Advanced Corrosion in Process Operations

5-Day Professional Training Course

Course Overview

This intensive 5-day Advanced Corrosion in Process Operations course provides experienced professionals with comprehensive knowledge of corrosion mechanisms, damage assessment, prevention strategies, and monitoring techniques specific to oil & gas, petrochemical, and refining operations. Based on API RP 571 standards and aligned with AMPP (NACE) certification requirements.

Target Audience: Corrosion engineers, inspection engineers, process engineers, maintenance engineers, materials engineers, integrity managers, and technical professionals responsible for corrosion control in process industries.

Day 1: Fundamentals and High-Temperature Corrosion

Morning Session (0900-1230)

Module 1: Course Introduction & Advanced Corrosion Fundamentals

• Course objectives and structure

• Electrochemical principles review

• Forms of corrosion (uniform, localized, SCC, fatigue)

• Material properties affecting corrosion

Module 2: API RP 571 Introduction

• Overview of 70 damage mechanisms

• Integration with API 510, 570, 580, 581, 579

• Application to RBI and FFS

• Latest edition updates (2020)

Afternoon Session (1330-1700)

Module 3: High-Temperature Corrosion Mechanisms

• Sulfidation: Mechanisms, temperature ranges, materials selection, McConomy curves

• Naphthenic Acid Corrosion (NAC): TAN significance, temperature effects, prediction techniques

• High-Temperature Oxidation: Scale formation, chromium requirements, steam oxidation

• Carburization: Carbon pickup mechanisms, metal dusting, materials resistance

• Creep & Stress Rupture: Larson-Miller parameter, remaining life assessment

Day 2: Environmental Cracking and Wet Corrosion

Morning Session (0900-1230)

Module 4: High-Temperature Damage (Continued)

• High-Temperature Hydrogen Attack (HTHA): Nelson curves, detection methods, API 941

• Thermal & Mechanical Fatigue: S-N curves, vibration damage, life prediction

Module 5: Environmental Cracking Mechanisms

• Wet H₂S Damage: Blistering, HIC, SOHIC, SSC (NACE MR0175/ISO 15156)

• Chloride SCC: Mechanisms, temperature thresholds, materials resistance

• Caustic SCC: Concentration effects, prevention strategies

• Polythionic Acid SCC (PASCC): Sensitized stainless steels, prevention

Afternoon Session (1330-1700)

Module 6: Process-Specific Corrosion - Part 1

• Amine Corrosion & Cracking: Degradation products, heat-stable salts, SCC conditions

• Ammonium Bisulfide/Chloride Corrosion: pH effects, wash water strategies

• HCl & HF Corrosion: Dew point corrosion, materials selection, safety considerations

Workshop 1: Damage Mechanism Identification Case Studies

Day 3: Aqueous Corrosion and Materials Selection

Morning Session (0900-1230)

Module 7: Process-Specific Corrosion - Part 2

• Sulfuric & Phosphoric Acid Corrosion: Concentration/temperature effects

• Phenol (Carbolic Acid) Corrosion

Module 8: Aqueous Corrosion Systems

• CO₂ Corrosion: Mechanisms, De Waard-Milliams model, inhibitors

• Cooling Water Corrosion: MIC, galvanic corrosion, treatment programs

• Boiler Water/Steam Condensate: Oxygen pitting, FAC, caustic gouging

• Corrosion Under Insulation (CUI/CUF): Temperature ranges, inspection strategies

Afternoon Session (1330-1700)

Module 9: Metallurgy and Materials Selection

• Carbon steels, low-alloy steels, Cr-Mo steels

• Stainless steels (austenitic, ferritic, duplex, super duplex)

• Nickel-based alloys (400, 600, 625, 825, C-276)

• Corrosion-Resistant Alloys (CRAs): PREN, CPT, cost-benefit analysis

• Non-metallic materials

Module 10: Corrosion Prevention Methods

• Protective Coatings: Selection, surface preparation, application

• Cathodic Protection: Galvanic anodes, ICCP systems, monitoring

• Corrosion Inhibitors: Types, application methods, performance monitoring

Day 4: Inspection, Monitoring & Risk Assessment

Morning Session (0900-1230)

Module 11: Corrosion Inspection Techniques

• NDT Methods:

  • Visual Inspection (VT), Remote Visual (RVI)

  • Ultrasonic Testing (UT): Conventional, PAUT, TOFD, corrosion mapping

  • Radiographic Testing (RT): X-ray, gamma-ray, digital radiography

  • Magnetic Flux Leakage (MFL), Eddy Current (ECT), Acoustic Emission

  • Infrared Thermography, 3D scanning

Module 12: Corrosion Monitoring Programs

• Online monitoring techniques

• ER probes, LPR probes, corrosion coupons

• Hydrogen probes for HTHA monitoring

• Data interpretation and trending

• Integration with integrity management systems

Afternoon Session (1330-1700)

Module 13: Risk-Based Inspection (RBI)

• API 580/581 Fundamentals:

  • Probability of Failure (POF) assessment

  • Consequence of Failure (COF) evaluation

  • Risk matrix development

  • Inspection planning based on risk

  • Qualitative vs. quantitative RBI

Module 14: Fitness-for-Service (FFS)

• API 579-1/ASME FFS-1:

  • Level 1, 2, 3 assessments

  • General/local metal loss evaluation

  • Pitting and crack-like flaw assessment

  • Remaining strength factor (RSF) calculations

  • Remaining life predictions

Workshop 2: Inspection Planning & Risk Assessment Exercise

Day 5: Integrity Management and Case Studies

Morning Session (0900-1230)

Module 15: Integrity Operating Windows (IOW)

• Safe operating envelope concepts

• Critical process parameters affecting corrosion

• Temperature, pressure, pH, composition limits

• Integration with process control and PSM

Module 16: Corrosion Management Systems

• Program development and implementation

• Organizational structure and responsibilities

• Industry standards (API, ASME, AMPP, ISO)

• Corrosion management software tools

• KPIs and continuous improvement

Afternoon Session (1330-1700)

Module 17: Case Studies & Failure Analysis

• Major Failures: Refinery, pipeline, storage tank incidents

• Failure investigation methodology

• Root cause determination

• Corrective actions and lessons learned

Module 18: Course Review & Assessment

• Key learning points summary

• Interactive Q&A session

• Final Examination: 70 questions, 3 hours, 70% passing score

• Course evaluation

• Certificate presentation

Learning Outcomes

✅ Identify 70+ damage mechanisms per API RP 571
✅ Analyze high-temperature corrosion (sulfidation, NAC, HTHA)
✅ Assess environmental cracking (SCC, HIC, SOHIC, SSC)
✅ Select appropriate materials for corrosive environments
✅ Implement corrosion monitoring and inspection programs
✅ Apply RBI methodologies (API 580/581)
✅ Conduct FFS assessments (API 579)
✅ Develop comprehensive corrosion management systems
✅ Investigate failures and determine root causes

Course Features

Training Methodology:

• 60% Theory: Interactive lectures, case studies, standards interpretation

• 40% Practice: Workshops, specimen analysis, NDT demonstrations, failure analysis

Materials Provided:

• Comprehensive 800+ page manual (digital & printed)

• API RP 571 reference summaries

• Materials selection guides

• USB drive with presentations

• 6-month online resource access

Assessment:

• Written exam (70 questions, 70% pass)

• Workshop participation

• Case study analysis

Certification:

• Advanced Corrosion Certificate

• 40 CPD/CEU hours

• Preparation for API 571 certification exam

Who Should Attend

• Corrosion engineers and specialists

• Process and mechanical engineers

• Inspection and integrity engineers

• Materials and metallurgical engineers

• Maintenance engineers and managers

• Plant and operations managers

• Asset integrity managers

• NDT Level II/III professionals

• Consultants and contractors

Prerequisites

• Engineering degree OR 5+ years relevant experience

• Basic corrosion knowledge

• Familiarity with process plant operations

• Understanding of materials and metallurgy

Keywords

Primary: Advanced corrosion training, Process operations corrosion course, API 571 training, Corrosion management certification, Refinery corrosion control

Secondary: NACE corrosion specialist, AMPP certification, High-temperature corrosion, Sulfidation training, Risk-based inspection, Fitness-for-service, Damage mechanisms course

Long-tail: 5-day advanced corrosion process operations training, API 571 damage mechanisms certification course, Refinery corrosion inspection techniques training, High-temperature hydrogen attack HTHA course, Corrosion failure analysis professional training

Investment & Registration

Course Fee Includes:

• 5 days expert instruction

• Comprehensive training materials

• Certificate of completion

• Meals and refreshments

• Networking opportunities

Special Offers:

• 🎯 Early Bird: 20% off (90 days advance)

• 🎯 Group: 15-20% off (3+ participants)

• 🎯 Alumni: 25% off previous graduates

Customization Available:

• In-house delivery at your facility

• Tailored content to specific operations

• Post-course consulting support

Testimonials

“The most comprehensive corrosion training in my 15-year career. I passed API 571 on first attempt!” — Senior Corrosion Engineer, Major Oil Company

“Excellent balance of theory and practice. My ability to identify and mitigate corrosion risks improved dramatically.” — Integrity Engineer, International Refinery

“Outstanding technical depth! The materials selection module alone was worth the investment.” — Chief Inspector, EPC Contractor

Why Choose This Course?

✓ Based on API RP 571-2020 latest edition
✓ Aligned with AMPP certification requirements
✓ Expert instructors with 20+ years experience
✓ 40% hands-on workshops and case studies
✓ Globally recognized certification
✓ Preparation for API 571 exam

Related Courses

• API 571 Certification Preparation (5 days)

• API 580/581 Risk-Based Inspection (5 days)

• API 579 Fitness-for-Service (5 days)

• High-Temperature Corrosion Specialist (3 days)

• CUI Management (2 days)

Meta Description: “5-day Advanced Corrosion in Process Operations course. Master 70+ damage mechanisms per API 571. Expert training in sulfidation, NAC, HTHA, SCC, RBI, FFS. API 571 exam preparation. Globally recognized. Register now!”

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Invest in excellence. Prevent costly failures. Lead corrosion management.

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