MatCorrC nsultancy

Corrosion and Corrosion Control in Process and Chemical

Industries

Presents Advanced Training Program on

VenueHotel Jaypee Vasant Continental

New Delhi-110057

Date1st & 2nd August 2014

ObjectiveCorrosion is a natural process whereby all metals tend to reverse back to their initial compounds. Thus corrosion cannot be prevented but can be controlled. Present training program has been developed to provide an overview of the corrosion and corrosion control measures in important capital intensive industries like Oil & Gas Production, Refining, Petrochemicals, Fertilizers, Process Plants, Power, Pulp & Paper Industries, Pipelines, Manufacturing and others. Emphasis of the program is to provide participants a right platform to discuss actual case studies through live question/answers to further enhance their depth of knowledge and get answers of the problems experienced in the plant.

Program OverviewThe Major Topics to be covered:A) Science of Corrosion Impact & Basics of Corrosion: An overview, Electrochemical Corrosion, Electromotive

Series, Polarization, Passivation. Mechanisms of Corrosion: Uniform, Pitting, Crevice, Galvanic, Inter-granular Corrosion,

Erosion, Impingement, Corrosion under insulation, SCC, De-alloying, HIC, Microbiologically Influenced Corrosion (MIC), High Temperature Corrosion, with practical examples.

Corrosion Survey & Corrosion Audit: Objective of Survey? Why to Survey? Cost Benefit Considerations, Major Benefits expected from Corrosion Survey.

B) Corrosion Prevention Methods Corrosion Management: Corrosion control

measures, Design aspects. Material Selection & Corrosion Resistant

Alloys (CRA): Selecting Materials for Corrosive Environments, Types of Material Available- Stainless Steels and alloys of Aluminium, Copper, Nickel, Titanium etc, use of Clad Material, Corrosion Behavior.

Corrosion Inhibitor: Type of Inhibitors, Hydrogen-Evolution Poisons, Scavengers, Neutralization Vapour Phase Inhibitors, Batch /Continuous Dosing and others.

Cathodic & Anodic Protection: Galvanic System, Impressed Current System, Anodes, Interference in Cathodic Protection, Pipeline, Buried Structure, Interior of Tanks and Vessels, Submerged Structures and others.

Advances in Coatings for Corrosion Protection: Selection of protective paint system, VOC limits, Main Constituents of Paint, Classification of paints, Surface Preparation, Primers, Metallic coatings, Specifying the protective system, Factors affecting choice.

C) Corrosion Monitoring and Damage Assessment Corrosion Monitoring- Assets life prediction tools: What is Corrosion Monitoring?

Why monitor? Direct and Indirect Techniques, Wt. loss, Electrical Resistance and Linear Polarization Resistance Tests, Ratio metrics, Electrochemical noise, EFSM, Hydrogen Probe, Potential measurement, Data-information-solution, ZRA, Information Flows.

Corrosion Damage Assessment through NDT: Corrosion Inspection Techniques, Visual Examination, Dimensional Changes, NDT techniques like Eddy Current, Ultrasonic, Time to Flight Diffraction (TOFD), Radiography, Acoustic Emission, Intelligent Pigging & others, Selection of inspection points, Maintenance strategies.

D) Corrosion in Oil & Gas Production Oxygen- an Important Entity in Corrosion, Corrosion of Completion Strings, Handling

Corrosive Situations, Basic Corrosion Cell, Off-shore structures, Splash Zone, Tidal Zone, Submerged Parts, Drill-pipe Corrosion, Mud Corrosion, Drilling Fluids, Oxygen Scavengers, Carbon Dioxide Effect, Effect of Hydrogen Sulphide, Sour service, Chloride, Inhibitors Loading, CRA, Monitoring Corrosion, Corrosion Rings, H2S Monitoring, Corrosion Logging Tools, Simulated Oil Field Water-injection System, Monitored by Smart Pigs.

E) Corrosion in Refinery & Petrochemical Industries

Technology Overview, Influencing factors for Corrosion, Common sources of oxygen, Corrosion Inhibitors, tests for screening

inhibitors, Autoclave, Rotating Wheel Corrosion Oven, Corrosion Loops, Common monitoring methods, Brine Sampling and Analyses, Sucker Rod Pins & connection, H2S & CO2 Corrosion, Sulfate Reducing Bacteria, Acid Producing Bacteria, Oilfield Scales, Paraffins and Asphaltenes, Naphthenic Acid attack, Caustic deposits /clogging and SSC, Polythionic acid and intergranular SCC, Alloys used, Sour crudes, amine-gas-treating systems, Overhead Corrosion, Neutralisation & Inhibition, High temperature Sulphur Attack, Thermal Damage, Hydrogen Damage & others. Producing Well Improvement Process (PWIP) - A Case study, Schlumberger Integrated Project Management.

F) Corrosion in Fertilizer Industries Fertilizer Production in India, Corrosion: A metaphor to cost of fertilizer, Major Corrosive

Materials/Parameters, Cost of Corrosion in Fertilizer Industries, Corrosion Problem and Selection of MOC in Nitrogenous Fertilizer Plant , Forms of Corrosion, Process Steps in Ammonia Manufacture, Desulfurization, Major corrosion problems in reforming sections, Reformer tube failures, Principal corrodents in the CO-shift conversion, Corrosion in ammonia synthesis section, Urea Plant, Various factors affecting corrosion rate in urea reactor, Ammonium Carbamate corrosivity, Corrosion Problem and Selection of Materials of Construction in Phosphatic Fertilizer Plant, Corrosive materials, at various stages of sulfuric acid operation, iso-Corrosion Chart, Nitric acid a second most important industrial acid after sulfuric acid.

G) Corrosion Problems in Power Plant Components Corrosion as a Process Factor, Thermodynamic Corrosion Cycle, Corrosion Causing

Failures, Locations of Impurity Ingress, Corrosion and Deposition, Power with Low Cost, Corrosion Chronic: not Acute, Manifestation of Corrosion Phenomena, Corrosion: due to Gaseous Corrodents, Deposits induced Corrosion, Corrosion action is multifarious, Corrosion: Transmission Equipment, >50% Failure: Corrosion Factor, Fireside & Waterside Corrosion, Corrosion Fatigue & Chemical Excursion, Fireside Corrosion: Low Temperature Corrosion; Coal Ash Corrosion; Oil Ash Corrosion; Oil ash Corrosion Mechanism; Water Side Corrosion Failures, Caustic Corrosion, Hydrogen Damage, Pitting or Localized Corrosion, Stress Corrosion Cracking, Corrosion Fatigue, Chemical Excursion Damage, Corrosion in Transmission Towers, Corrosion Effect on Overhead line Conductors (OHLD), Methods of Controlling Corrosion: Use Corrosion Resistant Alloys; Specialized Heat Treatments; Design Features; Controlling the Environment.

H) Corrosion in Pulp & Paper Industry Schematics of integrated pulp and paper mill, Corrosion problems in pulp and paper

industry with wide spectrum of corrosives, growing concern for the environment, Process technology and raw materials, Pulp making process, Sulfite process, Factors affecting corrosion in equipment, MOCs in paper mills, Known corrosion problems in pulp and paper industry, Uniform corrosion, Pitting corrosion, Stress Corrosion Cracking, Intergranular Corrosion Cracking, Corrosion Fatigue, Galvanic Corrosion, Chipper house, corrosion in digester, Remedial measures for overcoming the corrosion problem in digester.

I) Discussion & Analysis of Practical Case studies:All the participants are welcome to come along with their legitimate detailed query regarding

any technical issue/problems faced by them to discuss during the course of lecture period.

Faculty Dr G. H. Thanki(Corrosion Control & Monitoring Consultant)

- He has more than 40 years of experience in the field of Corrosion Technology to control materials and corrosion related problems. - He guided Metallurgical and Corrosion Technology Team with well established laboratory and field instrumentation to serve the process plant materials and corrosion problem solution.- Served as Dy. General Manager and Division Head (Research Centre of a diversified research arena like biotechnology, microbiology, specialty chemicals, analytical chemistry, Corrosion Technology, Pilot Plant and field studies of GSFC), (GSFC: A Largest Integrated Fertilizers & Petrochemicals Complex, Baroda, Gujarat, India, since 1965) & The Member Secretary to GSFC Science Foundation.

- He developed and practiced various corrosion combating programme like on-line corrosion monitoring and surveillance, corrosion resistance compatibility screening, MOC life cycle cost, weld overlays, cooling water treatment optimization to conserve water, corrosion control and effluent quality control, field testing and evaluation of corrosion by simulation etc.- He pioneered the practices of integrated real-time on-line corrosion monitoring (OLCM) in process plants in India,- He served as THE INDIAN CONSULTANT to The World Bank, UNESCO and overseas companies like Krupp-VDM; GmbH, RWTV, AVESTA Sheffield AB, Cormon Ltd. based in Germany, Sweden

and UK respectively.- He has WIDELY TRAVELLED in USA, Europe, Scandinavian Countries, Japan, China, Thailand, Middle East in corrosion control related activities like collaborative research programme, consultancy, training, technical conference and invited talk.

- He has > 65 TECHNICAL, RESEARCH PAPERS published in National and International Journal of repute and also recognized Ph.D. Guide in metallurgy & applied chemistry and visiting faculty to M.S. University Baroda, IIT Bombay, IIT Madras. M S University, Baroda. Chaired Technical sessions in various National and International conferences/Seminars.- He has conducted Corrosion Survey & Audit of industrial sectors like Fertilizer, Pharmaceutical, Hydrometallurgy, Power Plant, Hydrocarbon processing, Paint Manufacturing, etc.

- He led delegation from Europe Marketing Group in search of 200 SS grade series future growth in India. He served as the product promotion adviser to world largest Duplex and High Grade SS materials manufacturer based in Europe in India.- Served as invited Faculty/Course Director with (to name a few):NPC New Delhi, Fertiliser Association of India, Indira Gandhi Centre for Atomic Research, National Fertilizer Limited, SESA GOA, COROMANDAL FERTILISER, Gujarat Narmada Fertilizer Company, IFFCO, INDIAN RAYON, NATIONAL RAYON, KRIBHCO, Birla Copper Ltd, Gujarat Refinery, Bongaigaon Refinery, IPCL, Engineers India Limited,Gujarat State Electricity Corporation Ltd.(GSECL), Essar Oil Ltd., EVERTHINGABOUTWATER at Jamshedpur; Ahmedabad; Vapi, OMIFCO (OMAN), Petronet LNG, Rubamin, Fertilizer-Petrochemical-Power Industries in OMAN, Chulalongkorn University; Bangkok, QP and Qafco in Doha-Qatar, Indian Knowledge Centre, NACE Co-ordinator & faculty for Programme.

Recognition He is the recipient of GOLD PLAQUE in the recognition of his outstanding and meritorious contribution towards Research and Development in the State of Gujarat by IIM (1999) He is the Recipient of GOLD MEDAL FOR INDIA, from American Biographical Institute, Inc., North Carolina; USA (2004) He is honoured by Prestigious Corrosion Awareness Award. - 2007 LIFE TIME ACHIEVEMENT AWARD by NACE International India Section in the recognition of his Life Time Contribution in the field of Corrosion Science He is the Recipient of INDIAN ACHIEVERS AWARD FOR INDUSTRIAL DEVELOPMENT - 2012 from IEDRA He is the Invited Member to Confederation of Indian Industries- NATIONAL CORROSION MANAGEMENT COMMITTEE He is VICE CHAIRMAN of Indian Institute of Metals, Gujarat Chapter. He is on the board of Global Energy Talent as the corrosion consultant.

About MatcorrMatCorr is recognized as the premier service provider for corrosion control solutions. MatCorr provides specialist services to the upcoming and operating plants and industries in the fields of Material Selection, Corrosion Control, Cathodic Protection, Corrosion Monitoring, Coating/ Painting, Material & Corrosion Testing, Failure Analysis, Welding/Fabrication, Heat Treatment and Quality Control. MatCorr has a large pool of certified engineers in various fields with versatile experience. MatCorr is highly respected for its expertise, professionalism, timeliness, impartiality and confidentiality.

Who should attend?The course outline is designed for professionals engaged in inspection, maintenance, construction, design, corrosion control (plant and marketing), operation etc. in wOil and Gas Production and Processing w Oil RefinerieswFertiliser and Petrochemicals w Infrastructure CompanieswPower Plants w Pulp & Paper IndustrieswPipeline w Consulting OrganizationswEquipment Suppliers w Technical InstituteswVendors and Suppliers of Corrosion Related Products

The program will also be of special interest to those in Institutions and Agencies engaged in failure investigation. Faculties in Engineering Colleges and fresh engineers and students who would like to have a career in corrosion prone industries would be better able to understand the practical aspects of corrosion.

Course TimingsThe course begins at 9.00 am in the morning. There will be a half an-hour Buffet Lunch break at 13.00 pm with two tea/coffee breaks. The session will close at 18.00 hrs each day.

VenueThe course will be held at the Hotel Jaypee Vasant Continental, Vasant Vihar, New Delhi. Accommodation can be arranged on request basis in the Hotel Jaypee Vasant Continental or nearby hotels in payment basis with special discount for the participants. w8 kms from Domestic Airport. w13 kms from New Delhi Railway Station.

The Training Program IncludeswCertificate of attending the Training CoursewDelegate Kit with Comprehensive Course MaterialwArrangement of Tea/ Coffee and Buffet Lunch

Terms & ConditionsAll bookings carry a 10% cancellation charges. Substitutions of delegates prior to the event date may be allowed subject to managements discretion.For any reason, MatCorr decides to cancel or postpone this conference, MatCorr will not be responsible for any loss incurred by Client/ Participant. The conference fee will not be refunded and shall be adjusted with future event fee. Content of the event program can be changed without any intimation.

Contact PersonMr. A Mukherjee

Mob. No. +91-9971943010 / 9899694522

Email projects@matcorrconsultancy.com

Organized ByMatcorr Consultancy Pvt. Ltd., New Delhi

www.matcorrconsultancy.com

Registration DetailsThe registration fee can be paid through online (NEFT) or by sending Draft or Cheque drawn in favour of MatCorr Consultancy Pvt. Ltd., payable at New Delhi. Only 20 Participants shall be registered for the seminar on First Come First Served Basis. Request for nominations shall be sent before July 20, 2014.NEFT Details: Matcorr Consultancy Private LimitedA/c No. 1008102000003186; IFSC Code: IBKL0001008Delegate FeeIndian - Rs. 20,000/- Foreign - USD 600 Student - Rs. 6,000/-12.36% Service Tax on the delegate fee shall be applicable.Early bird discount: If registered before 1st July14, 20% discount on Standard fee applicable.If registered before 15th July14, 10% discount on Standard fee applicable.Corporate discount: 10% additional discount (more than 2 delegates from same organization).