Cathodic Protection System in Oil and Gas Exploration industry Training

Introduction

The aim of this workshop is to provide participants with a solid grounding in Applied Cathodic Protection Engineering. This workshop provides theoretical knowledge and fundamentals for testing on both sacrificial and impressed current Cathodic Protection systems for a wide range of industrial structures including buried and subsea pipelines, storage tanks, petrochemical plants and concrete structures.

Maintaining the aging infrastructure such as underground pipelines is a challenge to the oil and gas industry worldwide. Corrosion is one of the major causes of ageing industrial infrastructures. Understanding its mechanism and how to control it can lead to a remarkable reduction in the operation cost of piping and static equipment.

Cathodic Protection (CP) is one of the most widely used methods to control corrosion control in the industry. The Cathodic Protection is a method of that eliminates the corrosion of metals by the use of sacrificial anodes or the application of an electric current. It is a technique that has been known for 160 years and is extensively applied to pipelines and tank farms, etc. with great success. However, despite this long history and broad applicability, it is a technique that is all too often inadequately or even improperly applied; with the result that structures are poorly protected or, worse, adversely interfered with.

This 5-day training course provides you with fundamental principles, evaluation and applications of Cathodic Protection, helping participants recognize them, select Cathodic Protection control methods and apply them to protect the assets of the organization.

Objectives

This training course is designed to provide:

• The theoretical basis and the practical ability necessary to operate and maintain Cathodic Protection (CP) systems in the oil and gas surface production facilities
• Understanding of the basic principles of corrosion and applications of galvanic and impressed current CP systems
• Understanding of the field equipment used to monitor CP systems and how they work
• Understanding of the various factors that impact the performance of these systems
• Learn about essential CP monitoring techniques to ensure effective operation
• Understanding of increase productivity by avoiding costly shutdowns thus reducing the cost of the overall corrosion control program

Training Methodology

This is an interactive course. There will be open question and answer sessions, regular group exercises and activities, videos, case studies and presentations on best practice. Participants will have the opportunity to share with the facilitator and other participants on what works well and not so well for them, as well as work on issues from their own organizations.

Who Should Attend?

This program will benefit anyone who is responsible for Cathodic Protection systems, measuring the effectiveness of Cathodic Protection systems and/or recording this data, including Pipeline design engineers, Pipeline Operations engineers, Corrosion Engineers, Materials Engineers, Design Engineers, Mechanical Engineers, Inspection Engineers, Chemical Engineers, Marine Maintenance people, Offshore Structure design and Operation people, CP field personnel, technicians, and supervisors.

Course Outline

Day 1: Principles and Types of Corrosion and Corrosion Control

Section I - Significance of Corrosion Control

• Corrosion - Largest Single Cause of Plant Failure

• Economic Effects

• Environmental Effects

• Safety Effects

• Corrosion Management Preventive Strategies

• Cost of Corrosion

• Case Study: Catastrophic Corrosion Accidents

Section II - Corrosion & its Control

• Requirements for Corrosion to Occur

• Metallurgical Factors

• Forms of Corrosion

• Corrosion Control Methods

• Environmental Modification

• Protective Coatings

• Introduction to Cathodic Protection

Day 2: Corrosion Environment, Material Selection and Elements of Cathodic Protection

Section III - Corrosive Environments & Construction of Materials 

• Atmospheric Environments

• Marine atmospheres

• Industrial Atmospheres

• Underground Environments

• Material Selection

• Corrosion Properties of  Steels

• Concrete Structure Environment

Section IV - Fundamentals of Cathodic Protection Systems

• Galvanic Series

• General Application of Cathodic Protection

• Industry Standard & Codes

• Principle of CPS

• The Cathodic Protection Cell

• Methods of Applying for Cathodic Protection

• Sacrificial Cathodic Protection System

• Impressed-Current Cathodic Protection System

• Advantages of SCPS

• Disadvantages SCPS

• Advantages ICCP

• Disadvantages ICCP

• CPS Selection

• Basic Requirements for Cathodic Protection

• Cathodic Protection Criteria

• Current Rectifiers/DC Power Source

• High Impedance Voltmeter

• Reference Cells (Half Cells) Reference Cells

• Applicable NACE Standard for Cathodic Protection Systems

Day 3: Cathodic Protection Systems Design and Coating Issues

Section V - Cathodic Protection System Design

• Design Factors

• Electrolyte resistivity survey

• Electrolyte pH survey

• Structure versus electrolyte potential survey

• Current requirement

• Coating resistance

• Protective current required

• Sacrificial anode (galvanic) cathodic protection design

• Impressed current cathodic protection system design

• Soil resistivity

• Current requirement test

• Typical CPS Design Parameters

 Section VI - Cathodic Protection Systems and Coatings

• Role of Protective Coating in CPS

• Selection Factors

• Coating Defects

• Coating Efficiency

• Overvoltage

• Cathodic Disbandment

• Commonly used Coating in Conjunction with CPS

Day 4: Cathodic Protection Anodes and Construction

Section VII - Anodes & Rectifiers

• Anode Selection

• Anode material types, magnesium, zinc, aluminum, etc.

• Current output

• Driving Potential

• Anode life

• Anode Shape & Dimension

• Anode Efficiency

• Galvanic Anode Types

• Current Requirements for ICCP System

• Anode Materials for ICCP

• Anode Backfilling

• Installation of Sacrificial Anodes

• Impressed Current Anode Beds

• Impressed Current Rectifiers/DC Power Source

• Cathodic Protection Equations

• Solved Cathodic Protection calculation examples

Section VIII - Practicing & Construction of Cathodic Protection System

• Components of Cathodic Protection Systems

• Essential Components

• Isolating joints

• Junction Boxes

• Test stations, measuring points, and coupons

• Thermite Weld

• Earthing Systems

• Line current measurement

• Pipe Sleeves/Casings

• Cathodic Protection Vessels & Tank Internals Vessels & Tank

• Tanks for Storage of Chemicals

• Water Circulating Systems

• Heat exchangers (tube and shell)

• Case Study: Construction of Cathodic Protection Systems

Day 5: Line and Coating Inspection, Safety and Corrosion Comics

Section IX - Inspection of Pipeline and Coating defects

• Pearson Surveys

• Close Interval Potential Survey (CIPS) technique

• Direct Current Voltage Gradient (DCVG) technique

• Signal Attenuation Coating (SAC) Survey

• Common Impressed Current Rectifier Problems

• Over the Trench Pipe Holiday Inspection

Section X - Instrumentation & Safety Aspects

• Alkalinity

• Hydrogen Evolution

• Chloride Evolution

• Installation Adjacent to Telecommunication Services

• Installation Adjacent to Railway Signal & Protection Circuits

• Interaction at Discontinuities in Cathodically Protected Structures

• Installation at Jetties & Ships

• The danger of Electric Shock

• Installations on Immersed Structures

• Installations for the Internal Protection of Plant

• Fault Conditions in Electricity Power Systems

• Stray Current Corrosion

Section XI - Corrosion Management Systems

• Economic Considerations

• Corrosion Key Performance Indicators (KPIs)

• Asset Integrity and Corrosion Management

• Corrosion Data Management