Corrosion Management in Production Systems Training Course

Corrosion Management in Production Systems Training Course

Introduction

Corrosion Management in Production Systems Training Course is designed to equip oil and gas professionals with advanced technical knowledge and practical skills for identifying, monitoring, preventing, and controlling corrosion across upstream and downstream production facilities. This comprehensive course explores corrosion engineering, asset integrity management, corrosion risk assessment, materials selection, corrosion monitoring, chemical inhibition, and predictive maintenance to help organizations minimize equipment degradation, prevent unplanned shutdowns, and extend asset service life. Participants will examine common corrosion mechanisms, including uniform corrosion, pitting corrosion, crevice corrosion, galvanic corrosion, erosion-corrosion, microbiologically influenced corrosion (MIC), and carbon dioxide (CO₂) and hydrogen sulfide (H₂S) corrosion. The program also introduces industry-relevant standards, inspection technologies, risk-based inspection (RBI), and reliability-centered maintenance strategies for improving production system performance.

In addition, the training emphasizes practical approaches to developing and implementing effective corrosion management programs throughout the production asset lifecycle. Participants will learn to interpret corrosion data, assess degradation rates, evaluate protective coatings, apply cathodic protection principles, select corrosion-resistant materials, and optimize chemical treatment programs. The course integrates digital corrosion monitoring, predictive analytics, condition-based maintenance, inspection planning, and integrity operating windows to support data-driven asset management. Through real-world case studies, technical exercises, and scenario-based learning, participants will investigate corrosion failures, analyze root causes, prioritize mitigation actions, and develop cost-effective corrosion control plans. By the end of the course, participants will be better prepared to improve operational reliability, strengthen process safety, protect the environment, reduce lifecycle costs, and support regulatory compliance across complex oil and gas production systems.

Course Duration

5 days

Course Objectives

By the end of this training course, participants will be able to:

1. Explain fundamental corrosion mechanisms affecting oil and gas production equipment and infrastructure.
2. Identify and evaluate corrosion risks associated with CO₂, H₂S, oxygen, chlorides, and produced water.
3. Conduct systematic corrosion risk assessments for pipelines, pressure vessels, wellheads, and production facilities.
4. Develop effective corrosion management strategies aligned with asset integrity objectives.
5. Select appropriate corrosion-resistant materials based on operating conditions and fluid chemistry.
6. Apply corrosion inhibition technologies to reduce internal corrosion in production systems.
7. Evaluate protective coatings, linings, and cathodic protection systems for external corrosion control.
8. Interpret corrosion monitoring data using probes, coupons, ultrasonic testing, and inspection technologies.
9. Apply risk-based inspection (RBI) and risk prioritization to optimize inspection programs.
10. Investigate corrosion-related equipment failures using root cause analysis (RCA) techniques.
11. Integrate predictive maintenance and digital monitoring into corrosion management workflows.
12. Assess corrosion-related operational, environmental, financial, and process safety risks.
13. Develop a practical corrosion control and asset integrity improvement plan using performance indicators and lifecycle cost analysis.

Target Audience

1. Corrosion engineers and materials engineers.
2. Production engineers and petroleum engineers.
3. Pipeline integrity and asset integrity engineers.
4. Mechanical engineers and maintenance engineers.
5. Inspection engineers and non-destructive testing (NDT) technicians.
6. Oil and gas operations supervisors and production facility managers.
7. Reliability engineers and risk-based inspection specialists.
8. HSE professionals, technical consultants, and engineering project personnel.

Course Modules

Module 1: Fundamentals of Corrosion in Production Systems

• Principles of electrochemical corrosion and metal degradation.
• Common corrosion types in upstream production facilities.
• Effects of temperature, pressure, pH, salinity, and fluid composition.
• CO₂ corrosion, H₂S corrosion, and oxygen-related degradation.
• Overview of corrosion standards and asset integrity requirements.
• Case study: Investigate accelerated corrosion in a production flowline carrying wet natural gas and produced water.

Module 2: Corrosion Mechanisms and Damage Assessment

• Uniform corrosion, localized pitting, and crevice corrosion.
• Galvanic corrosion and the effects of dissimilar metals.
• Erosion-corrosion in high-velocity production systems.
• Microbiologically influenced corrosion (MIC).
• Corrosion damage morphology, severity assessment, and failure analysis.
• Case study: Analyze localized pitting discovered during inspection of a produced-water line and assess the potential influence of deposits, water chemistry, and microbial activity.

Module 3: Materials Selection and Corrosion-Resistant Alloys

• Carbon steel performance and limitations in production environments.
• Stainless steels, duplex steels, and corrosion-resistant alloys (CRAs).
• Material compatibility with CO₂, H₂S, chlorides, and produced fluids.
• Material selection for wellheads, tubing, valves, and pipelines.
• Lifecycle cost analysis and material qualification considerations.
• Case study: Compare carbon steel, duplex stainless steel, and a suitable corrosion-resistant alloy for a high-chloride production environment, considering corrosion performance, operating limits, and total lifecycle cost.

Module 4: Corrosion Inhibitors and Chemical Treatment

• Principles and mechanisms of corrosion inhibitor performance.
• Selection of film-forming inhibitors for oil and gas production.
• Chemical injection systems, dosing control, and compatibility.
• Produced-water treatment and management of corrosive contaminants.
• Monitoring chemical effectiveness and optimizing treatment costs.
• Case study: Evaluate a pipeline with increasing corrosion rates despite continuous inhibitor injection.

Module 5: Corrosion Monitoring, Inspection, and Testing

• Corrosion coupons and electrical resistance (ER) probes.
• Linear polarization resistance (LPR) monitoring principles.
• Ultrasonic thickness measurement and non-destructive testing (NDT).
• Inspection data interpretation and corrosion rate calculations.
• Digital inspection records, corrosion mapping, and trend analysis.
• Case study: Interpret historical ultrasonic thickness readings and corrosion coupon data to estimate metal loss trends and determine appropriate inspection priorities.

Module 6: Coatings, Linings, and Cathodic Protection

• Protective coating systems for production equipment and pipelines.
• Surface preparation, coating application, and quality assurance.
• Cathodic protection principles and system configurations.
• Coating defects, disbondment, and external corrosion mechanisms.
• Inspection, testing, and performance monitoring of protection systems.
• Case study: Assess external corrosion indications on a buried pipeline and recommend a coordinated inspection, coating rehabilitation, and cathodic protection verification program.

Module 7: Risk-Based Inspection and Predictive Corrosion Management

• Corrosion risk ranking based on likelihood and consequence of failure.
• Risk-based inspection (RBI) planning and inspection prioritization.
• Remaining life estimation and corrosion allowance evaluation.
• Predictive analytics, digital monitoring, and condition-based maintenance.
• Corrosion key performance indicators (KPIs) and integrity operating windows.
• Case study: Prioritize inspections for three production assets using corrosion rates, equipment condition, operating history, and failure consequences.

Module 8: Corrosion Failure Analysis and Integrated Management Programs

• Root cause analysis (RCA) of corrosion-related equipment failures.
• Corrosion management plans, procedures, and responsibilities.
• Process safety, environmental protection, and regulatory compliance.
• Maintenance optimization, lifecycle costs, and reliability improvement.
• Performance reporting, continuous improvement, and management review.
• Case study: Develop an integrated corrosion management improvement plan for a production facility experiencing repeated pipeline leaks.

Training Methodology

• Interactive lectures and presentations.
• Group discussions and brainstorming sessions.
• Hands-on exercises using real-world datasets.
• Role-playing and scenario-based simulations.
• Analysis of case studies to bridge theory and practice.
• Peer-to-peer learning and networking.
• Expert-led Q&A sessions.
• Continuous feedback and personalized guidance.

Register as a group from 3 participants for a Discount

Send us an email: info@datastatresearch.org or call +254724527104 

Certification

Upon successful completion of this training, participants will be issued with a globally- recognized certificate.

Tailor-Made Course

 We also offer tailor-made courses based on your needs.

Key Notes

a. The participant must be conversant with English.

b. Upon completion of training the participant will be issued with an Authorized Training Certificate

c. Course duration is flexible and the contents can be modified to fit any number of days.

d. The course fee includes facilitation training materials, 2 coffee breaks, buffet lunch and A Certificate upon successful completion of Training.

e. One-year post-training support Consultation and Coaching provided after the course.

f. Payment should be done at least a week before commence of the training, to DATASTAT CONSULTANCY LTD account, as indicated in the invoice so as to enable us prepare better for you.