OG90
Course Contents
Module 1: Corrosion Science, Metallurgy and Damage Assessment
Key Topics
- Electrochemical corrosion cells and controlling reactions
- Influence of pH, temperature, pressure and fluid chemistry
- Metallurgy, microstructure and mechanical property effects
- Uniform, galvanic, crevice and pitting corrosion mechanisms
- Corrosion rates, allowances and remaining life calculation concepts
- Damage mechanism reviews and corrosion threat assessment workflows
- Using process data to define credible degradation modes in field assets
Module 2: Process, Environmental and High-Temperature Mechanisms
Key Topics
- CO2 corrosion, H2S damage and sour service material threats
- Hydrogen embrittlement, HIC, SOHIC and sulphide stress cracking (SSC)
- Chloride, caustic and other environmental stress corrosion cracking (SCC) modes
- Erosion-corrosion, cavitation and flow-assisted corrosion kinetics
- Microbiologically influenced corrosion (MIC) and operational biofilm effects
- Corrosion under insulation (CUI) and atmospheric exposure damage
- High-temperature oxidation, sulfidation and naphthenic acid corrosion
Module 3: Engineering Materials and Selection Methodology
Key Topics
- Performance of carbon steels, low-alloy steels and stainless steels
- Duplex stainless steels, nickel alloys and high-performance corrosion-resistant alloys (CRAs)
- Non-metallics, linings, composites and industrial polymer limitations
- Process compatibility rules and sour-service material limits (NACE/ISO requirements)
- Design temperature, pressure, structural strength and toughness needs
- Weldability, fabrication, post-weld heat treatment (PWHT) and hardness control
- Generating material selection diagrams (MSDs), engineering specifications and philosophies
Module 4: Corrosion Control, Monitoring and Integrity Assurance
Key Topics
- Material upgrades, optimized corrosion allowance and mechanical design improvements
- Protective coatings, linings and surface barrier protection systems
- Chemical inhibition programs, dissolved oxygen control and process optimisation
- Cathodic protection (CP) principles, design parameters and application limits
- Corrosion coupons, electrical resistance probes and online monitoring methods
- Inspection planning using damage mechanisms and risk-based inspection (RBI) criteria
- Establishing integrity operating windows (IOWs) and key performance indicators
Module 5: Failure Analysis and Lifecycle Materials Optimisation
Key Topics
- Recognising distinctive corrosion morphology and component failure evidence
- Field sampling, metallurgical testing and laboratory examination methods
- Root cause analysis (RCA) for material degradation and corrosion failures
- Fitness-for-service (FFS) principles and structural repair decision fundamentals
- Lifecycle cost analysis (LCCA), asset availability and material trade-off analysis
- Managing vendor substitutions, engineering deviations and material changes safely
- Integrated capstone case study: developing a comprehensive material selection and corrosion control plan