Petroleum Corrosion Management

Course name:

Petroleum Corrosion Management

Course level:

Fundamental level

Prerequisite:

None

Target Audience:

  • Diploma or Undergraduate degree holders from any discipline
  • Working Professionals in Energy Sector
  • Candidates with Engineering experience, who are interested about the Subject matter

Entry requirements:

The candidates should be either a diploma or undergraduate degree holder or pursuing such a degree while applying.

Application procedure:

Students need to make a formal application via KIER website no later than a week before commencement of classes. After their application & qualifications are assessed, they will be invited to pay the fee and confirm their seat.

Number of seats:

30 per batch

Course description:

This 2 weeks course is designed to provide an in-depth knowledge about the corrosion occurring in oil & Gas industry and its management. The course starts by providing basic knowledge about properties of materials, the types of corrosion and the principle behind each corrosion type. Students will be taught to understand the cost of corrosion and the points of interest on the rig & production facilities. They will gain the knowledge to analyse & investigate the corrosion at hand and various corrosion management techniques with an understanding about which corrosion management technique to apply in each situation.

Course content:

  • Introduction to Corrosion
    • Environments in Corrosion
    • Losses Due to Corrosion
    • Chemistry of Corrosion
    • Importance of Corrosion
    • Tasks to be accomplished from a Corrosion Engineer
  • Basic Properties of Materials
    • Physical Properties of Metals
    • Mechanical properties
    • Thermal Properties
    • Chemical Properties
    • Definition and Measurement of Mechanical Properties
    • Why to Use a Hardness Test?
    • Other Mechanical Tests
  • Structures of Materials
    • Composition and Microstructure
    • Types of Material Structure
    • Choice of Material
  • Types of Corrosion
    • Uniform Corrosion
    • Galvanic Corrosion
    • Pitting Corrosion
    • Crevice Corrosion
    • Stress Corrosion Cracking
    • Erosion Corrosion
    • Inter-granular Corrosion
    • Microbiologically Influenced Corrosion
    • Concentration Cell Corrosion
    • Graphitic Corrosion
    • Exfoliation Corrosion
    • Fatigue Corrosion
    • Cavitation-corrosion
    • Fretting corrosion
  • Fundamentals of Corrosion
    • Corrosion Principles
    • An electrochemical description of corrosion
    • Cracking mechanisms
    • Mitigation Techniques
    • Corrosion Costs
    • Electrochemical corrosion
    • Aqueous Corrosion
    • Standard Electrode Potentials
    • Redox Reactions
    • Potential – pH Diagrams
    • EMF & Galvanic Series
  • Alloying Element
    • Steel Alloys
    • Effects of Alloying Elements in Steel
    • Stainless Steel
    • Carbon Steel
    • Some Commercial Steel Alloy Compositions
    • Process
    • Some Alloying Elements added Deliberately
    • Heat Treatment Process
    • Softening Heat Treatment Classification
  • Corrosion & Fouling
    • Microbiologically Influenced Corrosion
    • Microbial Enhanced Oil Recovery
    • Bacterial Corrosion
    • Control of Bacterial Corrosion
    • Corrosion by Sulphate Reducing Bacteria
    • Production systems
    • Offshore structures
    • Control & Treatment
    • Effects of Fouling
  • Polarization
    • The Polarized Cell
    • Concentration polarization
    • Resistance polarization
    • Polarization Curve
    • Diffusion Process
    • Fick’s First Law of Diffusion
    • The Electrical double layer
    • Polarization – The Tafel Equation
    • Passivity
  • Evan & Pourbaix Diagram
    • Evans Diagram
    • Pourbaix Diagrams
    • Iron E-pH (Pourbaix) Diagram
    • Key to features on Pourbaix diagrams
    • Limitations of Pourbaix Diagrams
  • Non-Metallic Diagram
    • Classification of Non Metallic Materials
    • Thermosetting plastics
    • Thermoplastics
    • Polymer
    • Mechanical Properties of Polymers
    • Composite materials (composites)
    • Particle Reinforced Composites
    • Fiber-reinforced Composites
    • Structural Composites
    • Parallel Fiber Composites
    • Some of other composites
    • Transverse Stiffness
    • Ceramics
  • Welding Processes
    • Welding Process
    • Welding Process System
    • Basic types of Weld joints
    • Welding Positions
    • Selection of Welding Rods
    • Weld Defects
    • Forms of corrosion most closely associated with welding
    • Weld Decay
    • Knife-line Attack
    • Carbon Steel Weld Corrosion
  • Fatigue Investigation
    • Root Causes that can be for failures to Occur
    • Points to be considered to avoid corrosion failure
    • Materials Resistant to Corrosion
    • Protective Coatings
    • Cathodic Protection
    • Corrosion Inhibitors
    • Corrosion Testing
    • Reliability of NDT for corrosion control
  • Fatigues
    • Additional factors causing fatigue failures
    • Stress Cycles
    • Goodman Diagram
    • Haig-Solderberg diagram
    • Mechanisms of failure
    • Structural features of fatigue
    • Minimization of Corrosion fatigue
  • Fracture Mechanics
    • Motivation
    • Toughness in Metals
    • Fracture Toughness
    • Linear Elastic Fracture Mechanics
    • Modes of Cracking
    • Failure Analysis
  • Cathodic & Anodic Protection
    • Cathodic Protection
    • Cathodic protection through impressed current
    • Cathodic Protection by means of a sacrificial anode
    • Protective Potential
    • Linear Polarization Resistance Measurement
    • Anodic Protection
    • Active – Passive alloys
    • Cathodes for Anodic Protection
    • Comparison of Anodic Protection and Cathodic Protection
  • Corrosion Monitoring
    • Corrosion Monitoring Techniques
    • Analytical Techniques
    • Corrosion Monitoring methods in different system and number
    • of access fitting at each location
    • The Benefits of Corrosion Monitoring
    • Applications of Corrosion Monitoring Techniques
  • Corrosion Management
    • Simple Corrosion Management Strategy
    • Management work flow
    • Risk based inspection
    • Erosion-corrosion management system
    • Corrosion Testing
    • Classification of Corrosion Tests
    • Guidelines for Supporting Specimens
  • Corrosion Protection Paints
    • Coating New Steel Structures
    • Method For Steel Surface Preparation
    • Coating Options
    • Classification of corrosion protection methods
    • Permanent Corrosion Protection
    • Painting
    • Prefabrication primers
    • Paint – Applying Methods
    • Causes of Paint Film Failures
    • Surface Preparation
    • Inhibitors
    • Generic Inhibitors

Course Objective:

The main objectives of the course are:

  1. To provide a basic & strong understanding about the corrosion occurring in Oil & Gas industry and how they are managed
  2. To provide a wider understanding about the major corrosion types and the principle & chemical reactions behind each of them
  3. To provide an In-depth knowledge about the various scenarios in which corrosion can occur and the reasons for the occurrence
  4. To impart theoretical knowledge about how to investigate and evaluate the corrosion at hand and to determine the severity of corrosion with the use of Evans & Pourbaix diagram
  5. To explain the various corrosion prevention & remedial methods available and the pros & cons of each method
  6. To provide a strong understanding of the ‘Cost of Corrosion’ concept and its effect on the corrosion management method chosen

Student Handouts:

More than 220 pages of handout notes will be provided to the participants during the class. The e-version of these handouts will also be available on the INFONIX for the participant to access, for up to 90 days from the start of the course.

Tutor Information:

Mr. S.B. Srivastava, General manger of Construction & Maintenance (Rtd) department of ONGC, has over 32 years of field experience with process facilities. He has extensive experience in execution and handling of LSTK / EPIC contracts for various pipelines, Process facilities, eg.GGS, GCS, Crude Oil Tanks Farm, Effluent treatment Plant construction at Offshore as well as Onshore Assets. Over the years he has held several positions within ONGC, which includes being Project Head for construction of 6 offshore well platforms and Project Manager for construction of 5 other offshore well platforms. He has also held the position of ‘Head of Pipeline & Civil Works’ and carried out construction of Trunk & Flow pipelines and drill site civil construction work. He has also worked as ‘Group Head & Design Manager’ for various offshore well platform & subsea pipeline projects. He has also got more than 12 years of hands on experience in various pipeline laying projects, both offshore & onshore. He was involved in the first ever offshore underwater pipe laying project in India in the year 1985, and laid a 36” dia pipeline from an offshore platform to onshore terminal.

Method of delivery:

The instruction is conducted in a classroom provided with a spacious & a friendly environment for the students. Each individual will have separate seating arrangement, with enough space providing comfort. Projector & board will be used to show slides and to explain concepts. Beside this, reading room & desktops with internet facility is available for every individual student to further enrich their knowledge outside class hours. KIER has developed an online self assessment portal called INFONIX were every participant can log into their account (username & password will be provided by the institute) were they can take self assessment for the course they have enrolled for and also can read the electronic version of each module. The user account will stay active for 3 months from the date of joining.

Access to Course content via INFONIX :

KIER has developed an online self assessment portal called INFONIX were every participant can log into their account (username & password will be provided by the institute upon registration) were they can access the course content and take self assessment for the course they have enrolled for. The course content includes, more than 220 pages of class handouts, presentation slides used while taking the class and other relevant reference material. The user account will stay active for 90 days from the first day of the class.

Examination and pass percentage:

Examination will be conducted at the last day of the course. The examination will be in the form of multiple choice questions. Totally 50 questions needs to be answered and the student needs to score more than 60% to pass the examination.

Course completion certificate:

Candidates who have scored more than 60% in the exam conducted at the end of the course, will be presented with a course completion certificate. This certificate can be either sent via courier or can be collected at the office.

Course calendar:

  • Course
  • Petroleum Corrosion Management
  • Week
  • Day
  • Session-1
    9 am to 12 pm
  • Session-2
    2 pm to 5 pm
  • 1
  • Monday
  • Introduction To Corrosion
  • Basic Properties Of Material
  • Tuesday
  • Structures Of Material
  • Types Of Corrosion
  • Wednesday
  • Fundamentals Of Corrosion
  • Alloying Element
  • Thursday
  • Corrosion & Fouling
  • Polarization
  • Friday
  • Evan & Pourbaix Diagrams
  • Non-Metallic Materials
  • 2
  • Monday
  • Welding Processes
  • Fatigue Investigation
  • Tuesday
  • Fatigues
  • Fracture Mechanics
  • Wednesday
  • Cathodic & Anodic Protection
  • Corrosion Monitoring
  • Thursday
  • Corrosion Management
  • Corrosion Protection Paints
  • Friday
  • Discussion & Doubts Clarification
  • Final Exams

Student complaints & feedback system:

KIER is committed to providing a good quality education which meets or exceeds the participant’s expectations. One of the ways we continue to improve our standards is by listening to the participant’s comments about our course. At the end of the course, participants will be invited to fill out a Feedback Form which will be accessed and necessary actions will be taken. The participants can also make complaints, comments and feedback at any time during the course. We are committed to learn from the comments that we receive and improve the quality of the courses offered.

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