"Fundamentals of Corrosion (NACE)" Course

Course Objectives

The goal of the course is to provide corrosion engineers, technical supervision inspectors and managers with modern knowledge about corrosion mechanisms and skills for identifying, monitoring and inspecting corrosion. The course includes general information about corrosion mechanisms and causes of its occurrence. It provides a basic overview of corrosion effects on various materials and protective measures used for its prevention, as well as references to other issues related to risks, inspections, monitoring and safe equipment operation.

Corrosion is one of the most serious problems in the oil and gas industry, which can lead to accidents and productivity loss. Our course will help you understand the basic principles of corrosion management and control in production, as well as learn to apply them in practice. We offer a full spectrum of training by our experienced instructors ready to share their knowledge and production experience. Our course will help you become a specialist in the field of corrosion management and control at oil and gas preparation and oil and gas processing enterprises.

A specialist who successfully completes this course will gain understanding of basic corrosion mechanisms sufficient for further professional development within the NACE certification program.

Who the Course is Intended For

The course is intended for persons interested in studying corrosion fundamentals, including but not limited to the following:

• Engineers
• Managers
• Supervisors
• Technical specialists
• Consultants
• Inspectors

What Course Participants Receive

• Quality knowledge about basic corrosion mechanisms.
• Modern experience in combating corrosion based on analysis of real examples.
• Certificate, set of informational reference materials.

How Training is Conducted

• Format: in-person or online mode (by choice).
• Classes are held in a friendly atmosphere with comfortable coffee breaks.
• Course duration: 5 days.
• Course is conducted in Russian.
• All course participants will receive a digital copy of materials.

Training Program "Fundamentals of Corrosion (NACE)"

At the end of each chapter, review questions are provided to help participants test their own knowledge. A final written exam is also provided, which will be taken on the 5th day of training. Exam questions are based on learning objectives and material covered in lectures.

Day 1

Module 1: Fundamentals of Corrosion Processes

• Definition of corrosion.
• Importance of corrosion control.
• Direct costs of corrosion.
• Maintenance, repair and replacement costs.
• Indirect costs of corrosion.
• Environmental impact.
• Corrosion impact on design.
• Overview of corrosion forms.

Module 2: Electrochemistry and Metal Corrosion

• Basic terms and definitions.
• Oxidation/reduction reactions.
• Corrosion as an electrochemical process.
• Thermodynamics.
• Concepts of electrolytic potential and its influence.
• Reference electrode.
• Galvanic series.
• Kinetics.
• Faraday's law / Evans diagrams.
• Impact on individual areas.
• Galvanic corrosion.
• Thermogalvanic corrosion.
• Passivation and pH acidity.

Module 3: Corrosive Environments

• Atmospheric influence on corrosion.
• Industrial.
• Marine.
• Soil.
• Confined spaces.
• Corrosion under insulation.
• Water impact.
• Dissolved gases impact.
• Dissolved salts impact.
• pH acidity.
• Mineral deposits impact.
• Microbiological corrosion.
• High-temperature environments.

Day 2

Module 4: Materials

• Material properties.
• Metallurgy fundamentals.
• Structure manufacturing methods.
• Material specifications.
• Metals.
• Cast irons, carbon and low-alloy steels.
• Stainless steels.
• Martensitic and ferritic steels.
• Austenitic and super-austenitic.
• Duplex and super-duplex.
• Nickel-based alloys.
• Copper alloys.
• Titanium alloys.
• Aluminum, zinc.
• Non-metallic materials.
• Polymers.
• Polymer degradation.
• Polymer joining.
• Composite materials.
• Concrete.
• Ceramics.

Day 3

Module 5: Forms of Corrosion

• Types of corrosion and their interaction.
• General corrosion.
• Description.
• Corrosion rates.
• Predictability and measurements.
• General corrosion control.
• Localized corrosion.
• Pitting corrosion.
• Definition of pitting corrosion.
• Pitting corrosion, pit formation rate, control and measurement.
• Crevice corrosion.
• Definition of crevice corrosion.
• Control and measurement.
• Filiform corrosion.
• Definition.
• Control and measurement.
• Galvanic corrosion.
• Electrochemical process.
• Metal electronegativity series.
• Galvanic corrosion rate.
• Potential difference.
• Environmental nature, polarization, spatial effects.
• Electrolyte resistivity influence.
• Prediction and control of galvanic attack.
• Material selection.
• Electrical insulation.
• Role of anti-corrosion coatings.
• Cathodic protection.
• Changing corrosive activity of environments.
• Cracking mechanism.
• Cracking factor control.
• Types of corrosion cracking, including stress corrosion cracking.
• Hydrogen and sulfide stress cracking.
• Hydrogen cracking recognition.
• Hydrogen cracking mechanism.
• Sulfide stress cracking.
• Metal fatigue and corrosion.
• Erosion.
• Cavitation.
• Intergranular corrosion.
• Fretting corrosion.
• Alloying element loss.
• High-temperature oxidation.
• High-temperature sulfur corrosion.
• Decarburization (Hydrogen effect).
• Carburization.
• High-temperature corrosion control.

Module 6: Design Considering Corrosion Processes

• Structural properties.
• Process parameters: temperature, flow rate, pressure, chemical composition.
• Drainage.
• Dissimilar metals.
• Crevices.
• Corrosion allowance/service life.
• Maintenance and inspections.

Day 4

Module 7: Corrosion Control Methods

• Material selection.
• Factors affecting material selection.
• Corrosion resistance in contact with environments.
• Availability of design and test data.
• Mechanical properties.
• Cost/availability.
• Expected equipment service life.
• Reliability.
• Changes in corrosive activity of environments.
• Chemical treatment.
• Water treatment.
• Anti-corrosion coatings and applications.
• Protection mechanisms.
• Expected coating properties.
• Anti-corrosion coating system selection.
• Application.
• Quality control.
• Cathodic and anodic protection.
• Operating principle.
• Sacrificial anode cathodic protection.
• Impressed current electrochemical protection.
• Measurements and effectiveness verification.
• Maintenance.

Module 8: Inspection, Monitoring and Testing

• Introduction to corrosion diagnostics.
• Control methods.
• Visual inspection.
• Radiography.
• Ultrasonic testing.
• Eddy current testing.
• Penetrant testing (liquid penetrant inspection).
• Magnetic particle testing.
• Material identification.
• Thermographic inspection.
• Corrosion monitoring.
• Corrosion control.
• Corrosion coupons, witness samples.
• Corrosion rate measurement sensors based on electrical resistance measurement.
• Corrosion rate measurement sensors based on linear polarization resistance measurement.
• Galvanic monitoring.
• Hydrogen probes.
• Water chemical composition monitoring.
• Microbiological contamination control.
• Cathodic protection systems.

Day 5

Module 9: Enterprise Corrosion Management System

• Introduction to corrosion management.
• Responsibilities, job division and authorities.
• Corrosion management strategy.
• Material selection stages and barrier effectiveness assurance measures.
• Corrosion management system audit.
• Continuous improvement of corrosion management processes.
• Reporting.
• Corrosion management guidelines.
• Corrosion condition report.
• Corrosion management analysis.
• Risk-based inspection plan.
• Data update control.