COURSE OVERVIEW:

Coating failure analysis serves as a critical forensic discipline within the asset integrity framework, focusing on identifying the root causes of protective film degradation. This course provides a comprehensive exploration of why industrial coatings fail prematurely, examining the complex interactions between chemical properties, environmental stressors, and application variables. Participants will learn to distinguish between various failure modes, such as osmotic blistering, inter-coat delamination, and cohesive fractures, ensuring that subsequent investigations are grounded in scientific principles and material science.

The scope of this training extends from initial field observation and site documentation to advanced laboratory analytical techniques. It encompasses the systematic evaluation of substrate preparation, environmental conditions during application, and the long-term effects of operational exposure on coating longevity. By integrating theoretical knowledge with practical diagnostic tools, the course equips professionals to navigate the complexities of multi-coat systems and the nuances of specialized linings used in aggressive industrial environments.

Coverage includes the development and implementation of robust corrective action plans designed to prevent the recurrence of identified failures. The curriculum emphasizes the selection of compatible repair systems, the refinement of quality control procedures, and the optimization of maintenance scheduling. Through detailed case studies and technical reviews, attendees will gain the expertise required to manage the economic and safety risks associated with coating degradation, ultimately enhancing the lifecycle of critical infrastructure and process equipment.

COURSE OBJECTIVES:

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

• Identify and categorize diverse coating failure mechanisms across various industrial sectors.
• Conduct systematic root cause analysis (RCA) to differentiate between application errors and material defects.
• Utilize specialized forensic tools and field kits for on-site diagnostic inspections.
• Interpret laboratory analytical reports, including FTIR spectroscopy and SEM/EDX data.
• Evaluate the impact of surface contaminants on long-term coating adhesion and performance.
• Assess the role of environmental conditions, such as humidity and dew point, in premature failure.
• Design comprehensive corrective action plans that address both immediate repairs and systemic improvements.
• Determine the economic feasibility of localized repairs versus full coating system replacement.
• Verify the compatibility of maintenance coatings with existing aged coating systems.
• Implement advanced quality assurance protocols to mitigate the risk of future coating breakdowns.
• Document failure findings in high-quality technical reports suitable for legal or insurance reviews.
• Advise on the selection of high-performance coating systems tailored to specific corrosive environments.

TARGET AUDIENCE:

This course is designed for corrosion engineers, coating inspectors, asset integrity managers, maintenance supervisors, and technical consultants involved in the protection of industrial assets. It is also highly beneficial for quality control personnel and project managers responsible for infrastructure longevity and failure investigation.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize 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:

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