Corrosion Control and Materials Selection

Maintenance and Engineering October 25, 2025
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Introduction

Corrosion is one of the leading causes of asset degradation and failure across all industries, leading to significant maintenance costs and safety risks. This specialized course provides a detailed understanding of the primary mechanisms of corrosion and the engineering strategies used for its control and prevention. Participants will learn how to select appropriate materials, implement cathodic protection, apply coatings effectively, and utilize inspection techniques to monitor asset integrity. The objective is to equip personnel with the knowledge to establish a robust corrosion management program that maximizes asset life and minimizes the lifecycle cost of equipment exposed to aggressive environments.

Objectives

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

  • Identify and classify the common types of corrosion (e.g., uniform, pitting, crevice, galvanic).
  • Select appropriate materials for various process and environmental conditions.
  • Develop and manage effective industrial coating and painting specifications.
  • Understand the principles and application of cathodic and anodic protection.
  • Implement inspection and monitoring techniques for corrosion management.
  • Determine optimal chemical inhibitors for process fluid systems.
  • Utilize NACE/ISO standards for corrosion management compliance.
  • Develop a long-term corrosion control strategy for critical assets.

Target Audience

  • Integrity and Corrosion Engineers
  • Materials Specialists and Metallurgists
  • Inspection and NDT Technicians
  • Maintenance Engineers and Planners
  • Quality Control Personnel (Coatings Inspectors)
  • Asset Managers in Chemical, Marine, and Oil & Gas industries

Methodology

  • Case studies on major corrosion-induced failures and the economic impact
  • Group workshop on developing a coating specification and QA/QC plan
  • Practical exercise selecting a material for a specific corrosive environment
  • Discussions on the maintenance requirements for Cathodic Protection systems
  • Individual assignment developing a structured inspection route for piping corrosion.

Personal Impact

  • Become a specialized expert in asset integrity management.
  • Gain in-demand skills in materials engineering and corrosion control.
  • Improve decision-making regarding material procurement and replacement.
  • Enhance ability to communicate corrosion risk to management.
  • Master best practices for coating application and inspection.

Organizational Impact

  • Significantly reduce asset degradation and extend asset service life.
  • Prevent catastrophic failures and safety incidents caused by material loss.
  • Lower maintenance costs associated with corrosion-related repairs.
  • Ensure regulatory compliance for pipelines and pressure equipment.
  • Improve the energy efficiency of assets by preserving material thickness.
  • Reduce environmental impact from leaks and failures.

Course Outline

Unit 1: Corrosion Mechanisms and Failure

Types of Corrosion
  • Understanding the electrochemical nature of corrosion.
  • Detailed analysis of localized corrosion (pitting, crevice, intergranular).
  • Stress corrosion cracking (SCC) and corrosion fatigue mechanisms.
  • Identifying erosion-corrosion and fretting corrosion.
Environmental Factors
  • The effect of temperature, pH, and fluid velocity on corrosion rates.
  • Identifying aggressive agents (chlorides, sulfates, oxygen) in the process stream.

Unit 2: Materials Selection and Design

Corrosion Resistance
  • Selection of common construction materials (carbon steel, stainless steel, alloys).
  • Using ISO/NACE data and compatibility charts for material selection.
  • The importance of design in minimizing corrosion risk (e.g., avoiding crevices).
Non-Metallic Materials
  • Application and limitations of corrosion-resistant plastics and composites.
  • Lining and cladding techniques for existing metal structures.

Unit 3: Coatings and Protective Systems

Protective Coatings
  • Types of industrial coatings (epoxies, polyurethanes, zinc-rich primers).
  • Developing effective coating specifications (surface preparation, thickness).
  • Best practices for application, curing, and quality assurance.
Cathodic Protection (CP)
  • Principles of Cathodic Protection (sacrificial anode vs. impressed current).
  • Designing and monitoring CP systems for pipelines and buried structures.
  • Testing and maintenance procedures for CP systems.

Unit 4: Chemical Inhibition and Monitoring

Chemical Treatment
  • Classification and application of corrosion inhibitors (filming, neutralizing).
  • Biocide use for Microbiologically Influenced Corrosion (MIC).
  • Water treatment principles for boiler and cooling systems.
Corrosion Monitoring
  • Techniques for monitoring corrosion rate (coupons, electrical resistance probes).
  • Using NDT (UT, RT) to measure wall thickness loss.
  • Managing corrosion data and trend analysis.

Unit 5: Corrosion Management Strategy

Inspection Programs
  • Developing a structured, risk-based corrosion inspection plan.
  • Integrating corrosion-related findings into the CMMS work process.
  • Auditing and validating the effectiveness of corrosion control measures.

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