Advanced Corrosion in Process Operation
$3500.00
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.
