Course Description

INTRODUCTION

The annual losses due to corrosion and the cost of rectification run to several billion dollars in oil & gas exploration industries around the world. High production under aggressive and extreme operational conditions necessitates the development of new materials which also have peculiar failure behaviors. Thus the industry operators are on continuous perusal with different corrosion management strategies. Yet unforeseen failures of top-side, sub-surface and sub-sea infrastructure due to corrosion not only entails in loss of production but loss of life as well. Prediction of failure behaviors, remaining useful life, corrosion preventive measures are all approaches in corrosion management for safe and economic operation of production wells and other facilities. The Successful corrosion management influences the economic outcome of the company by ensuring cost effective selection of materials, chemical treatments, coatings, cathodic protection systems and appropriate designs.

Objectives

This training course is designed for engineers and operators engaged in oil and gas exploration industry requiring an understanding of corrosion fundamentals: the causes and control of corrosion in oil and gas production and processing. This training course will provide an overview of what corrosion is and what the major corrosion issues are in upstream oil and gas operations. The focus will be on understanding how materials corrode, what techniques are used to monitor corrosion and some basic corrosion control fundamentals. The participants will be introduced to inhibitors and how they work, corrosion monitoring in field applications and cathodic protection. The training course content is presented from a practical production operations viewpoint and provides participants with the basic skills and understanding to control and solve corrosion issues.

The benefit of this course

The Company will achieve improved corrosion management system through the performance of an efficient corrosion control methods based on total life cycle corrosion economy.

Participants will be more able to actively contribute towards reducing the probability of less unforeseen failures in overall corrosion control approaches.

Participants will enhance their competence and productivity thereby enhancing their competence and performance and making additional value added contributions to their organizations in the discipline of corrosion management systems.

Course Outline

DAY 1

Section One - Oil & Gas Production Fluid

 

Origin and Production of Oil & Gas

Chemical Compositions of Production Fluids

Oilfield Equipment

Overview of Oilfield Processes & Operations

Section Two - Metallurgy

 

Chemical Properties of Metals

Mechanical Properties

Alloying Elements

Cooling of Metals

Crystalline Forms of Metals

Metal Defects

UNS Numbers

Properties of Common Oilfield Metals & Alloys

Metallurgy of Oilfield Equipment

DAY 2

Section Three - Corrosion Damage

 

Corrosion Fundamentals

Common Forms of Corrosion

Corrosion Monitoring in Plant and Facilities

Non-Destructive Testing (NDT)

Corrosion Failure & Root Cause analysis

Group Discussion- Applicable Standard Study for Corrosion Monitoring

Section Four - Oilfield-Specific Corrosion

 

Internal Corrosion

Water Corrosion

Sour Corrosion

Sweet Corrosion

Oxygen Corrosion

Top of Line Corrosion (TLC)

Microbiologically Induced Corrosion (MIC)

Sand Erosion

External Corrosion

Atmospheric (Marine) Corrosion

Corrosion Under Insulation (CUI)

Corrosion of Pipe Flanges

Underground Corrosion

Stray Current Corrosion

Seawater Corrosion

Oilfield Equipment Corrosion

Case Study-Plant Aging and Life Extension Program

DAY 3

Section Five - Corrosion Prevention & Control Measures

 

Corrosion Control by Operations

Corrosion Control by Processes

Corrosion Control Design

Corrosion Control by Material Selection

Group Discussion-NACE MR0175/ISO 15156-1 H2S Corrosion Resistant Materials

Section Six - Cathodic Protection (CPS) Systems

Cathodic Protection Fundamentals

Galvanic Anodes CPS

Impressed Current CPS

CPS System Maintenance

DAY 4

Section- Seven - Barrier Film (Coatings and Lining)

Coating Fundamentals

Performance Characteristics of Industrial Coatings

Types of Coating Systems

Surface Preparations

Coating Applications

Coating Defects

Section Eight - Chemical Treatment

Corrosion inhibitors

Performance Evaluation of Corrosion Inhibitor

Application of Corrosion Inhibitors

DAY 5

Section Nine - Biocide Treatment

Microbiologically Influenced Corrosion (MIC)

Sulphate-Reducing Bacteria

Biocide Selection & Treatment

Section Ten - Non-Metallic Materials

Polymers

Composite Materials

Section Eleven - Corrosion Management Strategy (CMS)

Corrosion Management of Oilfield Equipment

Corrosion Economy

Corrosion Key Performance Indicators (KPIs)

Asset Integrity and Corrosion Management

Codes & Standards

Corrosion Data Management

Case Study-Catastrophic Corrosion Failure