Corrosion Management & Cathodic Protection in Oil & Gas
Corrosion Management & Cathodic Protection in Oil & Gas
OBJECTIVES
- The theoretical basis and the practical ability necessary operate and maintain Cathodic Protection (CP) systems in the oil and gas surface production facilities
- Understanding of the basic principles of corrosion and applications of galvanic and impressed current CP systems
- Understanding of the field equipment used to monitor CP systems and how they work
- Understanding of the various factors that impact the performance of these systems
- Learn about essential CP monitoring techniques to ensure effective operation
- Understanding of increase productivity by avoiding costly shutdowns thus reducing the cost of the overall corrosion control program
WHO SHOULD ATTEND?
This course is designed for technical persons working in industries, where corrosion problem is a major concern. Only basic scientific and technical knowledge in the field of corrosion and materials are required. It is suitable for persons new to the field of CP but with some experience in corrosion control, as well as for those who have heavy engineering and scientific background and working knowledge. It is also perfect for supervisors, management, consultants, contractors, engineers, lab trainers and sales/marketing personnel in broad spectrum of industries.
COURSE OUTLINE
DAY 1
Principles and Types of Corrosion and Corrosion Control
Section I – Significance of Corrosion Control
- Corrosion – Largest Single Cause of Plant Failure
- Economic Effects
- Environmental Effects
- Safety Effects
- Corrosion Management Preventive Strategies
- Cost of Corrosion
- Case Study: Catastrophic Corrosion Accidents
Section II – Corrosion & Its Control
- Requirements for Corrosion to Occur
- Metallurgical Factors
- Forms of Corrosion
- Corrosion Control Methods
- Environmental Modification
- Protective Coatings
- Introduction to Cathodic Protection
DAY 2
Corrosion Environment, Material Selection and Elements of Cathodic Protection
Section III – Corrosive Environments & Construction of Materials
- Atmospheric Environments
- Marine Atmospheres
- Industrial Atmospheres
- Underground Environments
- Material Selection
- Corrosion Properties of Steels
- Concrete Structure Environment
Section IV – Fundamentals of Cathodic Protection Systems
- Galvanic Series
- General Application of Cathodic Protection
- Industry Standard & Codes
- Principle of CPS
- The Cathodic Protection Cell
- Methods of Applying Cathodic Protection
- Sacrificial Cathodic Protection System
- Impressed-Current Cathodic Protection System
- Advantages of SCPS
- Disadvantages SCPS
- Advantages ICCP
- Disadvantages ICCP
- CPS Selection
- Basic Requirements for Cathodic Protection
- Cathodic Protection Criteria
- Current Rectifiers / DC Power Source
- High Impedance Voltmeter
- Reference Cells (Half Cells) Reference Cells
- Applicable NACE Standard for Cathodic Protection Systems
DAY 3
Cathodic Protection Systems Design and Coating Issues
Section V – Cathodic Protection System Design
- Design Factors
- Electrolyte Resistivity Survey
- Electrolyte pH Survey
- Structure vs. Electrolyte Potential Survey
- Current Requirement
- Coating Resistance
- Protective Current Required
- Sacrificial Anode (Galvanic) Cathodic Protection Design
- Impressed current Cathodic Protection System Design
- Soil Resistivity
- Current Requirement Test
- Typical CPS Design Parameters
Section VI – Cathodic Protection Systems and Coatings
- Role of Protective Coating in CPS
- Selection Factors
- Coating Defects
- Coating Efficiency
- Over Voltage
- Cathodic Disbondment
- Commonly used Coating in Conjunction with CPS
DAY 4
Cathodic Protection Anodes and Construction
Section VII – Anodes & Rectifiers
- Anode Selection
- Anode Material Types – magnesium, zinc, aluminum, etc.
- Current Output
- Driving Potential
- Anode Life
- Anode Shape & Dimension
- Anode Efficiency
- Galvanic Anode Types
- Current Requirements for ICCP System
- Anode Materials for ICCP
- Anode Backfilling
- Installation of Sacrificial Anodes
- Impressed Current Anode Beds
- Impressed Current Rectifiers / DC Power Source
- CP Equations
- Solved CP Calculation Examples
Section VIII – Practicing & Construction of Cathodic Protection System
- Components of Cathodic Protection Systems
- Essential Components
- Isolating Joints
- Junction Boxes
- Test Stations – measuring points and coupons
- Thermite Weld
- Earthing Systems
- Line Current Measurement
- Pipe Sleeves / Casings
- Cathodic Protection Vessels & Tank Internals Vessels & Tank
- Tanks for Storage of Chemicals
- Water Circulating Systems
- Heat Exchangers (tube and shell)
- Case Study: Construction of Cathodic Protection Systems
DAY 5
Line and Coating Inspection, Safety and Corrosion Comics
Section IX – Inspection of Pipeline and Coating Defects
- Pearson Surveys
- Close Interval Potential Survey (CIPS) Technique
- Direct Current Voltage Gradient (DCVG) Technique
- Signal Attenuation Coating (SAC) Survey
- Common Impressed Current Rectifier Problems
- Over the Trench Pipe Holiday Inspection
Section X – Instrumentation & Safety Aspects
- Alkalinity
- Hydrogen Evolution
- Chloride Evolution
- Installation Adjacent to Telecommunication Services
- Installation Adjacent to Railway Signal & Protection Circuits
- Interaction at Discontinuities in Cathodically Protected Structures
- Installation at Jetties & Ships
- Danger of Electric Shock
- Installations on Immersed Structures
- Installations for the Internal Protection of Plant
- Fault Conditions in Electricity Power Systems
- Stray Current Corrosion
Section XI – Corrosion Management Systems
- Economic Considerations
- Corrosion Key Performance Indicators (KPIs)
- Asset Integrity and Corrosion Management
- Corrosion Data Management