Corrosion, Durability & Life Extension Techniques

About

Successful organisations cannot tolerate major corrosion failures, especially those involving personal injury, fatalities, unscheduled shutdowns and environmental contamination. Typically, once a system, a plant or any piece of equipment is put into service, maintenance is required to keep it operating safely and efficiently. This is particularly true for aging systems and structures, many of which may operate well beyond the original design life.

This seminar is an intensive examination of corrosion processes, corrosion monitoring, corrosion control and corrosion prevention techniques, with particular emphasis on extending the life of critical infrastructure.

Key learning objectives

• Understand the cost burden of corrosion in all industries
• Identify the relationship between inspection, monitoring and maintenance
• Understand the importance of adopting an inspection strategy
• Understand the durability requirements of the NZ Building Code
• Compare the advantages and disadvantages of available corrosion monitoring techniques
• Find out how to identify alternatives in structural design to minimise corrosion damage
• Examine material selection as a method of corrosion control
• Have a good working knowledge of protective coatings for corrosion control
• Be able to monitor the effectiveness of the corrosion control process
• Understand the principles of cathodic protection

Training style
This two-day course will use case study examples of corrosion, real corrosion samples, and a phased approach to life extension of infrastructure. All attendees will be provided with a workbook and a certificate of attendance.

Who should attend

• Chief/Project/Consulting/Plant/Service/Maintenance Engineers
• Inspection Officers - private, government and local bodies
• Asset/Pipeline Integrity Managers and Designers
• Risk Managers and Insurance Assessors
• Non-Destructive Testing personnel
• Building Inspectors and Certifiers
• Engineers who are beginning their professional development
• Technical Managers in the process industries - oil, gas, petrochemical, refinery, pipelines, construction, storage tanks, pumps, pressure vessels, heat exchangers
• Protective coating companies
• Companies supplying corrosion-resistant alloys/materials

Outline

Day one

8.30 Registration

Corrosion - introduction, identification and methods of control

• What is corrosion?
• What is the cost of corrosion to industry?
• How does corrosion take place?
• What drives the corrosion process?
• What are the distinct types of corrosion?
• What are the normal methods used to control corrosion?

Overview of corrosion technology

• Corrosion type identification
• How corrosion affects the durability of materials
• Material selection
• Design - good practices - Galvanic Series and its role
• Life extension of aging plant, equipment and infrastructure

Design guidelines for corrosion prevention

• General classification of engineering materials
• Corrosion resistant alloys
• General classification of environments
• Matching a material with an environment - good choices and bad choices

Examining various types of protective coatings - an overview

• Metallic coatings, galvanising and metal spray
• Liquid applied coatings: epoxies, alkyds, acrylics, polyurethanes, zinc silicate, tape wrappings
• Cementicious coatings

Day two

Mitigation of internal corrosion

• Corrosion rates, corrosion measurement and life prediction
• The effects on corrosion of chemical treatments, inhibitors and biocides
• Corrosion inhibitors - types and applications

Mitigation of external corrosion

• Construction requirements - material durability
• Coating applications
• Cathodic protection - when is it required?

Corrosion testing and monitoring

• Conventional methods - condition assessment and non-destructive testing
• Weight loss coupon method (practical exercise)
• Electrical resistance method
• Electrochemical method
• When, why, and how to monitor for corrosion damage

Identifying the make up and function of protective coatings

• The practicalities and limitations of various coating types
• Where they work and where they do not work
• Field testing of protective coatings
• Test equipment including paint film thickness and paint film integrity

Cathodic protection (CP)

• Theory and application of cathodic protection and how it inter-reacts with protective coatings
• The galvanic table and its role in corrosion protection
• Stray current corrosion
• Methodology of monitoring CP
• Evaluation of CP performance
• Anodic protection

Wrap up: an examination and group discussion on the present state of corrosion control in New Zealand

Facilitator

Les Boulton MSc, FICorr

• Fellow of the Institute of Corrosion (UK)
• NACE Corrosion Specialist (USA)
• Life Member of Australasian Corrosion Association (ACA)
• ACA Corrosion Technologist

Les Boulton & Associates Limited is a materials and corrosion consultancy based on the North Shore in Auckland. LBA offers professional consulting services in the fields of engineering materials technology, corrosion engineering, metallurgy, and materials management.

Principal Consultant Les Boulton has over thirty years experience in materials and corrosion consultancy for industry, corrosion research, project management, and the presentation of training seminars and workshops. He is the author of papers and articles on aspects of corrosion of engineering materials.

Les is an active Member of the Australasian Corrosion Association (ACA) with Branches in Australia and New Zealand. He has been the ACA NZ Branch President and ACA Australasian President. In 1994 he was awarded the prestigious ACA Corrosion Medal. He is now a Life Member of ACA and serves on the Auckland Committee as New Zealand Branch Editor.

Les has gained wide materials and corrosion consulting experience through employment at the former DSIR and with other consulting firms including Industrial Research Ltd. Les is the New Zealand Consultant to the international Nickel Institute (NI) based in Toronto, Canada. The New Zealand Nickel Institute office provides technical literature, seminars and workshops on stainless steels and nickel-containing materials applications, throughout the country.

In-house Training

Prices and Registration

* Early bird price available when you register and pay before the dates listed.