Metallurgy Corrosion and Prevention of Failures

Start Date End Date Venue Fees (US $)
19 Oct 2025 Dubai, UAE $ 3,900 Register

Metallurgy Corrosion and Prevention of Failures

Introduction

The first step in the safety and reliability of refinery equipment is identifying, understanding, preventing the relevant fail­ure mechanisms. Corrosion is the primary cause of the fail­ure of components in the process industries. The success or failure of the equipment to the corrosive environment to a great extent depends on the right metallurgy. Thus a proper understanding of the metallurgy and corrosion phenom­enon helps engineers to mitigate corrosion and to monitor it on a periodic basis, based on which, corrective actions can be taken. Premature failure of critical components like pipelines, tanks, pressure vessels, boilers and related equipment, heat exchangers, and welded joints often re­sults in operating downtime, loss of production, environ­mental pollution, and in some cases, loss of human life. Millions of dollars are spent every year by these industries to combat corrosion. The course crosses the boundaries from the fundamental information to top-notch in the re­cent technological achievement in this field.

Objectives

    Upon the successful completion of this course the partici­pants will:

    • Understand the fundamental theories of aqueous cor­rosion and dry corrosion
    • To understand basic metallurgy and choice of material selection suitable for the specific application
    • To enable the attendees to grasp the advanced infor­mation in preventive as well as predictive maintenance of equipment
    • To present different forms of corrosion from various mechanisms and related environmental factors
    • Corrosion control techniques
    • To illustrate study cases pertaining to corrosion failures, mainly pipelines, storage tanks, pressure vessels, boil­ers, and heat exchangers
    • To present the advanced corrosion monitoring tech­nologies
    • To present typical corrosion failures and to illustrate the inter-relationship between fabrication techniques, service conditions and their effect on the corrosion re­sistance of engineering metals and alloys

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies, and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations. The online course is conducted online using MS-Teams/ClickMeeting.

Who Should Attend?

The course is designed essentially for professionals such as process engineers, inspection personnel, mechanical engineers, material selection personnel, R&D persons, corrosion engineers, plant contractors, etc. The course is also useful for plant engineers as well as for operat­ing/maintenance staff related to pipelines, tanks, pressure vessels, etc. Anyone who needs to understand corrosion and other failures and how to carry out failure protection will find the course immensely beneficial.

Course Outline

   Introduction

  • Review of basic metallurgy
  • Review of iron-carbon equilibrium diagram
  • Effects of alloying elements, Alloy steel and stainless steels, ASTM specifications for carbon steels, alloy steels and stainless steels, Mechanical properties of metals, Materials for high-temperature service
  • Materials for low-temperature service
  • Materials of sour service (NACE standard)
  • Selection of material of construction
  • Selection of substitute materials
  • Forms of corrosion and prevention of failure in oil and gas industries
  • Common corrosion phenomenon
  • Erosion/ corrosion, atmospheric corrosion, corrosion under insulation (CUI)
  • Cooling water corrosion, boiler water condensate cor­rosion, Sulfidation, chloride stress corrosion cracking (ClSCC), Caustic stress corrosion cracking (caustic embrittlement), Wet H2S damage (Blistering/HIC/SO­HIC/SCC), Case studies pertaining to the corrosion failures
  • Prevention of equipment failure by choosing correct materials, Prevention of equipment failure by choos­ing correct operating conditions
  • Corrosion monitoring techniques :
  • Corrosion coupon testing, Electrochemical resistance probe, Ultrasonic thickness measurements, Mea­surements of corrosion potential, Alternating current impedance measurements, Hydrogen probes, corro­someter probes, Practical application of the corrosion monitoring methods
  • Final quiz & Feedback and concluding Session

Accreditation

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