TRAINING DATE:

26-30 SEPTEMBER 2022 CORROSION AND

LOCATION
DUBAI, UAE
CORROSION CONTROL
 ABOUT
TRAINING

The practical value of corrosion countermeasures, no matter how perfect they may be in the theoretical or
laboratory sense, depends upon specific knowledge and attitudes on the part of supervisors, and
individuals with related responsibilities.
This course is directed at field operating personnel, in the hope that continued use will enhance the
knowledge and attitudes mentioned, specifically:
Appreciation of the enormous cost of Fertilizers industries corrosion.
Ability to recognize early indications of corrosion.
Awareness of the importance of early reporting.
Desire to take effective part in the solution.
The course makes full use of the simplest possible terms and descriptions.
The circumstances of corrosion vary widely, and technical advice should always be sought when causes
are obscure, or the cost or severity is high.

MERIM ENGINEERING

WHY
MEC is committed to deliver targeted learning aided by technology
and innovative solutions blended with unmatched quality services.

CHOOSE
CUSTOM-MADE: Training is tailored as per specific needs
ECONOMICAL: is a cost-effective for group of candidates
QUALITY Assurance Duties and Responsibilities
IMPORTANT: Well-adjusted to latest global industry standards and

US?
business requirements

FLEXIBILITY: Training sessions are set according to client requirements

COMPLIANT: Trainer is picked by the client and trainees to fit the exact
proficiency level of the group
EXPERTS World Practiced Trainers that engage you in participative and
cooperative training
 TRAINING
OBJECTIVE

OBJECTIVES
WHO SHOULD
JOIN? Upon completion of this course, participants will gain an
understanding of corrosion ramifications in oil and Gas industries
and how to;

OPERATORS / SR. OPERATORS
/ASC/SCS
INSPECTION CORROSION
STAFF & ENGINEERS
PROCESS ENGINEERS,
REFINERY CHEMISTS
CHEMICAL ENGINEERS,
ENVIRONMENTAL SPECIALISTS
Aim to understand the basics of Corrosion, different types of
corrosion, its control, risk and impacts of corrosion in Fertilizer
industry installations.
Describe corrosion mechanism and chemical reactions.
Interpret corrosion theory. Describe corrosion mechanism
and chemical reactions.
Describe corrosion prevention/ control techniques.
Differentiate between corrosion due to dissolved oxygen,
microbiological, CO2, H2S, etc.,
Evaluate Corrosion inhibitors used in fertilizer industries, their
specs and work mechanism.
To present the advanced corrosion monitoring technologies.
Corrosion Testing methods
Describe Bacteria formation and effect
To illustrate study cases pertaining to corrosion failures,
mainly pipelines, storage tanks, pressure vessels, boilers and
heat exchangers.
Analyze corrosion coupons, corrosion rigs, corrosion probes,
etc., and suggest remedial measures for causes of corrosion
 KEY MODULES
Why is corrosion control important?

Corrosion prevention is used in industries to maintain the safety, reliability and

effectiveness of materials. It also helps in reducing the expensive replacement processes
required when corrosion occurs.

INTRODUCTION TO CORROSION
Historical background
Definitions
Corrosive environment

1
Consequences of corrosion
Cost of corrosion
Breakdown of spending on corrosion
Corrosion science and corrosion engineering
Inter-disciplinary nature of corrosion
Corrosion education
Functional aspects of corrosion
Five good reasons to study corrosion
 KEY MODULES

BASIC CONCEPTS IN CORROSION

Basic Concepts in Corrosion
Corrosion & Society
Corrosion: what it is, Corrosion: its economic, social, political and environmental impacts,
How to avoid liabilities due to corrosion,
2 Lessons of history.
Basic concepts relevant to corrosion
Terminology and convention,
Primer in chemistry and electrochemistry,
Potential-pH diagram,
Kinetics of corrosion,
High temperature oxidation

CHEMISTRY AND BASICS OF CORROSION

Electrochemistry of Corrosion,
Electrochemical Reactions,
Electrolyte Conductivity,
3 Faraday’s Law of Electrolysis,
Electrode Potentials and Current,
Corrosion Rate Expressions,
pH,
Passivity,
Potential-pH (Pourbaix) Diagrams
 KEY MODULES

CORROSIVE ENVIRONMENTS
External Environments:
Atmospheric Corrosion, Water as a Corrosive Environment,
Soils as Corrosive Environments, Corrosion under Insulation,
4 Internal Environments:
Crude Oil, Natural Gas, Oxygen, CO2, H2S, Organic Acids, Scale,
Microbially Influenced Corrosion (MIC), Mercury, Hydrates, Fluid Flow Effects on Corrosion

FORMS OF CORROSION
General Corrosion,
Galvanic Corrosion:
Galvanic Coupling of Two or More Metals, Area Ratio, Polarity Reversal,
Conductivity of the Electrolyte, Control of Galvanic Corrosion,
Pitting Corrosion:
Occluded Cell Corrosion, Pitting Corrosion Geometry and Stress Concentration,
Pitting Initiation, Pitting Resistance Equivalent Numbers (PRENs),
5 Statistics, Prevention of Pitting Corrosion,
Crevice Corrosion:
Alloy Selection, Filiform Corrosion,
Intergranular Corrosion:
Stainless Steels, Corrosion Parallel to Forming Directions, Aluminum, Other Alloys,
Dealloying:
Mechanism, Selective Phase Attack, Susceptible Alloys, Control,
Erosion Corrosion: Mechanism, Velocity Effects, Materials, Cavitation, Areas of Concern, Control,
Environmentally Induced Cracking:
SCC, HE and H2S-Related Cracking, Hydrogen Attack, Liquid Metal Embrittlement (LME), Corrosion
Fatigue,
Microbiologically induced corrosion (MIC)
Mechanical and Metal failures as per API 571
 KEY MODULES

AMMONIA AND UREA PLANTS EQUIPMENT

– CORROSION AND MATERIAL SELECTION
Overview of the Corrosion Types:
Desulphurization and Air-Compression, Steam Reforming
CO Conversion and Methanation, CO2 Removal, Syngas Compression
NH3 Synthesis, Refrigeration, NH3 & H2 Recovery, team and Condensate System

Corrosion Mechanism:
Uniform Corrosion, Selective (localized) Corrosion, Crevice Corrosion
Intergranular corrosion, Stress Corrosion Cracking (SCC), Galvanic Corrosion
Corrosion Fatigue, Erosion
Hydrogen, High Temperature Hydrogen Attack (HTHA)
Hydrogen Induced Cracking (HIC), Hydrogen Induced Stress Cracking (HISC)
Sulphide Stress Corrosion, Hydrogen Embrittlement, Measures to Prevent Damages Caused by
Hydrogen Attacks, High Temperature Corrosion (HTC)

6 Oxidation
Sulphur Attack
Nitriding
Carburization and Metal Dusting
Material Selection Philosophy for different Corrosion Mechanisms:
Hydrogen, H2S, CO2 Wet Corrosion, Metal Dusting, MDEA, Cooling water, Chlorides in the
atmosphere
Desulphurization and Air-Compression
Steam Reforming
CO Conversion and Methanation
CO2 Removal : CO2 Removal Potassium Carbonate, CO2 Removal MDEA
Syngas Compression
NH3 Synthesis
Refrigeration
NH3 & H2 Recovery
Steam and Condensate System
 KEY MODULES

CORROSIVE ENVIRONMENTS
Effect of pH on corrosion of carbon steel
Sea water
Sodium chloride and sea water
Sea water immersion
Fresh water
O2 solubility and effect on corrosion rate
7 Effect of temperature on corrosion rate
Effect of sulfates, chlorides and carbonates on corrosion rate
Effect of velocity on corrosion rate
Effect of H2S
Effect of CO2
Exposure time versus corrosion arte
Microbiological effects

MATERIALS
Metallurgy Fundamentals
Forming Methods,
Materials Specifications:
API,

8
AISI—The American Iron and Steel Institute,
ASTM International—formerly the American Society for Testing and Materials,
ASME,
SAE International,
UNS,
NACE—The Corrosion Society,
Carbon Steels, Cast Irons, and Low-Alloy Steels,
Corrosion Resistant Alloys CRAs,
Polymers, Elastomers, and Composites,
 KEY MODULES

CATHODIC PROTECTION
Basis of cathodic protection
Working of cathodic protection system
Factors leading to corrosion of underground metallic structures
Electrical basis of cathodic protection
Electrochemical theory of cathodic protection
Anodic polarization
Cathodic protection systems
Components of galvanic systems
Impressed current system
Components of impressed current systems and AC/DC systems
Types of ground-beds
Major impressed current anodes
Protection of submarine pipelines
9 Design parameters in cathodic protection
Current requirements
Backfill
Measurements in cathodic protection
Pipe-to-soil potential
Factors affecting pipe-to-soil potential
Potential survey
Measurement of current flow
Reference electrode
Coating resistance tests
Current requirement tests
Current density requirement for a bare structure
Stray current corrosion
Cathodic protection interference's, Design charts
Ground-bed design, Soil resistivity and pipe-to-soil potential survey
Calculations in cathodic protection design, Important formulae in cathodic protection calculations
 KEY MODULES

CORROSION INSPECTION, MONITORING,

AND TESTING
Inspection:
Visual Inspection (VI),
Penetrant Testing (PT),
Magnetic Particle Inspection (MT),
Ultrasonic Inspection (UT),
Radiography (RT),
Eddy Current,
Positive Material Identification (PMI),
Thermography,
Additional Remarks about Inspection,
Monitoring:
10 Monitoring Probes,
Mass-Loss Coupons and Probes,
Electrical Resistance (ER) Probes,
Electrochemical Corrosion Rate Monitoring Techniques,
Hydrogen Probes,
Sand Monitoring,
Fluid Analysis,
Bacterial Growth Monitoring,
Additional Comments on Monitoring,
Testing:
Hydrostatic Testing,
Laboratory and Field Trial Testing,
 KEY MODULES

CORROSION CONTROL
CORROSION CONTROL METHODS:
Approaches to Corrosion Control
Alter Material Composition
Alter Electrolyte Composition
Physical Alteration of the System
Isolate the Metal from the Electrolyte
11 Chemical Inhibitors
Cathodic Protection
Method Selection:
Cost of Materials, Labor Costs, The Present Value of Money

CORROSION CONTROL BY INHIBITION

Scope of inhibitor
Examples of application of inhibitors
Important consideration in selection of inhibitors
Important terms related to inhibitors
Classification of inhibitors

12 Description of inhibitors
Inorganic anodic inhibitors
Organic inhibitors
Synergistic inhibitors
Scavengers
Neutralizers
Scale inhibitors
Rebar inhibitors
Biocides
Inhibitor application techniques
Vapor phase inhibitors
Inhibitor efficiency and inhibitor concentration
 KEY MODULES

COATINGS AND PAINTINGS

Classification of coatings, Scope of coatings
Painting, coating and lining, Paint coating system, Paint coating components
Composition and functions of paint coating components, Classification of binders
Pigments, Solvent

13 Thinners (diluents), Additives

Metallic coatings, Aluminum coatings
Tin coatings, Nickel coatings
Cadmium coating, Conversion coatings
Anodized coatings, Glass flake coatings
Failure of paints and coatings. Selection of coatings

CORROSION MONITORING TECHNIQUES

Coupons: Types, Flat Plates, Rods, Discs, Spools
Holders and Insulators: Coupon Retrieval Systems, Coupon Handling, Coupon Location and
Orientation, Coupon Evaluation
Linear Polarization Meters - Instantaneous Corrosion Rates Theory, Potentiodynamic Polarization
14 Studies
Electrical Resistance Probes, Galvanic Probes
Hydrogen Permeation Rate Measurement: Pressure Hydrogen Probe, Electrochemical Hydrogen
Probe
Dissolved Gas Analysis, Corrosion Product Analysis
Iron Counts, Inhibitor Concentrations
Bacteria Counts, Downhole Inspection

CORROSION OF OILFIELD EQUIPMENT

15 Drilling and Exploration,
Wells and Wellhead Equipment,
Facilities and Surface Equipment,
Pipelines and Flowlines
MERIM ENGINEERING CONSULTING FZCO

CONTACT US
MERIM ENGINEERING CONSULTING FZCO
Dubai Silicon Oasis DDP, Building A2, Office 103
P.O. Box 7800 Dubai, United Arab Emirates

M: +971 50 6525 976 M: +971 54 719 9979

ISO 9001:2015 QMS # 200213019711 ISO 14001:2015 EMS # AE91913B

ISO 45001:2018 HSE # AE91040C-1 IFPS Membership # 64013 UK

JSRS # AE101615 OMAN Dubai Chamber # 366508

Email: info@me-consulting.ae Web: www.me-consulting.ae