Course Introduction
Corrosion is one of the most significant threats to the safety, reliability, and profitability of process plants. Left unchecked, it can lead to costly unplanned shutdowns, reduced equipment life, product contamination, environmental hazards, and catastrophic failures.
This course provides a comprehensive understanding of corrosion phenomena in process industries, covering the fundamental science, mechanisms, prevention techniques, monitoring tools, and best practices in corrosion management. Participants will gain the technical knowledge and practical skills needed to detect, evaluate, and control corrosion in various process plant systems, ensuring long-term operational integrity and compliance with industry standards.
Who Should Attend
This course is designed for professionals involved in the design, operation, maintenance, and integrity of process plants, including:
- Corrosion engineers and specialists
- Maintenance and reliability engineers
- Inspection and quality control personnel
- Process and operations engineers
- Asset integrity and plant managers
- Fabrication and welding supervisors
- HSE and risk management personnel
Course Objectives
By the end of this course, participants will be able to:
- Understand the principles of corrosion science and the factors influencing corrosion in process plants.
- Identify different types of corrosion damage and recognize early warning signs.
- Select appropriate materials and protective design practices to minimize corrosion risks.
- Apply effective corrosion prevention methods, including coatings, cathodic protection, chemical treatments, and environmental control.
- Use inspection and monitoring techniques to assess corrosion rates and equipment condition.
- Interpret industry codes and standards related to corrosion control (API, NACE, ISO, ASME).
- Develop a corrosion management plan integrated with asset integrity and risk-based inspection strategies.
- Evaluate corrosion-related failures and propose corrective actions to prevent recurrence.
Course Outline
Day 1 – Fundamentals of Corrosion in Process Plants
- Introduction to corrosion
- Electrochemical principles
- Factors affecting corrosion rate
- Common corrosion mechanisms: uniform, galvanic, pitting, crevice, intergranular, SCC
- Case studies: major corrosion failures in industry
Day 2 – Materials, Design, and Fabrication for Corrosion Resistance
- Materials selection: carbon steel, stainless steel, alloys, non-metals
- Role of metallurgy in corrosion resistance
- Design considerations to prevent corrosion
- Welding and fabrication best practices
- Surface preparation and protective coatings
Day 3 – Corrosion Prevention and Protection Methods
- Cathodic protection: principles, systems, monitoring
- Chemical treatment and corrosion inhibitors
- Environmental control measures
- Internal linings, claddings, thermal spray coatings
Day 4 – Corrosion Monitoring, Inspection, and Testing
- Monitoring techniques: coupons, probes, UT, online systems
- Inspection methods: visual, UT, RT, MT, PT
- Calculating corrosion rates and trend analysis
- Relevant codes and standards
- Failure analysis and root cause determination
Day 5 – Corrosion Management & Life-Cycle Integrity
- Corrosion management systems and RBI approach
- Life-cycle costing for corrosion control
- Corrosion control in pipelines, tanks, vessels, exchangers
- Developing a plant-wide corrosion control strategy
- Group exercise: corrosion control plan development
- Final review and Q&A