Introduction
Maintaining the ageing infrastructure such as underground pipelines is a challenge to the oil and gas, refinery operating and oil production/exploration industry worldwide. Corrosion is one of the major causes of ageing the industrial infrastructures. Understanding its mechanism and how to control it can lead to a remarkable reduction in the operation cost of piping and static equipment.
Cathodic Protection (CP) is one of the most widely used methods to control corrosion control in industry. The Cathodic Protection is a method of that eliminates the corrosion of metals by the use of sacrificial anodes or the application of an electric current. It is a technique that has been known for 160 years, and is extensively applied to pipelines and tank farms, etc with great success. However, despite this long history and broad applicability, it is a technique that is all too often inadequately or even improperly applied; with the result that structures are poorly protected or, worse, adversely interfered with.
This training course provides you with fundamental principles, evaluation and applications of Cathodic Protection, helping participants recognize them, select Cathodic Protection control methods and apply them to protect the assets of the organization.
Course Objectives
This training course is designed to provide:
- The theoretical basis and the practical ability necessary operate and maintain Cathodic Protection (CP) systems in the oil and gas surface production facilities
- Understanding of the basic principles of corrosion and applications of galvanic and impressed current Cathodic Protection CP systems
- Understanding of the field equipment used to monitor Cathodic Protection CP systems and how they work
- Understanding of the various factors that impact the performance of these systems
- Learn about essential Cathodic Protection CP monitoring techniques to ensure effective operation
- Understanding of increase productivity by avoiding costly shutdowns thus reducing the cost of the overall corrosion control program
- Understanding of increasing safety issues by eliminating accidents, fires or explosions
Who Should Attend?
This training course is suitable for personnel who are working in technical areas related to materials, maintenance and integrity who deal directly or indirectly with cathodic protection. They include:
- Professionals involved in designing, selecting, sizing, specifying, installing, testing, operating and maintaining systems.
- Professionals, Technologists, Supervisory personnel, Senior Engineers, Team Leaders and Managers engaged in the refinery operation and oil production/exploration activities, who have a considerable experience and who are required to understand and discuss issues related to their processes.
- Process Engineers, Technologists, Supervisory personnel Engineers, Team Leaders and Managers engaged in the refining activities who have a minimum of experience and who are required to understand and discuss issues related to their processes.
- Corrosion and Inspection: Supervisors, Engineers, Team Leaders and Managers.
- Health, Safety and Environment (HSE): Supervisors, Engineers, Team Leaders and Managers
- Mechanical Maintenance and Maintenance Planners: Supervisors, Engineers, Team Leaders and Managers.
- Oil and Gas Operation and Manufacturing (Upstream/Downstream): Filed/Control Room Operators, Supervisors, Engineers, Team Leaders and Managers. And scientific personnel with limited or no broad refinery operating experience, along with technical sales personnel.
- Those involved in selling equipment or supplies to the refining industry and those involved with economic evaluations of refinery operations will benefit from this training course.
- Those involved with economic evaluations of refinery operations and oil production/ exploration will benefit from this training course.
Course Outlines
Principles and Types of Corrosion and Corrosion Control
Section I – Significance of Corrosion Control
- Corrosion – Largest Single Cause of Plant Failure
- Economic Effects
- Environmental Effects
- Health, Safety and Environment (HSE): Effects
- Corrosion Management Preventive Strategies
- Cost of Corrosion
- Case Study: Catastrophic Corrosion Accidents
Section II – Corrosion & its Control
- Requirements for Corrosion to Occur
- Metallurgical Factors
- Forms of Corrosion
- Corrosion Control Methods
- Environmental Modification
- Protective Coatings
- Introduction to Cathodic Protection
Corrosion Environment, Material Selection and Elements of Cathodic Protection
Section III – Corrosive Environments & Construction of Materials
- Atmospheric Environments
- Marine atmospheres
- Industrial Atmospheres
- Underground Environments
- Material Selection
- Corrosion Properties of Steels
- Concrete Structure Environment
Section IV – Fundamentals of Cathodic Protection Systems
- Galvanic Series
- General Application of Cathodic Protection
- Industry Standard & Codes
- Principle of CPS
- The Cathodic Protection Cell
- Methods of Applying Cathodic Protection
- Sacrificial Cathodic Protection System
- Impressed-Current Cathodic Protection System
- CPS Selection
- Basic Requirements for Cathodic Protection
- Cathodic Protection Criteria
- Current Rectifiers/DC Power Source
- High Impedance Voltmeter
- Reference Cells (Half Cells) Reference Cells
- Applicable NACE Standard for Cathodic Protection Systems
Cathodic Protection Systems Design and Coating Issues
Section V – Cathodic Protection System Design
- Design Factors
- Electrolyte resistivity survey
- Electrolyte pH survey
- Structure versus electrolyte potential survey
- Current requirement
- Coating resistance
- Protective current required
- Sacrificial anode (galvanic) cathodic protection design
- Impressed current cathodic protection system design
- Soil resistivity
- Current requirement test
- Typical CPS Design Parameters
Section VI – Cathodic Protection Systems and Coatings
- Role of Protective Coating in CPS
- Selection Factors
- Coating Defects
- Coating Efficiency
- Overvoltage
- Cathodic Disbondment
- Commonly used Coating in Conjunction with CPS
Cathodic Protection Anodes and Construction
Section VII – Anodes & Rectifiers
- Anode Selection
- Anode material types, magnesium, zinc, aluminum, etc.
- Current output
- Driving Potential
- Anode life
- Anode Shape & Dimension
- Anode Efficiency
- Galvanic Anode Types
- Anode Backfilling
- Installation of Sacrificial Anodes
- Impressed Current Anode Beds
- Impressed Current Rectifiers/DC Power Source
- Cathodic Protection Equations
- Solved Cathodic Protection calculation examples
Section VIII – Practicing & Construction of Cathodic Protection System
- Components of Cathodic Protection Systems
- Essential Components
- Isolating joints
- Junction Boxes
- Test stations, measuring points and coupons
- Thermite Weld
- Earthing Systems
- Line current measurement
- Pipe Sleeves/Casings
- Cathodic Protection Vessels & Tank Internals Vessels & Tank
- Tanks for Storage of Chemicals
- Water Circulating Systems
- Heat exchangers (tube and shell)
- Case Study: Construction of Cathodic Protection Systems
Line and Coating Inspection, Safety and Corrosion Comics
Section IX – Inspection of Pipeline and Coating defects
- Pearson Surveys
- Close Interval Potential Survey (CIPS) technique
- Direct Current Voltage Gradient (DCVG) technique
- Signal Attenuation Coating (SAC) Survey
- Common Impressed Current Rectifier Problems
- Over the Trench Pipe Holiday Inspection
Section X – Instrumentation & Safety Aspects
- Alkalinity
- Hydrogen Evolution
- Chloride Evolution
- Installation Adjacent to Telecommunication Services
- Installation Adjacent to Railway Signal & Protection Circuits
- Interaction at Discontinuities in Cathodically Protected Structures
- Installation at Jetties & Ships
- Danger of Electric Shock
- Installations on Immersed Structures
- Installations for the Internal Protection of Plant
- Fault Conditions in Electricity Power Systems
- Stray Current Corrosion
Section XI – Corrosion Management Systems
- Economic Considerations
- Corrosion Key Performance Indicators (KPIs)
- Asset Integrity and Corrosion Management
- Corrosion Data Management