Introduction:
The initial step towards ensuring the safety and reliability of refinery equipment involves the identification, comprehension, and prevention of relevant failure mechanisms. In the process industries, corrosion stands as the primary cause of component failures. The ability of equipment to withstand corrosive environments and its subsequent success or failure largely relies on appropriate metallurgy selection.
Therefore, having a thorough understanding of metallurgy and the phenomenon of corrosion empowers engineers to effectively mitigate corrosion and implement regular monitoring. This monitoring enables the identification of any corrosion-related issues, allowing for timely corrective actions to be taken. Premature failure of critical components, such as pipelines, tanks, pressure vessels, boilers, heat exchangers, and welded joints, often leads to operational downtime, production losses, environmental pollution, and, in severe cases, even loss of human life.
Course Objectives:
Upon the successful completion of this course the participants will:
- Understand the fundamental theories of aqueous corrosion and dry corrosion
- To understand basic metallurgy and choice of material selection suitable for the specific application
- To enable the attendees to grasp the advanced information in preventive as well as predictive maintenance of equipment
- To present different forms of corrosion from various mechanisms and related environmental factors
- Corrosion control techniques
- To illustrate study cases pertaining to corrosion failures, mainly pipelines, storage tanks, pressure vessels, boilers, and heat exchangers
- To present the advanced corrosion monitoring technologies
- To present typical corrosion failures and to illustrate the inter-relationship between fabrication techniques, service conditions and their effect on the corrosion resistance of engineering metals and alloys
Who Should Attend?
The course is designed essentially for professionals such as: process engineers, inspection personnel, mechanical engineers, material selection personnel, R&D persons, corrosion engineers, plant contractors etc. The course is also useful for plant engineers as well as for operating/maintenance staff related to pipelines, tanks, pressure vessels etc. Anyone who needs to understand corrosion and other failures and how to carry out failure protection will find the course immensely beneficial
Course Outlines:
- Review of basic metallurgy
- Review of iron carbon equilibrium diagram
- Effects of alloying elements, Alloy steel and stainless steels, ASTM specifications for carbon steels, alloy steels and stainless steels, Mechanical properties of metals, Materials for high temperature service
- Materials for low temperature service
- Materials of sour service (NACE standard)
- Selection of material of construction
- Selection of substitute materials
- Forms of corrosion and prevention of failure in oil and gas industries
- Common corrosion phenomenon
- Erosion/ corrosion, atmospheric corrosion, corrosion under insulation (CUI)
- Cooling water corrosion, boiler water condensate corrosion, Sulfidation, chloride stress corrosion cracking (ClSCC), Caustic stress corrosion cracking (caustic embrittlement), Wet H2S damage (Blistering/HIC/SOHIC/SCC), Case studies pertaining to the corrosion failures
- Prevention of equipment failure by choosing correct materials, Prevention of equipment failure by choosing correct operating conditions
- Corrosion monitoring techniques :
- Corrosion coupon testing, Electrochemical resistance probe, Ultrasonic thickness measurements, Measurements of corrosion potential, Alternating current impedance measurements, Hydrogen probes, corrosometer probes, Practical application of the corrosion monitoring methods
- Final quiz & Feedback and concluding Session