Practical Corrosion Management

THE WORKSHOP

Process plants such as refineries and petrochemical plants are complex facilities consisting of a wide range of equipments and system components and their design, engineering and upkeep involves a multidisciplinary team effort. Corrosion management has a pivotal role to play in maintaining the integrity of a facility, since a large number of incidents and failures that occur in process plants are found to be related to the phenomena of corrosion and erosion. This is more so in the face of increased requirements for improved productivity and cost effectiveness, combined with an increased emphasis on environmental and safety related issues. By effectively managing the critical parameters and activities related to corrosion and material degradation, sufficient cost savings and safety in operation can be ensured. By paying adequate attention to corrosion in aspects related to material selection, construction, operation and maintenance of infrastructure facilities, it is possible to achieve savings to the tune of billions of dollars in repair, maintenance, and replacement costs.

This course will cover the fundamental principles and concepts related to corrosion, the metallurgical and environmental factors that influence it, and the various methods employed for corrosion control and failure prevention. Upon completion of this course the attendees will have a clear understanding of corrosion management and will be able to apply the latest state of the art technologies and techniques in their workplace. The outcome will be a work force with the required skills and increased productivity levels. While the plant can be operated with increased safety and reliability, the extension in useful service life of the equipments will result in huge cost savings, promote safety and protect the environment.

WHAT IS INCLUDED?

  • Receive a certificate of attendance in support of your continuing professional commitment
  • All workshops include the associated hardcopy technical manual
  • Printed workshop handouts
  • Lunch and refreshments
  • Interact and network with workshop attendees and experienced instructors
  • Practical, industry driven content to assist you in your continuing professional development (CPD)
  • Attendees automatically become IDC subscribers and receive exclusive deals and technical content every month

WHO SHOULD ATTEND?

This course is designed for personnel who want to learn, understand and effectively implement the principles related to corrosion management, metallurgy and failure prevention. Those who will benefit the most from this workshop include the following:

  • Mechanical Engineers
  • Metallurgical Engineers
  • Chemical Engineers
  • Project and Design Engineers
  • Process Control Engineers
  • Technical Managers
  • Material Procurement Personnel
  • Equipment Designers and Engineers
  • Consulting Engineers
  • Plant Inspection and Maintenance Personnel
  • Quality Control Engineers
  • Weld Inspectors

CONTENT SUMMARY

INTRODUCTION TO CORROSION

  • Introduction
  • Definition of corrosion
  • Types of corrosion     
  • Cost of corrosion

CORROSION FUNDAMENTALS

  • Thermodynamic aspects of aqueous corrosion
  • Aqueous corrosion kinetics
  • Effect of concentration
  • Electrode potentials, anodic and cathodic reactions
  • Utilities Potential measurement with reference electrode, standard redox
  • EMF series
  • Exchange current density
  • Mixed potential theory
  • E-log (i) Evans diagram
  • Corrosion cells
  • Tafel equation and Tafel plot for corrosion rate determination
  • Linear polarization and Stern-Geary equation
  • Types of polarization and rate controlling step
  • Passivity and passivation behavior of iron in nitric acid
  • Effect of temperature and pressure on rate of corrosion
  • Effect of velocity on rate of corrosion
  • Definition and effect of pH
  • Dissolved gases and importance of dissolved oxygen

BASIC METALLURGY AND ELECTRICAL CONCEPTS

  • Introduction to metallurgy
  • Principles of Metallurgy
  • Defects in metals
  • Metallurgical factors affecting corrosion
  • Iron-carbon phase diagrams
  • Common ferrous and non-ferrous metals/alloys
  • Microstructure of common metals/alloys
  • Weldment metallurgy
  • Basic electrical concepts  

OXIDATION

  • Oxidation of metal and alloys
  • Oxidation resistance of low alloy steel
  • Environments
  • High temperature corrosion

CORROSION FORMS

  • Uniform corrosion
  • Aqueous corrosion
  • Atmospheric corrosion
  • Galvanic corrosion
  • De-alloying and graphitization
  • Stray current corrosion
  • Pitting corrosion
  • Crevice corrosion
  • Filiform corrosion
  • Effects of metallurgical variables on aqueous corrosion
  • Effects of metallurgical variables on the corrosion of stainless steels, Aluminum alloys and de-alloying corrosion
  • Erosion corrosion, impingement attack and cavitation damage
  • Stress corrosion cracking, stress corrosion
  • Inter-granular stress corrosion cracking, weld decay and knife-line attack
  • Hydrogen damage, hydrogen embrittlement
  • Selective leaching
  • Liquid metal induced embrittlement
  • Solid metal induced embrittlement
  • Sulfide stress cracking
  • Exfoliation
  • Caustic embrittlement
  • Corrosion fatigue
  • Fretting
  • Microbiologically influenced corrosion in metals

CORROSION UNDER SPECIFIC ENVIRONMENTAL CONDITIONS

  • Corrosion in atmospheres
  • Corrosion in portable water, natural waters and sea water systems
  • Corrosion in soils
  • Corrosion of reinforcement and concrete

DESIGN AND MATERIAL SELECTION FOR CORROSION PREVENTION

  • Introduction to methods of corrosion protection
  • Corrosion resistance properties of stainless steels
  • Corrosion resistance properties of cast iron
  • Corrosion resistance properties of carbon steel and low alloy steels
  • Nickel and nickel alloys
  • Aluminum and aluminum alloy
  • Magnesium and magnesium alloys
  • Copper and copper alloys
  • Titanium and titanium alloys
  • Zinc and zinc alloys
  • Tin and tin alloys
  • Corrosion resistance of non-metallic materials

CORROSION PROTECTION METHODS

  • Surface treatment and conversion coatings
  • Ceramic, glass and oxide coatings
  • Metal coatings
  • Coatings and linings
  • Electrochemical corrosion control methods
  • Cathodic and Anodic protection
  • Corrosion inhibitors

FAILURE ANALYSIS AND PREVENTION

  • General approach to failure analysis
  • Rudiments of Corrosion Failure Analysis
  • General methods of failure prevention
  • Preventing Corrosion Failures by Design

CORROSION TESTING AND MONITORING

  • Basics of corrosion monitoring
  • Corrosion testing and monitoring techniques
  • NDT for off-line monitoring

BRIEF DISCUSSION ON CORROSION FOR DIFFERENT INDUSTRIES

  • Marine corrosion
  • Food industry
  • Pulp and paper industry
  • Aerospace industry
  • Mining industry
  • Electronics industry

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