Corrosion Control in Oil & Gas Exploration Industry

Overview:

Introduction:

The annual losses due to corrosion and the cost of rectification run to several billion dollars in oil & gas exploration industries worldwide. High production under aggressive and extreme operational conditions necessitates developing new materials with peculiar failure behaviors. Thus the industry operators are on continuous perusal with different corrosion management strategies. Yet unforeseen failures of top-side, sub-surface, and sub-sea infrastructure due to corrosion not only entail the loss of production but the loss of life as well. Prediction of failure behaviors, remaining useful life, and corrosion preventive measures are all approaches in corrosion management for the safe and economic operation of production wells and other facilities. Successful corrosion management influences the financial outcome of the company by ensuring the cost-effective selection of materials, chemical treatments, coatings, cathodic protection systems, and appropriate designs

Course Objectives:

At the end of this course, the participants will be able to:

• Understand the causes and control of corrosion in oil and gas production and processing

• Provide an overview of what corrosion is and what the major corrosion issues are in upstream oil and gas operations

• Understand how the materials corrode

• Learn techniques to be used to monitor corrosion and some basic corrosion control fundamentals

• Get skills and understanding to control and solve corrosion issues

• The basics of corrosion, its risk, and impacts on Oil and gas industry installations
• Different types of corrosion and their control
• The economic, environmental, and safety significance of corrosion
• Overview of different methods for monitoring corrosion
• Overview of corrosion protection techniques
• Cathodic protection and coating
• Identify the difference between the scarified and impressed current anodes
• The instrumentation required for cathodic protection of underground pipelines
• Various inspections, monitoring, and testing practices

Targeted Audience:

Professionals who are working in technical areas related to assets integrity management deal directly or indirectly with corrosion monitoring and its control.

Course Outlines:

Unit 1: Oil & Gas Production Fluid:

• Origin and Production of Oil & Gas

• Chemical Compositions of Production Fluids

• Oilfield Equipment

• Overview of Oilfield Processes & Operations

Unit 2: Metallurgy:

• Chemical Properties of Metals

• Mechanical Properties

• Alloying Elements

• Cooling of Metals

• Crystalline Forms of Metals

• Metal Defects

• UNS Numbers

• Properties of Common Oilfield Metals & Alloys

• Metallurgy of Oilfield Equipment

Unit 3: Corrosion Damage:

• Corrosion Fundamentals

• Common Forms of Corrosion

• Corrosion Monitoring in Plant and Facilities

• Non-Destructive Testing (NDT)

• Corrosion Failure & Root Cause Analysis

• Group Discussion- Applicable Standard Study for Corrosion Monitoring

Unit 4: Oilfield-Specific Corrosion:

• Internal Corrosion

• Water Corrosion

• Sour Corrosion

• Sweet Corrosion

• Oxygen Corrosion

• Top of Line Corrosion (TLC)

• Microbiologically Induced Corrosion (MIC)

• Sand Erosion

• External Corrosion

• Atmospheric (Marine) Corrosion

• Corrosion Under Insulation (CUI)

• Corrosion of Pipe Flanges

• Underground Corrosion

• Stray Current Corrosion

• Seawater Corrosion

• Oilfield Equipment Corrosion

Unit 5: Corrosion Prevention & Control Measures:

• Corrosion Control by Operations

• Corrosion Control by Processes

• Corrosion Control Design

• Corrosion Control by Material Selection

Unit 6: BIOCIDE TREATMENT

• Microbiologically Influenced Corrosion (MIC)

• Sulphate-Reducing Bacteria

• Biocide Selection & Treatment

Unit 7: Corrosion Management Strategy (CMS)

• Corrosion Management of Oilfield Equipment

• Corrosion Economy

• Corrosion Key Performance Indicators (KPIs)

• Asset Integrity and Corrosion Management

• Codes & Standards

• Corrosion Data Management

• Case Study-Catastrophic Corrosion Failure

Unit 8:  Chemical Treatment

• Corrosion inhibitors

• Performance Evaluation of Corrosion Inhibitor

• Application of Corrosion Inhibitors

Unit 9: Barrier Film (Coatings and Lining)

• Coating Fundamentals

• Performance Characteristics of Industrial Coatings

• Types of Coating Systems

• Surface Preparations

• Coating Applications

• Coating Defects

Unit 10: Cathodic Protection (CPS) Systems

• Cathodic Protection Fundamentals

• Galvanic Anodes CPS

• Impressed Current CPS

• CPS System Maintenance