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 on line monitoring.

Content

TOPICS COVERED

• Corrosion Basics
• Corrosion used by different HC streams (HP, LP, CRU lean gas, CRU 1st 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

COURSE OUTLINE

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 non aggressive condition-8 types of corrosion- micro and macro- corrosion in water – velocity and factors- cavitation- erosion-selective leachingpitting- filliform- 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 waste water-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 InhibitorBactericide-Emulsion Breakers- Flocculants-problem of inhibitors
Produced water separation and disposal problems- pH management and related problemsscale 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
Over head and heat exchanger problems

Day 4:

On line monitoring of water H2S, amine, combined and alone- hydrocarbon dew pointoverhead contactor- cryogenic extractor- NGL separation- molecular sieve control pipe line 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 solidssampling techniques- do’s and don’ts Analysis of-Solids- sludge types, depositscarbonates, 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- CUInegligence of timely action Introduction to MIC-Micro and macro organism – foulingTypes 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 in to groups), Role plays, 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. Very useful Course Materials will be given.

• 30% Lectures
• 30% Workshops and work presentation
• 20% Group/individual Work or projects & Practical Exercises
• 20% Videos& General Discussions, Case studies etc…