This 5-day corrosion short course aims to provide the participants with a thorough understanding of the various damage mechanisms contained in the latest edition of API RP 571-2020 that can affect process equipment, the type and extent of damage that can be expected, and how this knowledge can be applied to the selection of effective inspection methods to detect size and characterise damage. The 66 damage mechanisms to be discussed in this corrosion short course are common to a variety of industries including refining and petrochemical, pulp and paper, and fossil utility

This course will specifically benefit Engineers, Supervisors, and Managers from the following disciplines : Mechanical Engineering, Inspection, Maintenance& Operations, Technical & Engineering, QAQC, and technical personnel with 2-3 years of experience in the management and planning of inspection and
maintenance activities of piping system at upstream oil & gas facilities, refineries, process plants and
petrochemical facilities.

1. Introduction to Corrosion

    1.1 Corrosion: Definition and Examples

    1.2 Basic Concepts in Electrochemistry

    1.3 Why Do Metals Corrode

    1.4 Kinetics: the Rate of Corrosion

    1.5 How Do Metals Corrode: Different Forms of Corrosion

    1.6 General Methods for Corrosion Control

2. Common Alloys Used in the Refining and Petrochemical Industries
 

3. Overview of API RP 571-2011

4. General Damage Mechanisms – All Industries Including Refining and
    Petrochemical, Pulp and Paper, and Fossil Utility 

    4.1 General

    4.2 Mechanical and Metallurgical Failure Mechanisms

           4.2.1 Graphitization

           4.2.2 Softening (Spheroidization)

           4.2.3 Temper Embrittlement

           4.2.4 Strain Aging

           4.2.5 885oF Embrittlement

           4.2.6 Sigma Phase Embrittlement

           4.2.7 Brittle Fracture

           4.2.8 Creep / Stress Rupture

           4.2.9 Thermal Fatigue

           4.2.10 Short Term Overheating – Stress Rupture

           4.2.11 Steam Blanketing

           4.2.12 Dissimilar Metal Weld (DMW) Cracking

           4.2.13 Thermal Shock

           4.2.14 Erosion / Erosion-Corrosion

           4.2.15 Cavitation

           4.2.16 Mechanical Fatigue

           4.2.17 Vibration-Induced Fatigue

           4.2.18 Refractory Degradation

           4.2.19 Reheat Cracking

           4.2.20 Gaseous Oxygen-Enhanced Ignition and Combustion

    4.3 Uniform or Localized Loss of Thickness

           4.3.1 Galvanic Corrosion

           4.3.2 Atmospheric Corrosion

           4.3.3 Corrosion Under Insulation (CUI)

           4.3.4 Cooling Water Corrosion

           4.3.5 Boiler Water Condensate Corrosion

           4.3.6 CO2 Corrosion

           4.3.7 Flue Gas Dew Point Corrosion

           4.3.8 Microbiologically Induced Corrosion (MIC)

           4.3.9 Soil Corrosion

           4.3.10 Caustic Corrosion

           4.3.11 Dealloying

           4.3.12 Graphitic Corrosion

    4.4 High Temperature Corrosion [400oF (204oC)]

           4.4.1 Oxidation

           4.4.2 Sulfidation

           4.4.3 Carburization

           4.4.4 Decarburization

           4.4.5 Metal Dusting

           4.4.6 Fuel Ash Corrosion

           4.4.7 Nitriding

    4.5 Environment – Assisted Cracking

          4.5.1 Chloride Stress Corrosion Cracking (CI–SCC)

          4.5.2 Corrosion Fatigue

          4.5.3 Caustic Stress Corrosion Cracking (Caustic Embrittlement)

          4.5.4 Ammonia Stress Corrosion Cracking

          4.5.5 Liquid Metal Embrittlement (LME)

          4.5.6 Hydrogen Embrittlement (HE)

          4.5.7 Ethanol Stress Corrosion Cracking (SCC)

          4.5.8 Sulfate Stress Corrosion Cracking

 5. Refining Industry Damage Mechanisms

    5.1 General

           5.1.1 Uniform or Localized Loss in Thickness Phenomena

                      5.1.1.1 Amine Corrosion

                      5.1.1.2 Ammonium Bisulfide Corrosion (Alkaline Sour Water)

                      5.1.1.3 Ammonium Chloride Corrosion

                      5.1.1.4 Hydrochloric Acid (HCl) Corrosion

                      5.1.1.5 High Temperature H2/H2S Corrosion

                      5.1.1.6 Hydrofluoric (HF) Acid Corrosion

                      5.1.1.7 Naphthenic Acid Corrosion (NAC)

                      5.1.1.8 Phenol (Carbonic Acid) Corrosion

                      5.1.1.9 Phosphoric Acid Corrosion

                      5.1.1.11 Sulfuric Acid Corrosion

                      5.1.1.12 Aqueous Organic Acid Corrosion

            5.1.2 Environment–Assisted Cracking

                      5.1.2.1 Polythionic Acid Stress Corrosion Cracking (PASCC)

                      5.1.2.2 Amine Stress Corrosion Cracking

                      5.1.2.3 Wet H2S Damage (Blistering / HIC / SOHIC / SCC)

                      5.1.2.4 Hydrogen Stress Cracking – HF

                      5.1.2.5 Carbonate Stress Corrosion Cracking (ACSCC)

            5.1.3 Other Mechanisms

                      5.1.3.1 High Temperature Hydrogen Attack (HTHA)

                      5.1.3.2 Titanium Hydriding

      5.2 Process Unit PFD’s

             5.2.1 Crude Unit / Vacuum

             5.2.2 Delayed Coker

             5.2.3 Fluid Catalytic Cracking

             5.2.4 FCC Light Ends Recovery

             5.2.5 Catalytic Reforming – CCR

             5.2.6 Catalytic Reforming – Fixed Bed

             5.2.7 Hydroprocessing Units – Hydrotreating, Hydrocracking

             5.2.8 Sulfuric Acid Alkylation

             5.2.9 HF Alkylation

             5.2.10 Amine Treating

             5.2.11 Sulfur Recovery

             5.2.12 Sour Water Stripper

             5.2.13 Isomerization

             5.2.14 Hydrogen Reforming