COURSE OVERVIEW:

Erosion and erosion-corrosion represent critical degradation mechanisms that can lead to rapid wall thinning and catastrophic failure in industrial piping systems and equipment. This course provides a technical deep dive into the physical and chemical interactions that occur when high velocity fluids, multi-phase flows, or particle-laden streams impact metallic surfaces. Participants will explore how the mechanical action of fluid flow strips away protective scales and passive films, significantly accelerating the underlying corrosion rate.

The scope of this training encompasses the identification of high-risk zones within process plants, such as elbows, tees, reducers, and control valves. We will examine the variables that influence wear rates, including fluid velocity, angle of impingement, particle morphology, and metallurgy. The curriculum bridges the gap between theoretical fluid dynamics and practical integrity management, providing attendees with the tools to predict wear patterns and implement effective mitigation strategies through material selection and design optimization.

Coverage includes the latest technologies for monitoring and inspecting areas prone to flow-induced damage. Attendees will investigate the application of specialized coatings, hard-facing materials, and the use of computational fluid dynamics to identify erosion "hot spots." By the end of this course, participants will be equipped to develop comprehensive erosion management plans that improve asset reliability, reduce maintenance costs, and ensure the safe operation of high-velocity process systems.

COURSE OBJECTIVES:

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

• Distinguish between pure mechanical erosion and the synergistic effects of erosion-corrosion.
• Identify the physical characteristics of abrasive, impingement, and cavitation erosion.
• Analyze the impact of fluid velocity and turbulence on the removal of protective oxide films.
• Evaluate the role of multi-phase flow (gas-liquid-solid) in accelerating material loss.
• Predict the locations in piping systems most susceptible to flow-induced thinning.
• Calculate erosion rates based on empirical models and process parameters.
• Select erosion-resistant materials and alloys for high-velocity service environments.
• Design piping layouts and component geometries that minimize turbulence and impingement.
• Compare various hard-facing and cladding techniques for protecting vulnerable surfaces.
• Implement real-time erosion monitoring using acoustic and electrical resistance sensors.
• Utilize advanced NDT methods to map and track localized thinning in erosive services.
• Develop mitigation strategies, including the use of flow conditioners and velocity limits.

TARGET AUDIENCE:

This course is designed for Integrity Engineers, Inspection Engineers, Piping Designers, Maintenance Engineers, Process Engineers, and Reliability Specialists working in industries such as oil and gas, power generation, and chemical processing, where high-velocity or abrasive fluids are handled.

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.