Corrosion Management Masterclass

About the Course

Corrosion is a significant integrity threat to numerous assets in various industries, including oil & gas, petrochemicals, chemicals-producing companies, desalination, mining and metal processing, marine, military, nuclear, utilities, transportation and agriculture, to name a few.

To control and mitigate corrosion, any asset owner or operator has two options: the traditional or classical approach and the new or modern one. The conventional method of corrosion control was based on the corrosion engineering concept. However, in the early 2000s, it was revealed in the UK’s Offshore Industry that corrosion engineering alone could not efficiently mitigate corrosion, and some other parameters or factors were also required for comprehensive and efficient corrosion mitigation. The conclusion was that corrosion management would protect offshore oil & gas assets more efficiently than corrosion engineering alone. Such a conclusion paved the way for a modern asset integrity management approach or methodology based on corrosion management.

The modern asset integrity management approach will optimise corrosion costs based on the timely and proper implementation of corrosion management principles. At the same time, it simultaneously enhances the efficiency of the existing corrosion control and mitigation systems, leading to lower corrosion rates and a lesser number of corrosion leaks. Therefore, it is paramount to appreciate the corrosion management concept or process, its tools, how it is implemented across an asset, and what its application benefits are.

This 5-day interactive Corrosion Management Masterclass training course is crucial for the relevant personnel and their management. It will help them improve and evolve their notion of asset integrity management, using modern corrosion management techniques, leading to optimised integrity and corrosion costs.

Core Objectives

The main objective is that each delegate would learn about the corrosion management concept and its application. They would also learn how to create a more effective and efficient corrosion control system that is continually evolving and improving while optimising corrosion costs.

The delegates will achieve the following objectives:

• Learn what corrosion management concept is and how it differs from corrosion engineering
• Know how the corrosion management process is implemented across an asset
• Understand how the overall integrity management and inspections could become more efficient through a risk-based approach
• Analyse an existing asset integrity management system and evaluate its performance
• Create a failure risk assessment methodology and risk-based inspection scopes
• Improve the organisation’s capability in pre-empting corrosion failures 
• Know how the pertinent integrity and corrosion costs are optimised
• Learn how various non-corrosion engineering-based integrity measures could also significantly enhance corrosion control and mitigation, often at no or minimal costs

Training Approach

This training course will be facilitated via PowerPoint slides containing text, tables, plots, pictures, etc.; the delegates will be regularly asked to participate in an ongoing topic, discussion or challenge. Team exercises will also be presented to the audience to take part. Past integrity case studies will be offered throughout the programme to promote best international practices while discouraging integrity practices that had impaired asset integrity in various projects. At the end of the programme, there will be a post-course assessment to help all the delegates remember all the important subjects, concepts and practices.

The Attendees

The training course is intended for anybody whose duties include asset integrity management and corrosion control, and it has no technical or academic prerequisites.

Likewise, it will be valuable to the professionals but not limited to the following:

• Corrosion and Integrity Engineers and Managers
• Inspection Engineers
• Maintenance Engineers
• Cathodic Protection and Coating Engineers
• Operation and Production Managers
• Pipeline Integrity Engineers
• Process Engineers
• Health and Safety Engineers
• Chemical Treatment Engineers
• Asset Managers

Daily Discussion

DAY ONE: INTEGRITY, CORROSION, CORROSION ENGINEERING, AND CORROSION MANAGEMENT IN THE INDUSTRY

• Introductions
• Objectives, Attributes, and Scope
• The Significance of Creating the Integrity Picture
• Asset Integrity Management Systems (AIMS)
• AIMS Components, Objectives, and Benefits
• Corrosion and Corrosion Engineering (CE) in the Industry
• The Main International Corrosion Management (CM) Models
• The CM Concept Definition

DAY TWO: THE CORROSION MANAGEMENT IMPLEMENTATION PROCESS AND THE RISK-BASED INSPECTION FUNDAMENTALS

• The Integrity Review Process
• The Significance of the Integrity Review Process
• The CM Implementation Process
• The Failure Risk Assessment (FRA) Process
• A Brief Introduction to Risk-Based Inspection (RB)I
• Inspection Basics
• The Concept of Risk and Its Basics
• Risk-Based Inspection Basics
• Equipment Corrosion Loops and Process Flow Diagrams

DAY THREE: IDENTIFICATION AND MAINTENANCE OF THE TWELVE MANAGEMENT REQUIREMENTS

• Introduction to Management Requirements: Twelve Management Requirements
• Registers, Strategies, and Procedures
• Databases, Documentation, and Data Management
• The Significance of Communication
• The Asset Corrosion Management Strategy Document
• Corrosion Control Matrices and Corrosion Key Performance Indicators
• Team Structure, Roles, and Responsibilities
• The Significance of Competency

DAY FOUR: CORROSION MANAGEMENT PROCESS SHORTCOMINGS AND OTHER CORROSION MANAGEMENT TOOLS

• Shortcomings Associated with the CM Implementation Process
• The Corrosion Failure Pre-emption Capability
• Corrosion Cost Optimisation
• Other Important CM Requirements
• The Corrosion Management Audit
• The Management of Change Process
• The Anomaly Management System

DAY FIVE: CORROSION MANAGEMENT APPLICATION BENEFITS AND IMPLEMENTATION RECOMMENDATIONS

• The Leak Register Database, Failure Investigations and Learning from Past Mistakes
• Corrosion Management Application Benefits
• Recommendations for Optimised Corrosion Management Implementation
• Main Conclusions
• Main Recommendations