Corrosion & Risk Based Inspection

MCO/CORBI-E

Who should attend?

  • This course provides a practical knowledge of pressure equipment and piping corrosion, and Inspection strategy based on risk analysis.
Audience :
  • Experienced engineers, managers and technical staff involved in safe operation and integrity of pressure equipment installed in refineries, chemical and petrochemical plants.

Level : Proficiency

Course Content

  • CORROSION IN OIL & GAS INDUSTRIES & PETROCHEMICAL PLANTS - API 571

      • Each type of corrosion is studied along with possible prevention for piping, drums, columns, heat exchangers, boilers and furnaces already in service, or during a new plant design.
      • Specific corrosion occurring in industrial units based on API 571:
      • Metallurgical deterioration: brittle fracture, chromium precipitation, creep, fatigue.
      • Hydrogen induced cracking, high temperature hydrogen attack, high temperature sulfur corrosion, oxidation, flue gas corrosion, naphthenic acid corrosion, polythionic acid corrosion, caustic soda stress cracking, amines corrosion, CO2 corrosion.
      • Corrosion of alloys and plastics in chemical industry: corrosion by mineral acids, bases, nitrates, ammonia or chlorine
      • Many corrosion case studies observed in process industry units: identification of corrosion root cause and mitigation to apply.
  • CORROSION PREVENTION & INSPECTION - API 510

      • Material selection and detailed engineering design to avoid corrosion.
      • Identification of operating windows.
      • Corrosion control by means of sampling, use of corrosion coupons and probes.
      • Cathodic protection with sacrificial anodes or imposed current.
      • Anticorrosion coatings and cladding.
      • Basic non-destructive testing: PT, MT, RT, UT and advanced non-destructive testing: phased array…
  • RISK BASED INSPECTION - API 581

      • Collect Design data and inspection data.
      • Select Corrosion loops for each PID.
      • Calculate probability of failure based on damage factor - Quantitative approach using API581 workflow.
      • Calculate consequence of failure - Quantitative and semi quantitative approach using API581 workflow.
      • Evaluate the overall risk on API matrix.
      • Define inspection strategy: mitigations actions or inspection scheduling extension.
      • Overview of available commercial software “RBEYE”.
      • Example of industrial RBI strategy implemented.
      • RBI semi quantitative approach based on simplified Excel spreadsheet.
  • APPLICATION OF THE RBI METHOD WITH MINI-PROJECTS CASE STUDIES

      • Application of API 581 RBI method using mini projects - Case studies as teamwork:
      • Select the appropriate corrosion loops and pressure vessels.
      • Identify the degradation.
      • Apply API 581 workflow to define the probability of failure, the consequence of failure.
      • Analyze the risk and propose risk mitigations with more efficient NDT or adjust inspection frequency.
      • Apply RBI semi quantitative approach based on simplified excel spreadsheet and compare the 2 methods.
      • Each group presents its RBI analysis and conclusion.

Learning Objectives

  • Upon completion of the course, the participants will be able to:
  • identify operating windows beyond which corrosion phenomenon happen,
  • describe the RBI methodology for a petrochemical or chemical plant,
  • determine the probability and consequence of a failure,
  • set up a suitable inspection plan.

Ways & Means

  • Active teaching methods are used to promote a pooling of experience, under the lead of inspection specialist.
  • Actual accidents in refineries and chemical plants are analyzed to be aware of the risks.
  • Wide use of samples, videos and pictures to develop practical case studies for pressure equipment such as piping, heat exchanger, reactor, distillation column, boiler, etc.