Offshore Materials and Corrosion Engineering
Target Audience:
This course is intended for:
- Materials, corrosion, and integrity engineers working in offshore oil and gas environments
- Design and mechanical engineers responsible for selecting materials for offshore structures and equipment
- Operations and maintenance personnel involved in asset integrity and corrosion control
- Graduate engineers and trainees entering offshore materials and corrosion-related roles
Course Objectives:
By the end of this training, participants will be able to:
- Understand the challenges and environmental factors influencing material degradation in offshore environments
- Identify appropriate materials used in offshore oil and gas structures, piping, and equipment
- Evaluate different types of corrosion mechanisms specific to offshore applications (e.g., galvanic, microbial, crevice, pitting)
- Apply corrosion prevention and control methods such as coatings, cathodic protection, chemical treatment, and material selection
Module Highlight
Introduction to Offshore Corrosion Engineeringv
- Overview of offshore structures and materials
- Environmental challenges in offshore environments (splash zone, submerged, atmospheric)
- Basics of corrosion science and electrochemical principles
- Lifecycle approach to corrosion engineering
Corrosion Mechanisms in Offshore Systems
- Uniform corrosion
- Pitting and crevice corrosion
- Galvanic corrosion
- Microbiologically Influenced Corrosion (MIC)
- Stress corrosion cracking and hydrogen-induced cracking
- Corrosion under insulation (CUI)
Materials for Offshore Applications
- Carbon steel, low alloy steels, stainless steels, and duplex grades
- Corrosion Resistant Alloys (CRAs) and their applications
- Non-metallic materials: composites, polymers, elastomers
- Material degradation and selection criteria
- Weldability and fabrication considerations
Protective Coatings and Surface Preparation
- Types of coatings (epoxy, polyurethane, thermal spray, etc.)
- Coating systems for topside, splash zone, and subsea
- Surface preparation techniques (abrasive blasting, water jetting)
- Coating inspection and quality assurance
Cathodic Protection (CP) Systems
- Principles of cathodic protection
- Sacrificial anode systems
- Impressed current systems
- CP design, installation, and monitoring
- Integration with coating systems
Corrosion Monitoring and Inspection Techniques
- Visual inspection, UT, radiography, eddy current, and ACFM
- Corrosion coupons and probes
- Online monitoring systems
- Non-destructive testing (NDT) and inspection planning
- Data interpretation and reporting
Corrosion Management and Integrity Programs
- Corrosion Risk Assessment (CRA)
- Corrosion Control Documents (CCDs) and Materials Selection Diagrams (MSDs)
- RBI (Risk-Based Inspection) principles
- Integrity operating windows (IOW) and KPIs
- Role of inspection, monitoring, and maintenance in asset integrity
Codes, Standards, and Best Practices
- Overview of relevant codes
- Operator and regulatory expectations
Offshore Corrosion Case Studies
- Analysis of real-world corrosion failures
- Root cause analysis and corrective actions
- Lessons learned and preventive strategies