Corrosion Control by Cathodic Protection

Introduction

The aim of this course is to provide sufficient information for engineers and managers to identify and apply corrosion control and materials selection procedures to overcome corrosion issues. An in-depth understanding of corrosion is not required to effectively prevent untoward corrosion in 80% of the problem in industrial areas. Upon the successful completion of this course, the participant should have a high quality and in-depth understanding of the corrosion monitoring methods available. The advantages and limitations of each method are detailed and the methods of analysis to convert raw data to useful information are included.

Objectives

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

• Know the characteristics of external and internal corrosion in industrial areas.
• Recognize the different corrosion techniques by identifying the various forms of corrosions
• Determine the several designs and material selection related to corrosion control
• Distinguish the key aspects of atmospheric corrosion and its prevention by coatings
• Learn the components of corrosion, coating and lining of hydrocarbon storage tanks
• Describe the elements of buried and underwater corrosion and its prevention by coating and cathodic protection
• Apply the procedures of cathodic protection of buried and above-ground storage tanks
• Understand the attributes of corrosion of reinforced concrete and its prevention using additives, coatings and cathodic protection
• Identify the effects of corrosion in process pipelines and its prevention using inhibitors and biocides
• Employ the various methods of measurement of corrosion
• Characterize the advanced method of corrosion monitoring
• Become aware of the several associated chemical testing of fluids
• Perform the process of linking inspection and corrosion monitoring
• Know the procedure of trend analysis in corrosion
• Carry out the basic statistical techniques in corrosion monitoring
• Adopt several corrosion management strategies
• Implement the various risk assessment and inspection strategies
• Specify the aspects of associated failure analysis
• Know the functions of microbiological corrosion assessment
• Apply and gain in-depth knowledge in corrosion monitoring and control techniques
• Recognize the characteristics of external and internal corrosion and the various forms of corrosions and determine the designs and selection of material related to corrosion control
• Distinguish the key aspects of atmospheric corrosion and its prevention by coatings and discuss the components of corrosion, coating and lining of hydrocarbon storage tanks as well as the elements of buried and underwater corrosion and its prevention by coating and cathodic protection
• Carry out cathodic protection on buried and above-ground storage tanks
• Discuss the corrosion of reinforced concrete and its prevention using additives, coatings and cathodic protection
• Analyze the effects of corrosion in process pipelines and its prevention using inhibitors and biocides
• Carry out methods to measure & monitor corrosion, perform chemical tests in fluids, analyze corrosion trends, discuss basic statistical techniques and corrosion management strategies
• Execute risk assessments, inspection strategies, associated failure analysis, microbiological corrosion assessments as well as measure the efficiency of cathodic protection
• Develop the proficiency in measuring the effectiveness of cathodic protection

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?

Inspection and corrosion engineers will appreciate the frank discussion of the competing methods available in this course. Senior engineers and managers will gain by developing their interpretive skills in data analysis. Further, this course is ideal for all engineers and technical staff whose responsibilities include the reduction of corrosion either at the design stage or during the operation of the facility. Managers, in particular, will benefit by increasing their awareness of the options available to them.

Course Outline

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

Corrosion & Its Control

• Requirements for Corrosion to Occur
• Metallurgical Factors
• Forms of Corrosion
• Corrosion Control Methods
• Material Selection
• Environmental Modification
• Protective Coatings
• Cathodic Protection

Corrosive Environments & Construction of Materials 

• Atmospheric Environments
• Marine atmospheres
• Industrial Atmospheres
• Underground Environments
• Concrete Structure Environment
• Corrosion Properties of Carbon Steels
• Corrosion Properties of Cast Iron
• Corrosion Properties of Stainless Steels
• Corrosion Resistance Properties of Aluminum
• Corrosion Properties of Copper
• Corrosion Properties of Nickle

Section IV - Fundamentals of Cathodic Protection Systems

• Galvanic Series
• General Application of Cathodic Protection
• Economic Considerations
• 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
• Principles Of Cathodic Protection
• Cathodic Protection Criteria
• Current Rectifiers/DC Power Source
• Applicable NACE Standard for Cathodic Protection Systems

Cathodic Protection Systems and Coatings

• Role of Protective Coating in CPS
• Selection Factors
• Coating Defects
• Coating Efficiency
• Overvoltage
• Cathodic Disbondment
• Commonly used Coating in Conjunction with CPS

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
• pH TESTING PROCEDURES
• Current Requirement Testing

Anodes & Rectifiers

• Anode Selection
• Current output
• Driving Potential
• Anode life
• Anode Shape & Dimension
• Anode Material Cost
• Anode Efficiency
• Galvanic Anode Types
• Current Requirements for ICCP System
• Anode Materials for ICCP
• Anode Backfilling
• Installation of Sacrificial Anodes
• Anode Vent Piping
• Impressed Current Anode Beds
• Quality Control and Quality Assurance
• Impressed Current Rectifiers/DC Power Source

Practicing & Construction of Cathodic Protection System

• Components of Cathodic Protection Systems
• Essential Components
• Isolating joints
• Junction Boxes
• Test stations, measuring points and coupons
• Sleeve pipe
• Thermite Weld
• Earthing Systems
• Line current measurement
• Pipe Sleeves/Casings
• Concrete Encased Pipe
• Cathodic Protection Vessels & Tank Internals Vessels & Tank
• Tanks for Storage of Chemicals
• Water Circulating Systems
• Heat exchangers (tube and shell)
• Water box coatings
• Submarine pipelines
• Construction of Cathodic Protection Systems

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
• Danger of Electric Shock
• Installations on Immersed Structures
• Installations for the Internal Protection of Plant
• Fault Conditions in Electricity Power Systems
• Stray Current Corrosion
• High Impedance Voltmeter
• Reference Cells (Half Cells) Reference Cells

Corrosion Management Systems

• Oilfield Cathodic Protection Systems
• Corrosion Economy
• Corrosion Key Performance Indicators (KPIs)
• Asset Integrity and Corrosion Management
• Corrosion Data Management