COURSE OVERVIEW:

Advanced corrosion in process operations focuses on the complex chemical and metallurgical interactions that lead to the degradation of materials within industrial processing environments. This course moves beyond basic oxidation concepts to explore the aggressive damage mechanisms encountered in high-temperature, high-pressure, and chemically volatile settings. By understanding the intricate nature of these processes, engineers can develop sophisticated strategies to mitigate damage and extend the safe operating life of critical refinery and petrochemical assets.

The scope of this curriculum covers the thermodynamic and kinetic foundations of corrosion, including the role of electrolytes, electrochemical potential, and pH in driving metal loss. Participants will examine specific industry challenges such as sulfidation, high-temperature hydrogen attack, and various forms of environmental cracking. The course emphasizes the relationship between process variables—such as flow velocity, temperature fluctuations, and impurity concentrations—and the resulting corrosion rates observed in columns, reactors, and heat transfer equipment.

Coverage includes advanced monitoring techniques, the selection of corrosion-resistant alloys, and the application of chemical inhibition programs. The curriculum also addresses the implementation of Integrity Operating Windows to maintain process conditions within safe metallurgical limits. By the end of this program, participants will be equipped with the analytical tools necessary to perform root cause failure analyses and to design comprehensive corrosion management plans that integrate materials selection with rigorous process controls.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the electrochemical principles governing corrosion in aqueous environments.
2. Predict the occurrence of sulfidation in high-temperature hydrocarbon streams.
3. Assess the risk of High-Temperature Hydrogen Attack (HTHA) in refinery vessels.
4. Identify the precursors and mechanisms of Stress Corrosion Cracking (SCC).
5. Evaluate the impact of naphthenic acid on the integrity of distillation units.
6. Design effective cathodic protection systems for process plant infrastructure.
7. Select appropriate corrosion-resistant alloys for aggressive chemical services.
8. Monitor real-time corrosion rates using advanced electronic probes and coupons.
9. Implement Integrity Operating Windows (IOWs) to control corrosion-driving variables.
10. Analyze the role of microbiologically influenced corrosion in cooling water systems.
11. Perform detailed metallurgical investigations into corrosion-related failures.
12. Formulate chemical injection strategies for neutralizing acidic process streams.
13. Develop a comprehensive Corrosion Management Manual for a process facility.

TARGET AUDIENCE:

This course is tailored for corrosion engineers, materials specialists, process engineers, inspection supervisors, and integrity managers working in the oil, gas, and chemical processing industries.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.