Shielding Assets: Corrosion Control and Cathodic Protection Training Course

Introduction

Corrosion poses an insidious and pervasive threat across numerous industries, particularly in marine environments, oil and gas, infrastructure, and manufacturing. It degrades materials, compromises structural integrity, leads to costly failures, and significantly impacts safety and operational efficiency. Without robust corrosion control strategies, assets face reduced lifespans, increased maintenance expenditures, and heightened risks of environmental incidents or catastrophic breakdowns. A deep understanding of corrosion mechanisms and advanced protection techniques is therefore indispensable for safeguarding critical infrastructure and ensuring long-term asset reliability.

This intensive training course is meticulously designed to equip participants with a comprehensive and practical understanding of corrosion control principles and the critical application of cathodic protection. From mastering the electrochemical processes of corrosion and various prevention methods (coatings, inhibitors) to delving into the intricacies of galvanic and impressed current cathodic protection systems, their design, installation, and monitoring, you will gain the expertise to implement effective corrosion management strategies. This empowers you to extend asset lifespans, reduce maintenance costs, enhance safety, and ensure the integrity of structures in challenging environments.

Target Audience

Corrosion Engineers and Technicians.

Asset Integrity Managers.

Maintenance and Reliability Engineers.

Materials Engineers.

Coating and Painting Inspectors.

Oil and Gas Industry Professionals (Upstream, Midstream, Downstream).

Marine Engineers and Naval Architects.

Civil Engineers involved in infrastructure (bridges, pipelines, concrete structures).

Duration: 10 days

Course Objectives

Upon completion of this training course, participants will be able to:

Understand the fundamental principles of corrosion and its various forms.

Grasp the methods of corrosion prevention, including material selection, design, coatings, and inhibitors.

Analyze the theory and application of cathodic protection (CP) as a primary corrosion control method.

Comprehend the design considerations and components of both galvanic and impressed current CP systems.

Evaluate the effectiveness of CP systems through monitoring, testing, and troubleshooting techniques.

Develop practical skills in conducting CP surveys and interpreting survey data.

Navigate the relevant international standards and best practices in corrosion control and cathodic protection.

Formulate robust strategies for implementing and managing comprehensive corrosion management programs.

Course Content

Fundamentals of Corrosion

Basic Electrochemistry of Corrosion : anode, cathode, electrolyte, metallic path

Types of Corrosion : uniform, pitting, crevice, galvanic, intergranular, stress corrosion cracking (SCC), erosion-corrosion

Factors Influencing Corrosion : oxygen, temperature, pH, presence of salts, fluid velocity

Corrosion Cell Formation : understanding how and why corrosion occurs

Economic and safety impact of corrosion across industries

Corrosion Prevention Methods: An Overview

Material Selection : stainless steels, alloys, non-metallic materials, their corrosion resistance

Design Principles for Corrosion Control : avoiding crevices, proper drainage, dissimilar metals separation

Protective Coatings : types (paints, epoxies, polyurethanes), surface preparation, application methods

Corrosion Inhibitors : types (anodic, cathodic, mixed), application (batch, continuous injection)

Environmental considerations for corrosion prevention methods

Introduction to Cathodic Protection (CP)

Principle of Cathodic Protection : making the entire metal surface a cathode

How CP Works : driving current to the protected structure

Applications of CP : pipelines, storage tanks, ships, offshore structures, jetties, concrete structures

Benefits of CP : extended asset life, reduced maintenance, enhanced safety

Understanding the role of CP in a comprehensive corrosion management strategy

Galvanic (Sacrificial Anode) Cathodic Protection

Theory of Galvanic CP : galvanic series, potential differences

Types of Sacrificial Anodes : zinc, aluminum, magnesium, their properties and applications

Design Considerations for Galvanic CP : anode size, number, placement, expected lifespan

Installation Methods : welding, bolting, flushing

Practical examples of galvanic CP systems on ships and offshore platforms

Impressed Current Cathodic Protection (ICCP)

Theory of ICCP : external power source, inert anodes

Components of an ICCP System : transformer-rectifier (TR) unit, anodes (MMO, platinized titanium, graphite), reference electrodes, cables

Design Considerations for ICCP : current requirements, anode distribution, power supply

Installation and Commissioning of ICCP Systems : procedures, initial adjustments

Advantages and disadvantages of ICCP compared to galvanic CP

CP Monitoring and Testing

Reference Electrodes : types (Cu/CuSO4, Ag/AgCl, Zn), calibration, use in potential measurements

Potential Measurement Techniques : "ON" potential, "OFF" potential, IR drop considerations

Current Measurement : output current, drain points

Troubleshooting CP Systems : identifying common issues (anode depletion, cable breaks, rectifier failure)

Data logging and remote monitoring systems for CP

CP System Design and Calculations

Current Density Requirements : for various materials and environments

Anode Output Calculation : for galvanic anodes

TR Unit Sizing : determining power requirements for ICCP

Cable Sizing and Voltage Drop : ensuring adequate current delivery

Practical design exercises and case studies for CP systems

CP for Specific Applications

CP for Marine Vessels : hull protection, ballast tanks, internal tanks

CP for Offshore Structures : fixed platforms, FPSOs, subsea pipelines

CP for Onshore Pipelines : buried pipelines, tank bottoms

CP for Reinforced Concrete Structures : rebar protection in bridges, jetties

Challenges and specific considerations for different application environments

Coatings and CP: A Synergistic Approach

Role of Coatings in Corrosion Control : barrier protection, reducing current demand for CP

Types of Coatings for CP Systems : epoxies, polyurethanes, coal tar epoxies

Surface Preparation Standards : importance for coating adhesion and performance

Coating Application and Inspection : film thickness, holidays, quality control

Integrating coatings and CP for optimal long-term protection

Standards, Regulations, and Corrosion Management

Relevant International Standards : NACE, ISO, ASTM standards for CP and coatings

Regulatory Compliance : environmental regulations related to anode materials, waste disposal

Corrosion Risk Assessment : identifying threats, prioritizing mitigation

Developing a Corrosion Management Plan : inspection, maintenance, monitoring, budgeting

Case studies of effective corrosion control and CP implementation.

CERTIFICATION

Upon successful completion of this training, participants will be issued with Macskills Training and Development Institute Certificate

TRAINING VENUE

Training will be held at Macskills Training Centre. We also tailor make the training upon request at different locations across the world.

AIRPORT PICK UP AND ACCOMMODATION

Airport pick up and accommodation is arranged upon request

TERMS OF PAYMENT

Payment should be made to Macskills Development Institute bank account before the start of the training and receipts sent to info@macskillsdevelopment.com

For More Details call: +254-114-087-180

 

Shielding Assets: Corrosion Control And Cathodic Protection Training Course in Algeria
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