UNIVERSITY COLLEGE SEDAYA INTERNATIONAL SCHOOL OF ENGINEERING

COURSE OUTLINE

Subject Name Corrosion in Petroleum Industry Subject Code EG 205 Status major Credit Hours 4 Semester / Year

2-2

Pre-requisite Chemistry for pet. Eng. Technology - I & II, Calculus & Analytical Geometry - II, Physics for Scientists & Engineers

Teaching Method

Lectures + Laboratory experiments

Assessment Test 1 10% Mid Term Examination 20% Test 2 10% Laboratory 10% Final Examination 50% The course has five assessment components as described above. Test 1: it will be conducted on week 5 of the semester. The test 1 will usually have 4 questions of approximately 15 minutes duration each. Midterm exam: it will be conducted on week 9 of the semester. The midterm exam will have 4 questions of approximately 20 minutes duration each. Test 2: will be conducted on week 12 of the semester. The test 2 will usually have 4 questions of approximately 15 minutes duration each. Laboratory component: it is compulsory to attend all the lab sessions; failing to do so will result in complete failure in the subject. The student will carry out the experiments described below and submit a report to the lab tutor at the end of the semester. Final Exam component: it will consist of 5 questions of 3 hours duration. 40% ruling: Applicable Supplementary exam: Applicable (on the final exam only)

Lecturer Objectives The course aims to teach:

1. Corrosion principles and thermodynamics of corrosion 2. How corrosion starts and possible places for corrosion 3. Corrosion in acidic environment of Hydrogen sulphide and carbon

dioxide. 4. Corrosion in selected environments 5. Pitting and crevice corrosion

6. Methods of corrosion protection 7. Stress corrosion cracking 8. Material selection and corrosion 9. Cost of corrosion.

Learning Outcome

Upon completion, students should :

Be able to: 1. Identify the various types of corrosion. 2. Identify the causes and driving factors behind corrosion. 3. Determine the most practical method of mitigating corrosion. 4. Develop work procedures for corrosion control. 5. Identify and recommend alternatives in structural design to minimise

corrosion. 6. Select materials more efficiently 7. Monitor the effectiveness of the corrosion control process. 8. Have a good working knowledge of cathodic and anodic protection.

Have a good:

9. Appreciation of material selection as a method of corrosion control. 10. Working knowledge of protective coatings for corrosion control. 11. And adequate knowledge about the cost of corrosion in industry

Module Content: Lecture TutorialsLaboratory1. Introduction – cost of corrosion 1 2. Electrochemical Thermodynamics and Electrode

Potential 3

3. Electrochemical Kinetics of Corrosion 3 4. Passivity 2 5. Polarization Methods to Measure Corrosion

Rate 3

6. Galvanic and Concentration Cell Corrosion 3 7. Pitting and Crevice Corrosion 2 8. Effects of Metallurgical Structure 2 9. Corrosion Related Damage by Hydrogen, 2 10. Erosion and Wear 3 11. corrosion and material selection 3 12. Corrosion in Selected Environments; 3

Syllabus & Contact Hours

– Atmospheric Corrosion, – Corrosion in Soils, – Corrosion of Steel in Concrete, – Corrosion in Water,

13. Corrosion in the Petroleum Industry: – Well materials – acidic gases, salts ,

high temperature – Transporting via pipes – Storage and degassing stations – Refining – Flue gases,

4

14. Methods of Corrosion Protection:

– Material selection – Coating – Inhibitors – Impress currents – Sacrificial anodes

3

15. Stress corrosion cracking: – Sulfide stress corrosion cracking, – Chloride stress corrosion cracking, – Caustic stress corrosion cracking,

3

16. Removal of Corrosive Gases - Mechanical and Chemical Methods

2

Total Hours 42 28 Textbook Corrosion and Water Technology for Petroleum Producers Author: Loyd W.

Jones, Publisher: OGCI, ISBN: 0-930972-09-0 Reference Books

1. Practical Oilfield Metallurgy and Corrosion, Craig, B. D., 1993. 2nd ed. ,Penn Well Publishing Company, Tulsa, OK

2. Oil Field corrosion Detection and Control Handbook. Endean, H. J., 1989. Champion Technologies, Inc., Houston, TX

3. Water Initiated Problems in Production Operations. Endean, H. J. and Shelton, R. D., 1989. Champion Technologies, Inc., Houston, TX

4. Principles and Prevention of Corrosion, Jones, D. A., 1996. 2nd ed. Prentice Hall, Upper Saddle River, NJ

5. Corrosion in the Petroleum Industry. Tillis, W., 2003. Ondeo Nalco Energy Services, Sugar Land, TX

6. Corrosion Control in Petroleum Production, Byars, H. G., 1999. 2nd ed. TPC Publication 5. NACE International, Houston, TX

7. Corrosion and Scale Handbook , Author: J.R. Becker 8. Corrosion and Water Technology for Petroleum Producers

Author: Loyd W. Jones

Laboratory Session (if any)

1. Study Polarization of steels in acidic media 2. Measurement of dry corrosion using themo-gravimetry 3. Experiments on inter-granular corrosion and pitting 4. Cathodic and anodic protection methods 5. Galvanic experiments on corrosion – choose metals from the

following list. Experiments can be performed in salt free aqueous medium, and media containing salts.

– Low carbon hot rolled steel strip – Low carbon hot rolled steel strip, with weld bead – Low carbon hot rolled steel strip, with magnesium – Straight and bent common steel nails – Aluminium strip, 1100 series – Aluminium strip, 6061 series – CA 360 brass strip – Pure copper strip – Zinc plated hardware, such as an “S” hook – Hot-dipped zinc coated roofing nail – Cadmium coated bolts or screws – Stainless steel bolt

MATRIX CO/PO

Knowledge & Understanding

Intellectual Skills Practical Skills Transferable Skills

1 2 3 4 5 6 7 1 2 3 4 5 1 2 3 4 5 1 2 3 4

CO / PO A A B C A A A C B B A B C B A A B B A: Strongly Related , B: Moderately Related, C: Slightly Related