COURSE OVERVIEW:

Corrosion inspection, testing, and monitoring constitute the essential technical framework for verifying the structural health of industrial assets and validating the efficacy of corrosion control strategies. This course provides a comprehensive analysis of the various methodologies used to detect, quantify, and track material degradation in real-time and during scheduled outages. Participants will explore the fundamental differences between "inspection," which provides a snapshot of an asset's condition, and "monitoring," which offers continuous data on the corrosivity of the process environment. The curriculum is designed to bridge the gap between raw data collection and the high-level technical interpretation required for informed decision-making.

The scope of this training encompasses both intrusive and non-intrusive technologies, ranging from traditional weight-loss coupons to advanced phased-array ultrasonic testing and online electrochemical probes. Attendees will gain a deep understanding of the physics behind each method, including the limitations and advantages of different sensor types in varied operating conditions. The course emphasizes the importance of selecting the correct tool for the specific damage mechanism being targeted, ensuring that localized phenomena such as pitting or stress corrosion cracking are not overlooked by generalized monitoring programs.

Coverage includes the integration of inspection findings into broader asset integrity management systems and the use of data analytics to predict future corrosion trends. Participants will learn how to interpret complex signal data and laboratory results to determine corrosion rates and remaining life assessments. By focusing on the synergy between different monitoring techniques, the course empowers professionals to develop robust, multi-layered surveillance programs that reduce the risk of catastrophic failure, optimize maintenance intervals, and ensure compliance with international safety and environmental regulations.

COURSE OBJECTIVES:

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

• Differentiate between corrosion monitoring and corrosion inspection for asset integrity.
• Select the most appropriate NDT methods for detecting localized versus general corrosion.
• Interpret data from Electrical Resistance (ER) and Linear Polarization Resistance (LPR) probes.
• Manage and analyze weight-loss coupon programs for internal corrosion assessment.
• Utilize ultrasonic and radiographic techniques for precise wall thickness measurement.
• Evaluate the application of advanced monitoring, such as the Field Signature Method (FSM).
• Identify the presence of corrosion products through chemical and mineralogical analysis.
• Correlate monitoring data with process parameters to identify corrosive "excursions."
• Assess the reliability and confidence levels of different inspection data sources.
• Develop a strategic Corrosion Monitoring Plan (CMP) for complex process units.
• Translate raw inspection findings into actionable repair or replacement recommendations.
• Apply international standards, including NACE SP0110 and API 570, for monitoring.

TARGET AUDIENCE:

This course is designed for integrity engineers, corrosion technicians, NDT specialists, and maintenance managers responsible for the health of static equipment. It is also highly relevant for plant inspectors and process engineers who must interpret corrosion data to maintain safe operating envelopes in the petrochemical, power, and manufacturing industries.

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:

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.