COURSE OVERVIEW:

Corrosion monitoring represents a critical pillar of asset integrity management by providing real-time or periodic data on the rate of material degradation within industrial systems. This course explores the fundamental principles of data acquisition regarding metal loss and electrochemical activity. Participants will learn how to distinguish between intrusive and non-intrusive techniques, ensuring that the selected monitoring strategy aligns with the specific chemical and physical environment of the process plant.

The scope of this training extends from traditional weight-loss coupons to advanced digital online monitoring architectures. We will examine the installation, retrieval, and data interpretation of electrical resistance probes, linear polarization resistance sensors, and ultrasonic transmitters. The curriculum is designed to bridge the gap between raw data collection and actionable integrity intelligence, allowing operators to adjust chemical inhibition programs or process parameters before significant damage occurs to the pressure boundary.

Coverage includes the integration of monitoring hardware into modern Distributed Control Systems and the cloud-based analysis of corrosion trends. Attendees will investigate the placement of monitoring stations based on flow regimes, phase separation, and localized corrosion risks. By the end of the program, participants will be equipped to design a comprehensive corrosion monitoring plan that enhances safety, reduces unplanned downtime, and extends the remaining life of critical piping and vessel components.

COURSE OBJECTIVES:

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

• Identify the fundamental differences between corrosion monitoring and corrosion inspection.
• Select appropriate weight-loss coupons based on metallurgy and process fluid characteristics.
• Calculate corrosion rates accurately using gravimetric data from retrieved coupons.
• Explain the operating principles of Electrical Resistance (ER) probes for various environments.
• Utilize Linear Polarization Resistance (LPR) techniques for instantaneous corrosion rate measurement.
• Analyze the impact of probe orientation and location on the validity of gathered data.
• Configure online monitoring systems for seamless integration with plant control rooms.
• Evaluate the effectiveness of chemical corrosion inhibitors through real-time data trends.
• Troubleshoot common failures in probe instrumentation and signal transmission.
• Implement safety protocols for the high-pressure retrieval of monitoring tools.
• Interpret electrochemical noise and harmonic distortion analysis for localized corrosion.
• Develop a strategic corrosion monitoring map for complex process piping circuits.
• Compare the cost-to-benefit ratio of manual versus automated online monitoring solutions.

TARGET AUDIENCE:

This course is intended for Corrosion Engineers, Integrity Engineers, Plant Inspectors, Maintenance Managers, Chemical Treatment Technicians, and Process Engineers involved in the monitoring and mitigation of internal corrosion in oil, gas, and petrochemical facilities.

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.