An Interactive 5-Day Training Course
Corrosion Control and Materials Selection for Surface Facilities
Practical guide to corrosion control and materials selection.
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Duration
5 Days
Price
$ 4,000
Starting From
16 Aug 2027
Corrosion Control and Materials Selection for Surface Facilities
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Corrosion Control and Materials Selection for Surface Facilities - SF-CCMS-PEA27
| Code | Date | Time | Duration | Location | Currency | Early Bird Fee Per Person |
|---|---|---|---|---|---|---|
| SF-CCMS-PEA27 | 16 - 20 Aug 2027 | 10 AM CST | 5 Days - 4 Hours / Day |
Online |
USD |
4000 |
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Corrosion Control and Materials Selection for Surface Facilities
This training covers corrosion control across production and processing facilities. It works through the corrosion mechanisms found in oil and gas service, rate prediction, environmental cracking in sour conditions, materials selection and specification, protective coatings, cathodic protection, chemical inhibition, monitoring and inspection methods, and the corrosion management systems that hold these together over asset life.
Description
Corrosion is the dominant cause of loss of containment in oil and gas facilities and the largest single driver of integrity expenditure. It is also predictable. The mechanisms are known, the conditions that drive each of them are measurable, and the control options are established. What separates facilities that manage corrosion well from those that do not is whether the mechanisms present in each system have been correctly identified and matched to an appropriate control, and whether that control is verified in service.
The training covers the mechanisms in detail, including carbon dioxide corrosion, hydrogen sulphide corrosion, oxygen corrosion, microbiologically influenced corrosion, under-deposit attack, erosion-corrosion, galvanic corrosion, crevice and pitting attack in stainless materials, and corrosion under insulation. Environmental cracking is addressed separately because it fails without warning and without measurable wall loss, covering sulphide stress cracking, hydrogen induced cracking, stress oriented hydrogen induced cracking and chloride stress corrosion cracking, together with the requirements of NACE MR0175 and ISO 15156. Materials selection follows, covering carbon steels, stainless steels, duplex grades, nickel alloys, clad and lined products and non-metallics, with the selection logic and lifecycle cost comparison behind them. Control methods, monitoring techniques, inspection planning and corrosion management system structure complete the training.
Materials selection is a lifecycle decision made at design stage under commercial pressure. Carbon steel with a corrosion allowance and an inhibition programme is cheaper to install than a corrosion resistant alloy and more expensive to operate, because inhibition requires chemicals, injection equipment, monitoring and availability management for the life of the asset. Corrosion resistant alloys eliminate that operating burden but carry high capital cost and their own failure modes, particularly chloride cracking and crevice attack. Making that choice correctly requires understanding both the corrosion environment and how it will change as water cut rises, souring develops and operating conditions shift.
Sour service deserves particular attention because the failure mode is different. Sulphide stress cracking occurs in susceptible materials under stress in the presence of hydrogen sulphide and water, and it produces sudden brittle failure in components that show no wall loss. Compliance with NACE MR0175 and ISO 15156 governs material hardness, heat treatment, welding procedure and hardness control in the weld and heat affected zone. A material that meets the specification in the mill can fail it after field welding, which is why weld procedure qualification and hardness verification matter.
Corrosion under insulation is the most consistently underestimated threat in operating facilities. It occurs out of sight, on lines that are frequently in service, at temperatures where water is present under the cladding, and it is discovered when a line leaks. Its control is a combination of coating specification, insulation design, cladding integrity and an inspection programme that targets the locations where water enters.
Finally, corrosion control only works if it is verified. Inhibitor availability, injection rate, coupon and probe data, inspection findings, water analysis and process condition monitoring together tell whether the strategy is achieving its assumed corrosion rate. Where that verification is weak, the corrosion allowance is being consumed at an unknown rate and the remaining life of the equipment is unknown.
By the end of this training, participants will be able to:
- Identify the corrosion mechanisms active in a given production or processing system from process and fluid data
- Predict corrosion rates using recognised models and understand the limitations of those predictions
- Assess environmental cracking risk and apply NACE MR0175 and ISO 15156 requirements to material selection
- Select and specify materials for defined service conditions and compare options on lifecycle cost
- Specify protective coating systems and insulation arrangements appropriate to the service and environment
- Design cathodic protection for buried, immersed and internal applications
- Design chemical inhibition programmes including product selection, injection, dosage and availability management
- Establish corrosion monitoring and inspection programmes matched to the mechanisms present
- Structure a corrosion management system including risk based inspection, remaining life assessment and integrity reporting
The training establishes corrosion mechanisms and their driving conditions first, then applies them to materials selection, control method selection and monitoring design, so that every control is traceable to a specific mechanism. Corrosion rate predictions, inhibitor dosage calculations, cathodic protection current demand and remaining life assessments are worked through numerically. Failure case histories are examined with photographs of the failed components, and participants identify the mechanism from the morphology and the operating conditions. Materials specifications, corrosion monitoring data, inspection reports and coating specifications from operating facilities are used as working documents throughout.
Organisations sending participants to this training will:
- Reduce loss of containment incidents caused by corrosion and environmental cracking
- Improve materials selection decisions and reduce both premature failure and unnecessary over-specification
- Optimise corrosion inhibition expenditure by matching treatment to the actual mechanism and rate
- Improve inspection targeting so that effort is directed at the locations that actually corrode
- Extend asset life through better corrosion management and earlier detection of accelerated attack
- Strengthen integrity assurance documentation and remaining life justification
Participants will:
- Identify corrosion mechanisms from operating conditions and from the appearance of failed components
- Select and specify materials for sour, corrosive and erosive service with confidence
- Design and evaluate inhibition, coating and cathodic protection programmes
- Interpret corrosion monitoring and inspection data and act on it appropriately
- Contribute to risk based inspection planning and remaining life assessment
- Build specialist capability applicable across facilities, pipelines and wells
- Corrosion, materials and integrity engineers
- Inspection engineers and inspection technicians
- Facilities, process and production engineers
- Production chemists and chemical treatment specialists
- Maintenance and reliability engineers
- Project and design engineers making materials selection decisions
- Technical staff responsible for asset integrity and life extension
Module 1 - Corrosion Fundamentals
- Electrochemical basis of corrosion: anode, cathode, electrolyte, circuit
- Corrosion potential, polarisation and passivity
- Pourbaix and Evans diagrams and their practical use
- Uniform and localised corrosion morphologies
- Corrosion rate expression and conversion between units
- Corrosion allowance, design life and material wastage
- Environmental variables: water, pH, temperature, pressure, velocity, gas composition
- Identifying mechanism from corrosion morphology
Module 2 - Corrosion Mechanisms in Oil and Gas Service
- Carbon dioxide corrosion: mechanism, film formation, rate prediction models
- Effect of temperature, partial pressure, pH, flow and iron carbonate scale
- Hydrogen sulphide corrosion and sulphide film behaviour
- Mixed carbon dioxide and hydrogen sulphide environments
- Oxygen corrosion and its sources in production systems
- Microbiologically influenced corrosion and sulphate reducing bacteria
- Reservoir souring and its consequences for materials
- Under-deposit corrosion beneath scale, sand, wax and corrosion product
- Top of line corrosion in wet gas lines
- Erosion-corrosion and velocity effects
- Galvanic, crevice and pitting corrosion
- Corrosion in glycol, amine and produced water systems
Module 3 - Environmental Cracking and Sour Service
- Sulphide stress cracking mechanism and susceptibility factors
- Hydrogen induced cracking and stress oriented hydrogen induced cracking
- Chloride stress corrosion cracking in austenitic stainless steels
- Hydrogen embrittlement and cathodic hydrogen charging
- Sour service definition and severity regions
- NACE MR0175 and ISO 15156 requirements and their application
- Hardness limits, heat treatment and weld hardness control
- Material qualification testing for sour service
- Welding procedure qualification in sour service
- Consequences of non-compliance and field failures
Module 4 - Materials Selection
- Carbon and low alloy steels: grades, specifications and limitations
- Low temperature service and impact toughness requirements
- Austenitic stainless steels and their chloride limitations
- Duplex and super duplex stainless steels: properties and processing constraints
- Nickel based alloys and their applications
- Titanium and its use in seawater service
- Clad, lined and weld overlaid products
- Non-metallics: GRP, HDPE, elastomers, and their service limits
- Materials selection methodology and decision logic
- Lifecycle cost comparison: carbon steel with inhibition versus corrosion resistant alloy
- Material specification, certification and positive material identification
Module 5 - Coatings and Linings
- Coating function and failure mechanisms
- Surface preparation standards and their importance
- External coating systems for atmospheric, buried and immersed service
- Internal linings and their application limits
- Thermal spray aluminium and metallic coatings
- Coating specification, application quality control and inspection
- Coating breakdown, disbondment and holiday detection
- Insulation systems and corrosion under insulation prevention
- Cladding, weatherproofing and water ingress control
- Maintenance painting programmes and their prioritisation
Module 6 - Cathodic Protection
- Cathodic protection principle and protection criteria
- Sacrificial anode systems: anode materials, sizing, distribution
- Impressed current systems: rectifiers, anodes, ground beds
- Current demand calculation and system design
- Application to buried piping, tanks, jetties, subsea structures and vessel internals
- Potential measurement, survey methods and interpretation
- Interference, stray current and alternating current corrosion
- Coating and cathodic protection as a combined system
- Commissioning, monitoring and maintenance of cathodic protection systems
- Internal cathodic protection of tanks and vessels
Module 7 - Chemical Inhibition and Treatment
- Corrosion inhibitor types and film forming mechanisms
- Inhibitor selection and laboratory qualification testing
- Dosage determination and residual monitoring
- Continuous injection versus batch treatment
- Injection point design, atomisation and distribution
- Inhibitor availability and the effect of downtime on corrosion rate
- Oxygen scavengers and their limitations
- Biocides, bacterial control and treatment strategy
- Interaction between corrosion inhibitor and other production chemicals
- Environmental acceptability and discharge constraints on chemical selection
- Chemical programme performance evaluation
Module 8 - Corrosion Monitoring
- Monitoring strategy and location selection
- Weight loss coupons: design, placement, retrieval and interpretation
- Electrical resistance and linear polarisation resistance probes
- Hydrogen probes and their application in sour service
- Chemical monitoring: iron counts, manganese, residual inhibitor
- Bacterial monitoring: planktonic and sessile sampling
- Water analysis and its interpretation for corrosion assessment
- Process parameter monitoring as corrosion evidence
- Correlating monitoring data with inspection findings
- Designing a monitoring programme that reflects actual mechanisms
Module 9 - Inspection and Integrity Assessment
- Inspection techniques: ultrasonic thickness, radiography, eddy current, guided wave
- Advanced techniques: phased array, time of flight diffraction, pulsed eddy current
- Corrosion monitoring locations and thickness measurement points
- Inspection of insulated lines and corrosion under insulation detection
- Vessel and tank internal inspection
- Risk based inspection methodology
- Corrosion rate determination from inspection data
- Remaining life calculation and reassessment intervals
- Fitness for service assessment principles
- Repair options: weld repair, sleeves, composite wraps, replacement
Module 10 - Corrosion Management Systems
- Structure of a corrosion management system
- Corrosion risk assessment and threat identification by system
- Corrosion management plans and their content
- Key performance indicators for corrosion control
- Roles, accountabilities and competence requirements
- Management of change for materials, chemicals and operating conditions
- Ageing plant, life extension and integrity in mature facilities
- Deferred maintenance and its corrosion consequence
- Documentation, records and integrity assurance
- Continuous improvement and learning from corrosion failures
Upon successful completion of this training course, delegates will be awarded an official Certificate of Completion issued by the Petroleum Engineers Association (PEA), an ISO 9001:2015 certified training organization. The certificate carries 10 Credits and formally records the total learning hours completed.
Each certificate is signed by the Course Facilitator and the CEO of the Petroleum Engineers Association, and serves as verifiable proof of professional training that delegates can present to employers and professional bodies worldwide.
This course is led by a corrosion and materials engineering specialist with more than 20 years in the oil and gas industry, built on choosing the right material and keeping the containment boundary intact.
He currently holds materials and corrosion engineering leadership responsibility with a major operator managing surface production and processing facilities, covering corrosion mechanism identification, materials selection and cathodic protection systems — the disciplines that keep facilities safe over their operating life. Earlier in his career he served as a corrosion engineer on major facility developments, leading materials selection and corrosion management programme design on some of the industry's most corrosion-prone assets. Across two decades he has taken several corrosion management programmes from design through monitoring into sustained, effective containment integrity.
That operating background shapes how he teaches. Delegates learn not only how corrosion mechanisms are understood on paper, but how they actually progress in the field — where corrosion rate predictions fall short of real conditions, why sour service and cracking mechanisms demand different materials thinking, what makes materials selection and specification defensible, how coatings and cathodic protection perform under real exposure, and how engineering and operations teams manage chemical inhibition, monitoring and inspection together. Every module is anchored in real corrosion data, materials decisions and lessons from operating facilities.
His subject coverage spans the full corrosion control chain: corrosion mechanisms and rate prediction, sour service and cracking, materials selection and specification, coatings and cathodic protection, chemical inhibition, monitoring and inspection, and corrosion management systems.
He has delivered corrosion control and materials selection training for many years across the Middle East, North Africa and Southeast Asia, working with mixed groups of materials engineers, corrosion engineers and technical management at every level of experience. He is an active contributor to industry forums on corrosion engineering and materials integrity.
His approach is practical, discussion-led and grounded in real corrosion management experience — not the textbook.
Frequently Asked Questions
All course bookings made through PEA are strictly non-refundable. By registering for a course, you acknowledge and accept that all fees are payable in full and are not subject to refund under any circumstances, including changes in personal or professional commitments or partial attendance.
PEA reserves the right to make reasonable adjustments to course content, trainers, or schedules where necessary, without entitling delegates to a refund. Comprehensive details of each course — including objectives, target audience, and content — are clearly outlined before enrolment, and it is the responsibility of the delegate to ensure the course's suitability prior to booking.
For any inquiries related to cancellations or bookings, please contact our support team, who will be happy to assist you.
