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 Holy See
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