Corrosion Prevention in Oil and Gas Industry

5-Day Professional Training Course

Course Overview

This 5-day Corrosion Prevention course provides comprehensive knowledge of corrosion mechanisms, prevention strategies, monitoring techniques, and materials selection specific to upstream, midstream, and downstream oil & gas operations. Covers practical solutions for corrosion control in production, processing, transportation, and storage facilities.

Target Audience: Corrosion engineers, production engineers, operations engineers, maintenance engineers, inspection engineers, integrity engineers, materials engineers, and technical professionals in oil & gas operations.

5-Day Course Outline

Day 1: Corrosion Fundamentals and Oil & Gas Environments

Morning:

• Course introduction and objectives

• Corrosion fundamentals and electrochemistry

• Forms of corrosion: uniform, pitting, crevice, galvanic, erosion-corrosion

• Economic impact of corrosion in oil & gas (NACE impact study)

• Major corrosion-related failures and incidents

Oil & Gas Corrosion Environments:

• Upstream: wellbore, downhole, production tubing

• Midstream: pipelines, gathering systems, processing

• Downstream: refining, storage, distribution

• Offshore vs. onshore challenges

Afternoon:

• CO₂ corrosion (sweet corrosion):

  • Mechanisms and chemistry

  • Partial pressure calculations

  • De Waard-Milliams prediction model

  • Temperature and pH effects

  • Protective iron carbonate scales

• H₂S corrosion (sour corrosion):

  • Sour service environment definition

  • Sulfide film formation

  • Weight loss corrosion

  • Hydrogen damage mechanisms

• Combined CO₂/H₂S corrosion

• Organic acid corrosion

Day 2: Corrosion Mechanisms and Damage Types

Morning:

• Localized corrosion:

  • Pitting corrosion mechanisms

  • Crevice corrosion

  • Under-deposit corrosion

  • Top-of-line corrosion (TLC)

• Microbiologically Influenced Corrosion (MIC):

  • Sulfate-reducing bacteria (SRB)

  • Acid-producing bacteria (APB)

  • Iron-oxidizing bacteria

  • Detection and monitoring

  • Biocide treatment programs

• Galvanic corrosion:

  • Galvanic series

  • Mixed metallurgy issues

  • Prevention strategies

Afternoon:

• Environmental cracking:

  • Stress Corrosion Cracking (SCC)

  • Sulfide Stress Cracking (SSC) - NACE MR0175/ISO 15156

  • Hydrogen-Induced Cracking (HIC)

  • Stress-Oriented Hydrogen-Induced Cracking (SOHIC)

  • Hydrogen blistering

  • Corrosion fatigue

• Erosion-corrosion and flow-induced corrosion:

  • Sand production effects

  • Velocity limits

  • Cavitation damage

  • Impingement attack

Workshop 1: Corrosion mechanism identification from case photos

Day 3: Materials Selection and Corrosion-Resistant Alloys

Morning:

• Materials selection methodology:

  • Service condition analysis

  • Corrosion rate prediction

  • Design life considerations

  • Cost-benefit analysis

• Carbon and low-alloy steels:

  • API grades and specifications

  • Limitations and applications

  • Corrosion allowance determination

• Corrosion-Resistant Alloys (CRAs):

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

  • Nickel alloys (Alloy 625, 825, C-276, Inconel)

  • Titanium alloys

  • PREN (Pitting Resistance Equivalent Number)

  • Critical Pitting Temperature (CPT)

Afternoon:

• NACE MR0175/ISO 15156 compliance:

  • Sour service material requirements

  • SSC-resistant materials

  • Hardness limits (HRC 22 maximum for carbon steel)

  • Environmental limits and testing

• Material selection for specific services:

  • High CO₂ environments

  • High H₂S environments

  • High temperature/high pressure (HTHP)

  • Produced water systems

  • Gas processing facilities

• Non-metallic materials:

  • Glass-reinforced plastics (GRP/FRP)

  • Lined pipe and vessels

  • Coatings and linings

Workshop 2: Materials selection exercise for given conditions

Day 4: Corrosion Prevention Methods

Morning:

• Corrosion inhibitors:

  • Inhibitor types: filming, neutralizing, scavenger

  • Application methods: batch, continuous, squeeze

  • Inhibitor selection criteria

  • Performance testing and monitoring

  • Dosage optimization

  • Green inhibitors and environmental considerations

• Chemical treatment programs:

  • Scale inhibition

  • Oxygen scavengers

  • H₂S scavengers

  • pH control and buffering

  • Biocide programs for MIC control

Afternoon:

• Protective coatings:

  • External coatings for pipelines:

    • Three-layer polyethylene (3LPE)

    • Fusion-bonded epoxy (FBE)

    • Polyurethane coatings

    • Coating selection and application

  • Internal coatings:

    • Epoxy coatings

    • Phenolic coatings

    • Polyurethane linings

    • Application and quality control

  • Surface preparation standards (NACE/SSPC)

  • Coating inspection and testing

• Cathodic protection (CP):

  • Sacrificial anode systems:

    • Aluminum, zinc, magnesium anodes

    • Anode selection and design

    • Installation methods

  • Impressed current systems (ICCP):

    • Rectifier systems

    • Anode beds and groundbeds

    • Design calculations

  • CP criteria and monitoring

  • Pipeline CP systems

  • Offshore platform CP

  • Internal CP for storage tanks

Day 5: Monitoring, Inspection, and Management

Morning:

• Corrosion monitoring techniques:

  • Online monitoring:

    • Electrical Resistance (ER) probes

    • Linear Polarization Resistance (LPR) probes

    • Galvanic probes

    • Sand monitors

    • Hydrogen probes

    • Biofilm monitors

  • Offline monitoring:

    • Corrosion coupons (weight loss)

    • Spool piece examination

    • Side-stream monitoring

• Inspection methods:

  • Visual inspection

  • Ultrasonic thickness measurement (UT)

  • Radiographic testing (RT)

  • Magnetic flux leakage (MFL)

  • In-line inspection (smart pigging)

  • Electromagnetic inspection

  • Corrosion mapping

Afternoon:

• Corrosion management programs:

  • Corrosion management framework

  • Integrity Operating Windows (IOW)

  • Key Performance Indicators (KPIs)

  • Data management and trending

  • Corrosion risk assessment

  • Failure investigation procedures

• Specific applications:

  • Wellbore and downhole corrosion:

    • Tubing and casing protection

    • Packer fluid selection

    • Completion fluid corrosivity

  • Pipeline corrosion management:

    • External corrosion (soil corrosion)

    • Internal corrosion control

    • Pipeline integrity management (IMP)

    • Inline inspection planning

  • Production facility corrosion:

    • Separator systems

    • Produced water handling

    • Gas processing units

    • Storage tank corrosion

  • Refinery corrosion prevention:

    • Crude unit corrosion control

    • High-temperature units

    • Amine systems

    • Cooling water systems

Case Studies: Major corrosion failures and prevention strategies

Course Review and Assessment:

• Key concepts summary

• Q&A session

• Final Exam: 50 questions, 90 minutes, 70% pass

• Course evaluation

• Certificate presentation

Learning Outcomes

✅ Understand corrosion mechanisms in oil & gas environments
✅ Identify and predict CO₂, H₂S, and MIC corrosion
✅ Select materials per NACE MR0175/ISO 15156
✅ Apply corrosion inhibitors effectively
✅ Design and implement coating systems
✅ Specify cathodic protection systems
✅ Implement corrosion monitoring programs
✅ Develop corrosion management strategies
✅ Investigate corrosion failures
✅ Optimize corrosion prevention economics

Course Features

Materials: 500+ page manual, standards guides, selection charts, calculation tools, USB resources

Assessment: Workshops, case studies, written exam

Certification: 40 CPD/CEU hours, industry-recognized certificate

Method: 55% theory, 45% practical exercises and case studies

Who Should Attend

• Corrosion engineers and specialists

• Production engineers

• Operations engineers

• Maintenance engineers

• Inspection engineers

• Integrity engineers

• Materials engineers

• Process engineers

• Facility engineers

• Pipeline engineers

• Asset integrity managers

• HSE professionals

Prerequisites: Engineering degree or technical diploma + 2 years relevant experience, OR 5+ years field experience