OG90
Course Contents
Module 1: Fundamental Mechanics of Fluid-Driven Wall Thinning
Key Topics
- Definitions and clear distinctions between FAC and erosion-corrosion
- Electrochemical and transport-layer kinetics of iron oxide dissolution
- Mass transfer models and the impact of localized fluid turbulence
- Visual morphology, surface patterns and identifying physical degradation modes
- Distinguishing chemical dissolution profiles from pure mechanical abrasion paths
- Historical review of industry failures, lessons learned and regulatory outcomes
Module 2: Flow Assisted Corrosion (FAC) Variables and System Screening
Key Topics
- Environmental factors: influence of dissolved oxygen, pH values and temperature profiles
- Hydrodynamic variables: linear velocity limits, flow regimes and turbulence factors
- Metallurgical parameters: tracking the critical role of chromium and alloying elements
- Component geometry variations: local vulnerability at elbows, tees, reducers and orifices
- Single-phase vs two-phase flow configurations, wet steam lines and liquid film damage
- System screening methodologies and isolating highly vulnerable process streams
Module 3: Erosion-Corrosion and Related Mechanical Wear Mechanisms
Key Topics
- Solid particle erosion dynamics: sand profiles, slurry services and impact angles
- Liquid droplet impingement (LDI) kinematics in high-velocity wet steam headers
- Cavitation, flashing and localized vacuum implosion damage at control valves
- Flow restrictions, valve trim vulnerabilities and structural impingement wear
- Material hardness dependencies, particle size parameters and velocity thresholds
- Synergistic effects: tracking the combined impact of corrosion and mechanical erosion
Module 4: Inspection Technologies, Data Analytics and Remaining-Life Assessment
Key Topics
- Inspection planning frameworks, component prioritizing and risk metrics
- Ultrasonic thickness (UT) scanning loops, grid generation and data density
- Profile radiography, pulsed eddy current (PEC) and advanced internal examination tools
- Statistical analysis of wall-thinning trends: establishing reliable wear rates
- Determining baseline wall parameters, t-min calculations and remaining-life windows
- Fitness-for-service (FFS) analysis, structural engineering evaluation and repair limits
Module 5: Strategic Mitigation, Material Upgrades and Programme Governance
Key Topics
- Water chemistry optimization: oxygen injection, pH controls and amine programs
- Materials engineering: selecting chromium-alloy additions, stainless steels and clad lines
- Piping design adjustments: layout rules, expanding bend radii and reducing flow upsets
- Velocity controls, sizing rules, choke parameters and operating envelope limits
- Application boundaries for protective coatings, hardened liners and wear pads
- Managing an institutional integrity team, tracking performance KPIs and documentation rules