Advanced Corrosion Management in Refinery Plants

This advanced-level course is designed to provide refinery professionals with in-depth knowledge and practical expertise in managing corrosion across refinery plants, with special emphasis on sour service environments involving hydrogen sulfide (H₂S). The course explores a wide range of corrosion mechanisms, refinery-specific damage modes, and proven mitigation strategies aligned with global best practices and international standards such as NACE MR0175, API 571, API 580, and ISO 15156.

By the end of this course, participants should be able to:
- Identify and analyze corrosion risks associated with key refinery equipment, such as distillation units, exchangers, reactors, pipelines, and storage systems.
- Develop proficiency in advanced inspection techniques, risk-based inspection (RBI), and materials selection.
- Develop a strong understanding and proficiency in applying chemical inhibitors, coatings, and cathodic protection systems.
- Enhance problem-solving skills and gain practical tools to support integrity management programs through real-world case studies.

Training will be conducted via Microsoft Team Meeting. Meeting invites will be shared one day before the first day of training.

Face-to-face training is available as per request.

Upon successful completion of training, participants will receive an"Advanced Corrosion Management in Refinery Plants"certificate.

This course is appropriate for a wide range of professionals, but not limited to:
- Target Audience: Corrosion Engineers, Inspection Engineers, Maintenance & Operations Staff, HSE Engineers.
- Prerequisites: Engineering background with refinery operations knowledge or basic corrosion understanding.

Group Discount (same company only)
- 15% Discount for groups of 5 or more
- 10% Discount for groups of 3-4
Bundle Discount
- Sign up for 2 courses and get an extra 10% off
- Sign up for 3 courses and get an extra 15% off

how can we help you?

Fees + VAT as applicable

Tax Registration Number: 100442245500003

(including coffee breaks and a buffet lunch daily)

Day 1: Introduction & Corrosion Fundamentals

1.1 Overview of Refinery Corrosion Management
- Importance of corrosion control in refinery operations.
- Design throughput (5.5 million tons/year) – implications for corrosion management
- International regulatory and safety requirements in Kazakhstan.
1.2 Fundamentals of Corrosion
- Basic corrosion mechanisms (electrochemical principles)
- Forms of corrosion: Uniform, Galvanic, Crevice, Pitting, Intergranular, Stress Corrosion Cracking (SCC)
- Factors influencing corrosion in refinery environments
1.3 Refinery Equipment and Corrosion Exposure
- Atmospheric & vacuum distillation units
- Hydrodesulfurization units
- Reformers and catalytic crackers
- Heat exchangers, reactors, separators, furnaces, pipelines
- Storage tanks, flare systems, and wastewater treatment units

Day 2: Hydrogen Sulfide (H₂S) Corrosion in Refineries

2.1 H₂S Corrosion Mechanisms
- H₂S-related corrosion in sour service environments
- Sulfide Stress Cracking (SSC)
- Hydrogen-induced cracking (HIC)
- Stress-oriented hydrogen-induced cracking (SOHIC)
- Decarburization and embrittlement
2.2 H₂S Service Design and Material Considerations
- NACE MR0175/ISO 15156 compliance
- Equipment design for sour service
- Material selection and compatibility
2.3 Case Studies & Group Discussion
- Failures in H₂S service components
- Discussion on mitigation strategies and lessons learned

Day 3: Corrosion Monitoring, Inspection & Risk-Based Approach

3.1 Corrosion Monitoring Techniques
- Online/offline monitoring: corrosion probes, coupons, ultrasonic thickness monitoring
- Non-destructive testing (NDT) methods: UT, RT, MFL, PEC, AE, IRIS
- Online data integration and corrosion-tracking tools
3.2 Inspection Planning and RBI
- API 580 & API 581 Risk-Based Inspection methodology
- Inspection planning for high-risk areas
- Data management and integration with CMMS
3.3 Workshop
- Risk prioritization exercise using refinery flow diagram
- Interpreting inspection results for critical equipment

Day 4: Corrosion Mitigation Strategies

4.1 Material Selection & Coatings
- Corrosion-resistant alloys (CRAs) and lining materials
- Protective coatings and linings (organic/inorganic, high-temp options)
- Thermal spray coatings and applications
4.2 Cathodic and Anodic Protection
- CP for underground pipelines, storage tanks, and buried infrastructure
- ICCP and sacrificial anode systems
- Field measurements, maintenance & troubleshooting
4.3 Chemical Inhibition Programs
- Types of inhibitors: filming, neutralizing, scavengers
- Inhibitor selection, application methods, and effectiveness monitoring
4.4 Water Treatment and Process Chemistry Control
- Boiler and cooling water treatment best practices
- Amine systems and corrosion control strategies
- Desalter operations and corrosion impact

Day 5: Integrity Management, Best Practices & Future Technologies

5.1 Integrity Management Systems (IMS)
- Integration of IMS in refinery operations
- Role of corrosion loops and circuits
- Maintenance & turnaround considerations
5.2 Case Studies and Best Practices
- Corrosion failures in refineries: root causes and corrective actions
- Best practices in turnaround planning to minimize corrosion risk
- Role of HSE and risk communication in corrosion management
5.3 Future Technologies in Corrosion Management
- Digital twins and AI in corrosion prediction
- Smart sensors and IoT integration
- Advanced coating technologies
5.4 Final Assessment & Course Wrap-up
- Group assessment or quiz
- Certification of completion
- Feedback & course improvement discussion

From	To	Status	Type
		Completed	Training

	Al-Ghaith Tower, Suite No. 1104, Hamdan Bin Mohammad Street, P.O.Box No:114192, Abu Dhabi (UAE)
	+971 2 6349815
	+971 2 6349816
	info@velosiaims.com
	Mon–Fri: 8:30AM–6:00 PM Sun 11:00AM–04.00PM