Course Overview

All industrial problems which confronts the engineers, few can be economically more important than the prevention of metallic corrosion and mechanical failure. The corrosion failure of metallic materials causes billions of dollars globally every year.

This seminar combines two major aspects of industrial and governmental problems. These are corrosion and fracture mechanics. The lack of understanding will not only cost a lot of money it will also cost human life.

Preventing or reducing the corrosion mechanism will increase the productivity and efficiency of any plant. The corrosion process is a wonderfully elegant example of nature at work. We take natural materials and work them to change our environment. For example we work metal ores to produce structural steelwork and then are dismayed when it returns to its native form. We do, however use the corrosion process to our benefit, a battery; electroplating and galvanizing are prime examples of controlled corrosion.

The whole science of corrosion, engineering and control is unfortunately often ignored, sometimes with disastrous consequences. Many engineers now actively engaged in corrosionÌ¢‰âÂårelated problem solving have little training in corrosion due to lack of availability or interest during their formal education.

The course is structured in order to train people in the fundamental understanding of corrosion and fracture mechanics. The course also highlights protection methods and fracture prevention methods. Alloy selection and material design is also considered from a practical angle. This course will provide exposure to monitoring and prevention of corrosion in chemical and petroleum industry. The course combines two important elements, namely, theoretical background and real life case studies

Course Objectives

After attending participants will:

• Have sound working knowledge of corrosion issues

• Be able to identify the various types of corrosion

• Be able to identify the causes and driving factors of the corrosion

• Be able to determine the most practical method of mitigating the corrosion

• Be able to develop work procedures for corrosion control.

• Be able to identify and recommend alternatives in structural design to minimize corrosion

• Have a good working knowledge of Protective Coatings for corrosion control.

• Be able to monitor the effectiveness of the corrosion control process

Who Should Attend

This course is designed for a variety of individuals with different background. Since the corrosion and failure effects everyone in industry, almost all the industrial engineers should be trained in this field. For example Oil and Gas Industry, PetroÌ¢‰âÂåchemical industry, Gas turbine and Steam Turbine engineers, civil engineers etc.

Course Content

Module (01) Introduction to Corrosion

1.1 Corrosion Theory

1.2 Corrosion Identification

1.3 Types of Corrosion

1.4 Causes of Corrosion

1.5 Losses due to Corrosion

1.6 Electrochemical Aspects of Corrosion

1.7 Thermodynamics of Corrosion

1.8 Kinetics of corrosion Processes

Module (02) Forms of Corrosion

2.1 Uniform Attack

2.2 Galvanic Corrosion

2.3 Crevice Corrosion

2.4 Pitting

2.5 Selective Leaching

2.6 Erosion Corrosion

2.7 Corrosion Cracking

2.8 InterÌ¢‰âÂågranular Corrosion

Module (03) Monitoring of Corrosion

3.1 Mechanism of Corrosion

3.2 mass Transfer Limited Corrosion

3.3 Basics of d.c measurement of Corrosion

3.4 Basics of Electrochemical Impedance Techniques

3.5 Environmental Corrosion in chemicals and Petroleum Industries

3.6 Corrosion in Reinforced Concrete Structure

Module (04) Prevention of Corrosion

4.1 Coatings

4.1.1 Fundamentals

4.1.2 Selection

4.1.3 Monitoring

4.1.5 Failure Mechanism

4.2 Inhibitors

4.2.1 Fundamentals

4.2.2 Selection

4.2.3 Monitoring

4.3 Control of Process Parameters

4.4 Materials Selection and Design

Module (05) Laboratory Demonstration

5.1 Corrosion Rate Measurements

5.1.1 By Linear Polarization

5.1.2 By Tafel Plots

5.2 PotentioÌ¢‰âÂådynamic Scanning

5.3 Electrochemical Impedance Spectroscopy for Coating and Inhibitors

Module (06) High Temperature Corrosion

6.1 Hot Corrosion

6.2 Oxidation and Corrosion if Stainless Steel

6.3 Metallurgical Evaluation Ni base Metal Corrosion

6.4 Metallurgical Nature of Co base alloy Corrosion

6.5 Hot Gas atmosphere for Hot Corrosion

6.6 Industrial Examples of High Temperature Corrosion

6.7 Failure initiation from hot corrosion

6.7.1 Creep

6.7.2 Fatigue Failure

Module (07) Cathodic Protection

7.1 Theory and Applications

7.2 Types of Cathodic Protection

7.3 Stray Current Corrosion

7.3 Methodology of Monitoring CP