This course aims to provide the participants with an understanding of why and how corrosion occurs, the metallurgical and environmental factors influencing corrosion, and practical methods of corrosion control and failure prevention.  Participants will be able to grasp the basic concepts related to corrosion, metallurgy and failure analysis, and to apply the state-of-the-art technology in their workplace with an aim to achieve low-cost reliability.  This course is designed to take a break and learn why problems persist in different parts and plants and machinery and how to address them by careful online monitoring.

TOPICS COVERED

• Corrosion Basics
• Corrosion used by different HC streams (HP, LP, CRU lean gas, CRU 1^st stage, X manifolds, export gas, Customer Networks etc.)
• Differentiate between corrosion coupons, corrosion rings, corrosion probes, etc.
• Bacteria corrosion due to microbial, H2S & Water.
• Basic corrosion control in gas, oil & water
• Corrosion analysis and remedial actions
• Integrity Management

Content

Day 1:

• Problems relating to Carbon steel, the common metal used in refinery equipment.
• Manufacture and Physical properties of carbon steel-Trace elements that alter the properties significantly- Grain boundary problem-Types of carbon steel used in refining-Addition of Cr Ni etc. and effects –stainless steels.  
• Environment that affects metals
• Water and atmosphere- simple nonaggressive condition-8 types of corrosion- micro and macro- corrosion in water – velocity and factors- cavitation- erosion-selective leaching-pitting- filiform- MIC- Galvanic Corrosion - Atmospheric Corrosion- Uniform or Localized Loss of Thickness Factors that influence corrosion Stress assisted corrosion-Hydrogen embrittlement-HIC- 

Day 2:

• Problems relating to input material crude complexity and corrosivity- Water related problems. 
• Produce water-Desalter wash water-Hydro treater waste-Other wastewater-a high volume - low toxicity waste. -Water separation and transport- site preparation, pumping, treatment equipment, storage equipment, management of residuals and associated corrosion problems.  All that contains in crude Solids- silt sand carbonates, corrosion products Liquids- oil, condensate, TDS in water, Gases- soluble and insoluble- Oxygen, H2S, CO2 Bacteria-types Flow related problems.  
• Problem related to Treatment Chemical
• Hydrate Inhibitor-Water Vapor: Dehydrator- Scale Inhibitor-corrosion Inhibitor- Bactericide-Emulsion Breakers- Flocculants-problem of inhibitors 
• Produced water separation and disposal problems- pH management and related problems- scale removal and problem of sulphates-waste water and solids disposal-Environmental issues-salinity and aquatic toxicity. 
• NORM in produced water- radium-226 and radium228-surface, temperature changes and precipitation.  

Day 3:

• Multiphase problems- temperature, water-oil partitioning, water chemistry and flow patterns-impact on metallurgy of pipe material-type of corrosion products formed on the steel surfaces-, inhibitor ad- sorption on suspended particles-- inhibitor accumulation on gas bubbles, oil/water droplets and emulsions. Flow patterns and types of corrosion   

• Crude distillation-process related problems  
• The effect of Chemicals added to crude and water entering desalter.
• The role of oxygen in presence of chloride, H2S, and CO2 
• Desalter and mixed crude problems 
• Overhead and heat exchanger problems  

Day 4:

• Online monitoring of water H2S, amine, combined and alone- hydrocarbon dew point- overhead contactor- cryogenic extractor- NGL separation- molecular sieve control pipeline quality- liquefaction and storage-consumer and product line analysis for moisture and Sulfur-in LNG and LPG-re gasification and recheck H2S- hyd. carbon dew point on vaporization.
• NDT and lab testing-measuring corrosion 
• Coupons and probes – what information we get-Sample collection- precautions and methodology-Field testing- simple instruments- Sample collection of oil water and solids- sampling techniques- dos and don’ts Analysis of-Solids- sludge types, deposits- carbonates, Liquids-water –pH –temperature- soluble H2S- CO2-Gase s- CO2. 
• Corrosion control 

Day 5

• General methods of control- coating- cathodic protection-selection of alternative material and design- inhibitors and chemicals – biocides Use of non-metallics- Fiber glass and composites- concrete – rubber –Corrosion Resistant Alloys.   corrosion Video- CUI- negligence of timely action Introduction to MIC-Micro and macro-organism – fouling-Types of bacteria in crude lines- case study of fouled oil lines- PIM-what is Pipeline Integrity Management- How it is important- Role of laboratory staff 

NOTE:

Pre & Post Tests will be conducted

Case Studies, Individual & Group Exercises, Project works (making into groups), Role plays, Group Discussions, Last Day Review & Assessments will be carried out.

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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 motivating everybody to find the right answers. You will also be encouraged to raise your questions and to share in the development of the right answers using your analysis and experiences.  Tests of the multiple-choice type will be made available daily 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