Guarding Against Corrosion: Cathodic Protection for Pipelines and Tanks Training Course

Introduction

Corrosion is a pervasive and relentless threat to the integrity of metallic structures, particularly buried pipelines and storage tanks, leading to significant material degradation, leaks, environmental contamination, and costly failures in the oil and gas, water, and chemical industries. Among the most effective and widely adopted methods for mitigating this destructive process is Cathodic Protection (CP). By transforming the entire surface of a metal structure into a cathode, CP prevents the electrochemical reactions that drive corrosion, thereby extending asset lifespan and ensuring operational safety and reliability.

This intensive training course is meticulously designed to equip participants with a comprehensive and practical understanding of Cathodic Protection principles and their application for pipelines and tanks. From exploring the fundamental electrochemistry of corrosion and various CP system types to mastering design considerations, installation techniques, monitoring methodologies, and troubleshooting common issues, you will gain the expertise to implement and manage robust CP programs. This empowers you to safeguard critical infrastructure, ensure regulatory compliance, reduce maintenance costs, and strategically contribute to the long-term integrity and sustainability of metallic assets.

Target Audience

  • Corrosion Engineers and Specialists.
  • Pipeline Integrity Engineers and Technicians.
  • Tank Integrity Engineers and Inspectors.
  • Maintenance Managers and Supervisors.
  • Project Engineers involved in Pipeline/Tank Construction.
  • HSE (Health, Safety, and Environment) Professionals.
  • Electrical Engineers working with CP Systems.
  • NACE (AMPP) Certification Candidates.

Duration: 10 days

Course Objectives

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

  • Understand the fundamental principles of corrosion and electrochemistry.
  • Grasp the theory and application of cathodic protection for pipelines and tanks.
  • Analyze the design considerations for both galvanic and impressed current CP systems.
  • Comprehend various installation techniques for CP components.
  • Evaluate different methods for monitoring and testing CP system performance.
  • Develop practical skills in troubleshooting common CP problems.
  • Navigate relevant industry codes, standards, and regulatory requirements for CP.
  • Formulate robust strategies for designing, implementing, and maintaining effective cathodic protection programs.

Course Content

  1. Introduction to Corrosion and Its Control
  • Definition of corrosion and its impact on assets.
  • Economic, safety, and environmental consequences of corrosion.
  • Basic electrochemistry of corrosion: anode, cathode, electrolyte, metallic path.
  • Types of corrosion: uniform, pitting, crevice, galvanic, stress corrosion cracking.
  • Overview of corrosion control methods: material selection, coatings, inhibitors, cathodic protection.
  1. Fundamentals of Cathodic Protection (CP)
  • Principles of cathodic protection: preventing corrosion by making the structure a cathode.
  • Polarization and its role in CP.
  • Criteria for cathodic protection (e.g., NACE SP0169, −850mV criterion).
  • Advantages and limitations of CP.
  • Applications of CP for pipelines, storage tanks, well casings, marine structures.
  1. Galvanic (Sacrificial Anode) CP Systems
  • Principles of galvanic CP: using a more active metal to provide current.
  • Anode materials: magnesium, zinc, aluminum.
  • Design considerations for galvanic anode systems: anode size, number, placement.
  • Backfill materials for anodes.
  • Applications and limitations of galvanic CP.
  1. Impressed Current Cathodic Protection (ICCP) Systems
  • Principles of ICCP: using an external DC power source.
  • Components of an ICCP system: rectifier, anodes, groundbed, cables.
  • Anode materials for ICCP: high silicon cast iron, mixed metal oxide (MMO), graphite.
  • Design considerations for ICCP systems: rectifier sizing, groundbed resistance, current distribution.
  • Applications and limitations of ICCP.
  1. Coatings and Their Role in CP
  • Importance of coatings in conjunction with cathodic protection.
  • Types of coatings for pipelines and tanks: fusion bond epoxy (FBE), tape wraps, liquid epoxies.
  • Coating defects and their impact on CP performance.
  • Holiday detection and coating inspection.
  • Synergy between coatings and CP.
  1. CP System Installation and Commissioning
  • Installation procedures for galvanic anodes and groundbeds.
  • Installation of rectifiers and associated electrical components.
  • Cable connections and insulation.
  • Pre-commissioning checks and start-up procedures.
  • Initial surveys and performance verification.
  1. CP System Monitoring and Testing
  • Test stations and their importance.
  • Reference electrodes: types (Cu/CuSO4, Ag/AgCl), care, and calibration.
  • Potential measurements: pipe-to-soil potential, structure-to-electrolyte potential.
  • Current measurements: rectifier output, current distribution.
  • Other surveys: close interval potential survey (CIPS), DCVG (Direct Current Voltage Gradient).
  1. Troubleshooting CP System Problems
  • Common CP problems: insufficient protection, interference, stray current corrosion.
  • Diagnosing low potential, high potential, fluctuating potential.
  • Identifying coating holidays and shield effects.
  • Rectifier troubleshooting.
  • Practical exercises in problem identification and resolution.
  1. Interference and Stray Current Corrosion
  • Definition of interference: interaction between CP systems or with foreign structures.
  • Types of interference: galvanic, impressed current, AC interference.
  • Stray current corrosion from DC traction systems or HVDC lines.
  • Detection and mitigation of interference.
  • Coordination with other asset owners.
  1. Standards, Regulations, and Advanced CP Concepts
  • Relevant industry standards (e.g., NACE/AMPP SP0169, RP0169, RP0177).
  • Regulatory requirements for CP of pipelines and tanks.
  • Data management for CP systems.
  • Digitalization in CP: remote monitoring, IoT-enabled CP systems.
  • CP for specialized applications: internal tank CP, concrete structures.
  • Future trends in corrosion control.

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

 

Guarding Against Corrosion: Cathodic Protection For Pipelines And Tanks Training Course in Papua New Guinea
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