Industrial Corrosion and Integrity in the Oil and Gas Industry

Oil and Gas Technology October 25, 2025
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Introduction

This specialist course provides a comprehensive understanding of corrosion mechanisms, monitoring, and control strategies specifically within the oil and gas environment, covering upstream, midstream, and downstream assets. Participants will explore the full asset lifecycle, learning to identify key corrosion threats, select appropriate materials, and implement effective mitigation techniques, including chemical inhibition and cathodic protection. The program emphasizes a risk-based approach to inspection and maintenance to ensure asset integrity, prevent catastrophic failures, and comply with stringent industry regulations. Ultimately, the knowledge gained is vital for enhancing operational safety, maximizing asset lifespan, and cultivating a robust integrity management system.

Objectives

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

  • Identify and classify the various forms of corrosion prevalent in oil and gas systems (e.g., CO2, H2S, MIC).
  • Select and specify appropriate materials for construction in corrosive environments according to industry standards.
  • Design and manage effective chemical inhibition and corrosion monitoring programs.
  • Apply principles of cathodic protection (CP) and protective coatings for asset preservation.
  • Implement Risk-Based Inspection (RBI) strategies for prioritizing corrosion management efforts.
  • Evaluate the impact of sweet and sour service conditions on materials integrity.
  • Develop and maintain comprehensive Asset Integrity Management (AIM) systems focused on corrosion.
  • Analyze and interpret corrosion monitoring data to predict remaining asset life accurately.

Target Audience

  • Corrosion and Integrity Engineers and Specialists
  • Process and Facilities Engineers
  • Maintenance and Reliability Engineers
  • Asset Integrity Managers
  • Inspection Personnel (API 510/570/653 certified)
  • Project Engineers involved in facility design and construction
  • Chemical Treatment Specialists

Methodology

  • Case studies of major corrosion failures and prevention strategies
  • Group activities on material selection for specific corrosive environments
  • Practical exercises in interpreting corrosion monitoring data and predicting failure
  • Expert-led discussions on NACE and API standards updates
  • Scenario-based design of a Cathodic Protection system

Personal Impact

  • Deepened expertise in corrosion science, material failure, and control technologies.
  • Ability to design and manage complex corrosion mitigation programs effectively.
  • Improved skill in applying API and NACE industry standards and best practices.
  • Enhanced capability to perform risk-based assessments and integrity planning (RBI).
  • Greater contribution to HSE performance by preventing equipment failure.
  • A formal qualification in essential asset integrity management principles.

Organizational Impact

  • Significant reduction in equipment failure rates and costly unscheduled shutdowns.
  • Extended lifespan of critical assets (pipelines, vessels, processing equipment).
  • Optimization of maintenance budgets through RBI-driven inspection prioritization.
  • Ensured compliance with regulatory requirements for asset integrity and reporting.
  • Reduced environmental liability and improved public perception due to fewer leaks and spills.
  • Cultivation of a proactive and technically proficient Asset Integrity team.

Course Outline

Unit 1: Fundamentals of Corrosion and Asset Integrity

Section 1: Corrosion Mechanisms and Forms
  • Electrochemical principles and thermodynamics of corrosion
  • Pitting, crevice, galvanic, and intergranular corrosion
  • Stress Corrosion Cracking (SCC) and Hydrogen Embrittlement
  • Flow-Accelerated Corrosion (FAC) and erosion-corrosion
Section 2: Environmental and Metallurgical Factors
  • The role of CO2 (sweet) and H2S (sour) in corrosion
  • Microbiologically Influenced Corrosion (MIC) in water systems
  • Impact of temperature, pressure, and flow dynamics on corrosion rates
  • Material selection for corrosive service and common alloys (e.g., Duplex, Inconel)

Unit 2: Corrosion Mitigation Strategies I: Chemical

Section 1: Chemical Inhibition and Control
  • Types and selection of corrosion inhibitors (film-forming, scavenging)
  • Designing and optimizing a chemical injection and delivery program
  • Application of biocides for MIC control in water systems
  • Chemical treatment for scale and asphaltene deposition prevention

Unit 3: Corrosion Mitigation Strategies II: Barriers

Section 1: Coatings and Linings
  • Classification and selection of protective coating systems (epoxies, polyurethanes)
  • Surface preparation standards (e.g., SSPC, NACE) and application techniques
  • Inspection and quality control of coating application and integrity
  • Use of internal linings for pipelines and storage vessels
Section 2: Cathodic Protection (CP) Systems
  • Understanding galvanic and impressed current CP system principles
  • CP design calculations and criteria for pipelines and structures
  • Installation, commissioning, and troubleshooting of CP systems
  • Monitoring and maintenance of CP system effectiveness and performance

Unit 4: Corrosion Monitoring and Data Analysis

Section 1: Monitoring Techniques
  • Invasive methods: weight loss coupons and electrical resistance (ER) probes
  • Non-Invasive and real-time techniques: Linear Polarization Resistance (LPR) and UT probes
  • Interpreting corrosion monitoring data and trending analysis
  • Using Non-Destructive Testing (NDT) methods for corrosion detection (MFL, UT)

Unit 5: Risk-Based Inspection (RBI) and Integrity Management

Section 1: RBI Frameworks
  • Implementation of Risk-Based Inspection (RBI) methodologies (API 580/581)
  • Determining the Probability of Failure (POF) based on damage mechanisms
  • Assessing the Consequence of Failure (COF) (safety, environmental, financial)
  • Developing optimized inspection plans and frequency based on calculated risk

Unit 6: Asset Integrity Management (AIM) System

Section 1: AIM Integration
  • Developing a comprehensive AIM program structure and documentation
  • Integrating corrosion control into maintenance and operational procedures
  • Fitness-For-Service (FFS) assessments for corroded equipment (API 579)
  • Compliance with regulatory requirements for asset integrity reporting

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