Corrosion Monitoring in Oil & Gas Industry

COURSE OVERVIEW
 Corrosion is a major threat to the oil and gas, petrochemical and other
process-intensive industries and is responsible for countless of dollars in
damage and maintenance costs.
 Additionally, ageing equipment becomes more susceptible to corrosion and
loses its ability to withstand harsh operating environments (e.g. high
temperature and pressure).
 The purpose of a strong corrosion monitoring program is to improve safety,
reduce maintenance and inspection costs, and maximize efficiency.
 Corrosion monitoring plays a vital role throughout the equipment lifecycle.
 Inspection and monitoring strategies and techniques may change according to
the age and condition of equipment. Therefore, inspection and monitoring
strategies should be reviewed at specific intervals at the owner-operator’s
discretion.
 The goal of this course is to provide interested persons with a basic overview
of the theoretical and practical aspects of corrosion and its control.

Program Objectives
Upon completion of the course, participants will:
 Recognize the different inspection tools and techniques.
 Be able to evaluate how the cost of corrosion is.
 Have FOUNDATION Level understanding of how to Analyze annual
inspection plans and reports.
 Be able determine which pipelines need to be inspected.
 Assesse the need for corrosion and repair as per asset criticality.
 Conduct (physical) investigations to identify causes of failure and suggest
mitigation measures (root cause analysis).

 Inspection technicians and chemists responsible for inspection programs.

 Corrosion technicians responsible for corrosion monitoring and field
measurement.
 Asset integrity engineers responsible for equipment health,
 Operating (field) personnel responsible for collecting samples.
 QC technicians responsible for field examination and non- destructive testing.

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COURSE OUTLINES:
Day one
The benefit of applying inspection program
The cost of Corrosion
Basics of Corrosion
The Corrosion Cell
Driving Force for Corrosion
Voltage
Metal Driving Voltage and Activity
Electrolyte
Corrosion Rate
Faraday’s Law
Voltage Difference
Reference Electrodes (Half-Cells)
Standard Hydrogen Electrode (SHE)
Copper-Copper Sulfate Electrode (CSE)
Other Reference Electrodes
Polarity
Conversion Between Reference Electrode Values.
Portable vs. Stationary Electrodes
Polarization
IR Drop
Factors Affecting Polarization
Current (Charge Transfer)
Anode/Cathode Ratio
Temperature
Electrolyte/Electrode Movement Effect
Electrolyte Concentration Effect (Interface Area)
Passivity
Videos
Exercise I
Group study I

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Day Two
Forms of Corrosion
Uniform Corrosion
Localized Corrosion
Pitting
Crevice Corrosion
Mesa Corrosion
Weld Zone Corrosion
Environmentally Assisted Cracking (EAC
Flow-Assisted Damage
Corrosion Mechanisms
Galvanic Corrosion
Concentration Cells
Potentially Corrosive Species
Carbon Dioxide (CO2)
Hydrogen Sulfide (H2S)
Oxygen.
Microbiologically Influenced Corrosion
Environmentally Assisted Cracking Mechanisms
Hydrogen Damage
Hydrogen Induced Cracking (HIC)
Hydrogen Embrittlement (HE)
Stress-Oriented Hydrogen Induced Cracking (SOHIC)
Sulfide Stress Cracking (SSC)
Stress Corrosion Cracking (SCC)
Liquid Metal Embrittlement (LME)
Flow-Assisted Damage Mechanisms
Erosion
Impingement
Erosion-Corrosion
Cavitation
Videos
Exercise II
Group study II

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Day Three
Inspection Methods
Selection of Representative Inspection Locations
Visual Inspection
Magnetic Flux Leakage
Ultrasonic Testing (UT)
Manual UT
Automated UT (AUT)
Guided Wave Ultrasonic Testing Technology (GWUT)
Eddy Current (EC)
Radiographic Testing (RT)
Inspection Method Selection
Wall Thickness Measurements
Screening Tool/Quick Inspection
Detection of Internal Cracking
Pipeline Replacement / Internal Surface Exposed
Videos
Exercise III
Group study III
Day Four
Concept of Cathodic Protection
Polarization of a Structure
Current Requirement
Surface Area
Examples (Bare and Coated)
Polarization
Effect of Environment pH on CP Current Requirement
Temperature Effect on CP Current Requirement
Effect of Oxidizers on CP Current Requirement
Effect of Relative Movement Between the Structure and Electrolyte on
CP Current Requirements
Applied Current vs. Corrosion Rate
Criteria for Cathodic Protection
SP0169 Criteria

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Designing for Corrosion Prevention
Design
Materials Selection
Modification of Environment
Cathodic and Anodic Protection
Protective Coatings
Videos
Final Test (Multiple Choice Questions)
Review

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