Materials and Corrosion Engineering Management: Istanbul

Course overview

This course provides a sound understanding of the use, design and selection of materials. It also addresses essential corrosion related subjects including but not necessarily limited to:

• Corrosion principles
• Corrosion types
• Typical onshore and offshore oil and gas operational assets
• Managing materials and corrosion as a complete system
• Corrosion rate evaluation
• The use of corrosion control
• Prevention and mitigation methods
• Including Cathodic Protection systems
• Structural coatings
• The impact of asset design
• Fabrication installation and operations on the management of corrosion and asset integrity.

The course is intended to deliver a basic to intermediate level of understanding of materials engineering, corrosion principles, and its engineering, management and practical applications in specific relation to maintaining asset integrity within the oil and gas industry.

The course is designed for

Oil and gas professionals who require a thorough overview of current and emerging best practices of design principles and engineering guidelines related to flexible pipe for the offshore and subsea environment.

• Materials Engineers
• Corrosion Engineers
• Pipelines Engineers
• Integrity engineers
• Facilities engineers
• Project managers

Course outline

Introduction to and understanding operational oil and gas assets in the onshore offshore and subsea environment

Global energy and the increasing demands for oil and gas infrastructure

Operational assets - their functions and architecture – wellheads, production and processing and transport systems - pipelines, ESDVs, pig launchers/receivers, separators

An Introduction to Materials Selection

Materials for the oil and gas industry:

• C-steels
• Corrosion Resistant Alloys
• Non-metallics and composites

Selection process – criteria for selection:

• Deciding on the ‘optimum’ material
• Consideration of internal and external environments
• Flow conditions
• Materials and process data
• Strength, corrosion resistance, ductility, weldability, toughness
• Carbon Equivalent (CE)

Materials manufacture and testing

Putting it all together – production, processing and transport assets

Materials and Corrosion Codes & Standards

Corrosion Engineering – Basics

Corrosion in the oil and gas industry, and oil and gas operational assets

Corrosion and the overall influence on oil and gas operations – corrosion and safety risks

Dealing with corrosion in terms of asset design, fabrication, installation and operations

Corrosion Mechanisms and Corrosion Forms

Understanding typical corrosion forms and corrosion mechanisms - pitting, crevice, stress corrosion cracking (SCC), microbial corrosion (MIC), H2S, CO2 corrosion, hydrogen induced cracking (HIC), corrosion fatigue, erosion corrosion, CUI.

Types of corrosion typically found in operational assets

Corrosion models, corrosion rate evaluation, corrosion software

Looking at Internal and External Corrosion

Pipelines/flowlines

Risers

Valves

Platforms

Processing equipment

Impact of corrosion on oil and gas assets, corrosion failures and the consequences of asset failure, failure statistics

Looking at oil and gas asset failure statistics

Corrosion and the consequences of asset failure – hydrocarbon releases – statistics

An Introduction to Corrosion Integrity Management – interaction with HSE Management

What is integrity anyway?

Corrosion hazards and corrosion risk assessment

The RoadMAP to Corrosion Integrity Management - corrosion as a threat to Asset Integrity - the importance of maintaining asset integrity for oil and gas assets – risk based inspections

Integration of Corrosion and Safety Management – key elements – policies, organisation, roles and responsibilities, planning, performance measurements, audit review, corrosion management information flows

Health and Safety Management – key elements

Providing integrity management solutions – controlling and managing the risk of corrosion threats and failure

Criticality analyses/FMECA

Detailed Corrosion Integrity Management - “Corrosion management is that part of the overall management system, which is concerned with the development, implementation, review and maintenance of the corrosion policy.”

Why manage corrosion

Structured framework for corrosion integrity management, methodology and development

Sample checklist for assessment of Corrosion management system for processing facilities

Management of Oilfield Corrosion - Fundamentals of Corrosion Control, Prevention and Mitigation – the management of oilfield corrosion:

Corrosion mechanisms

Materials selection – C-Mn steels, CRAs, polymers

Chemical treatment (inhibitors, biocides)

Use of Cathodic Protection (CP) – theory and practical applications – ICCP and sacrificial anode systems

Linepipe and structural coatings (metallic, non-metallic and organic / paints)

Process & environmental control

Design (concept, engineering & detailing reviews, life cycle implications, risks)

Inspection and Monitoring

Corrosion Inspection and Monitoring systems

The role of inspection and monitoring for corrosion management

Corrosion monitoring and asset integrity

Monitoring tools and techniques for oil and gas assets and systems

Corrosion monitoring systems design

Practical corrosion monitoring

Corrosion – Industry Related Matters

Corrosion related codes and standards

Putting corrosion into perspective – the cost of corrosion to the oil and gas industry

Dealing with ageing assets – corrosion and structural assessments