COURSE OVERVIEW:

High-temperature corrosion and sulfidation represent some of the most aggressive degradation mechanisms encountered in the refining, petrochemical, and power generation industries. This course provides an in-depth technical analysis of how metallic components react with sulfur-bearing environments and oxidizing atmospheres at elevated temperatures, typically above 200°C. Participants will explore the chemical kinetics of scale formation and the factors that lead to the rapid thinning of pressure boundaries in hydroprocessing and crude distillation units.

The scope of this training focuses on the practical application of industry standards, such as API RP 939-C, to manage the risk of sulfidation. We will examine the critical role of silicon content in carbon steels and the "Hales-McConomy" curves used to predict corrosion rates based on temperature and sulfur concentration. The curriculum bridges the gap between metallurgical theory and field application, providing attendees with the knowledge to identify susceptible piping circuits and equipment that may be at risk of sudden failure.

Coverage includes advanced mitigation strategies such as the use of high-chromium alloys, stainless steel cladding, and the implementation of Integrity Operating Windows (IOWs). Attendees will investigate specialized inspection techniques, including Positive Material Identification (PMI) and high-temperature ultrasonic thickness monitoring. By the end of this course, participants will be equipped to design and manage a comprehensive high-temperature corrosion control program that enhances asset reliability and personnel safety in high-heat environments.

COURSE OBJECTIVES:

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

• Explain the fundamental mechanisms of sulfidation and high-temperature oxidation.
• Identify the impact of sulfur species (H2S, mercaptans, and elemental sulfur) on corrosion rates.
• Analyze the critical influence of silicon content in carbon steel performance under sulfidation.
• Utilize the McConomy and Modified McConomy curves to estimate material loss.
• Distinguish between sulfidation with and without the presence of hydrogen.
• Evaluate the risks associated with naphthenic acid corrosion in high-temperature circuits.
• Apply API RP 939-C guidelines to develop a robust sulfidation monitoring program.
• Select appropriate chromium-molybdenum alloys and stainless steels for high-heat service.
• Execute Positive Material Identification (PMI) strategies to detect "rogue" low-silicon components.
• Implement Integrity Operating Windows (IOWs) to control temperature and sulfur fluctuations.
• Compare the effectiveness of different types of high-temperature coatings and linings.
• Conduct root cause analysis on failures caused by high-temperature hydrogen attack (HTHA).

TARGET AUDIENCE:

This advanced course is designed for Corrosion Engineers, Materials Specialists, Integrity Engineers, Inspection Managers, and Process Engineers responsible for high-temperature units in refineries and chemical plants.

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.