Offshore Corrosion Assessment O-CAT

 

The Offshore Corrosion Assessment Training course is a four-day intensive program addressing the elements of in-service inspection and maintenance planning for fixed offshore structures. The course also addresses the Minerals Management Services (MMS) A-B-C facility evaluation grading system requirements for Level I inspection reporting. NACE is recognized as an Authorized Provider of Continuing Education Units by the International Association for Continuing Education and Training (IACET). To receive CEUs, participants are required to be engaged in the entire course and successfully pass the final exam. At the conclusion of the course you will be asked to complete a course evaluation.

PRICE MEMBER. 2250 EUROS

PRICE NO MEMBER. 2500 EUROS.

The hotel is included in the Price. The lunch is included in the Price

CERTIFICACIION

NACE is recognized as an Authorized Provider of Continuing Education Units by the International Association for Continuing Education and Training (IACET). To receive CEUs, participants are required to be engaged in the entire course and successfully pass the final exam. At the conclusion of the course you will be asked to complete a course evaluation

 

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5DAYS CLASSROOM COURSE

8.00 TO 17.00

HOTEL. PAX TORRELODONES, Calle Sama de Langreo S/N, Torrelodones

 

Offshore Corrosion Assessment Training

 

 

Corrosion is one of the most significant problems facing

owners and operators of offshore platforms. If corrosion is not

managed and controlled, it can lead to large costs in repairs or

replacement. Environmental damage, injuries, and fatalities

attributed to corrosion can create even greater costs. As part of

the overall operations and maintenance plan, platform owners

are responsible for implementing corrosion control programs.

This course is designed to train personnel to perform surveys

in support of an on-going corrosion control program

established for maintenance planning and facility integrity

management. The course requires a basic knowledge of

corrosion, corrosion control programs and corrosion protection

systems. The desired end result is a consistent, orderly process

of evaluation that has the confidence of all those involved in

offshore maintenance.

In this course, we will also examine the attributes identified in

API RP 2A-WSD (Recommended Practice for Planning,

Designing and Constructing Fixed Offshore Platforms –

Working Stress Design) for Level I inspections, (a required

annual inspection by the leaseholder) and the Bureau of Safety

and Environmental Enforcement (BSEE) A-B-C Grading

System.

 

 

 

 

Table of Contents

Chapter 1—Introduction

The Course …………………………………………………………………………………………….. 1

Audience (Who Should Attend) ………………………………………………………………….. 2

Prerequisites …………………………………………………………………………………………… 2

Length and Schedule ……………………………………………………………………………….. 2

Reference Materials …………………………………………………………………………………. 4

Objectives ………………………………………………………………………………………………. 4

Course Overview …………………………………………………………………………………….. 5

Lecture Sections ……………………………………………………………………………. 5

Team Exercises …………………………………………………………………………….. 5

Survey Simulation ………………………………………………………………………….. 5

Examinations …………………………………………………………………………………. 5

Introductions ………………………………………………………………………………….. 6

Team Formation Exercise ……………………………………………………………….. 6

Inspection ………………………………………………………………………………………………. 6

In-Process Inspection ……………………………………………………………………… 7

In-Service Inspection ………………………………………………………………………. 9

Offshore Surveyor’s Job …………………………………………………………………………. 10

Disclaimer …………………………………………………………………………………………….. 11

Chapter 2—Oil Platforms/Rigs and Equipment

Objectives ………………………………………………………………………………………………. 1

Introduction …………………………………………………………………………………………….. 1

Various Types of Oil Platforms/Rigs and Equipment …………………………………….. 1

Fixed Platform ……………………………………………………………………………….. 3

Compliant Tower ……………………………………………………………………………. 4

Jack-up Drilling Rig ………………………………………………………………………… 6

Semi-submersible Platform ……………………………………………………………… 6

Drillship ………………………………………………………………………………………… 8

Tension-Leg Platform ……………………………………………………………………… 9

Spar Platform ………………………………………………………………………………… 9

Floating Production Systems ………………………………………………………….. 11

Subsea ……………………………………………………………………………………….. 12

Chapter 3—Corrosion and Corrosion Control

Objectives ………………………………………………………………………………………………. 1

Corrosion ……………………………………………………………………………………………….. 1

Corrosion Process …………………………………………………………………………………… 2

Corrosion as an Electrochemical Process …………………………………………………… 3

The Corrosion Cell …………………………………………………………………………………… 3

Anode …………………………………………………………………………………………… 5

Cathode………………………………………………………………………………………… 6

Return Path (Metallic Pathway) ………………………………………………………… 6

Electrolyte …………………………………………………………………………………….. 6

Summary ………………………………………………………………………………………. 7

Corrosion of Steel Structures Offshore ……………………………………………………….. 9

Corrosion Rates …………………………………………………………………………………….. 10

The Offshore Environment ………………………………………………………………………. 12

Affect of Design on Coatings ………………………………………………………….. 14

Affect on Substrate ……………………………………………………………………….. 16

Types of Corrosion ……………………………………………………………………….. 17

General Corrosion ………………………………………………………………. 17

Localized Corrosion …………………………………………………………….. 17

Pitting Corrosion …………………………………………………………………. 17

Crevice Corrosion ……………………………………………………………….. 19

Significance of Corrosion ………………………………………………………………. 19

Effects of Corrosion ……………………………………………………………………………….. 20

Safety …………………………………………………………………………………………. 20

Cost ……………………………………………………………………………………………. 22

Environmental Protection ………………………………………………………………. 22

Corrosion Control …………………………………………………………………………………… 22

Design ………………………………………………………………………………………… 23

Corrosion Inhibitors ………………………………………………………………………. 23

Material Selection …………………………………………………………………………. 23

Cathodic Protection Systems …………………………………………………………. 25

Protective Coating Systems …………………………………………………………… 25

Splash Zone Systems …………………………………………………………………… 26

Alteration of the Environment …………………………………………………………. 26

Corrosion Control Programs ……………………………………………………………………. 26

Other Resources ……………………………………………………………………………………. 29

NACE Standard SP0176

Chapter 4—Protective Coatings

Objectives ………………………………………………………………………………………………. 1

Coating Definition …………………………………………………………………………………….. 1

Liquid-Applied Coatings ……………………………………………………………………………. 1

Coating Terms ………………………………………………………………………………………… 1

Classification of Coatings ………………………………………………………………………….. 2

Coating Components ……………………………………………………………………………….. 3

Pigment ………………………………………………………………………………………… 4

Vehicle …………………………………………………………………………………………. 5

Binder …………………………………………………………………………………. 5

Solvents ………………………………………………………………………………. 5

Curing Mechanism …………………………………………………………………………………… 6

Modes of Protection …………………………………………………………………………………. 7

Barrier ………………………………………………………………………………………….. 7

Inhibitive ……………………………………………………………………………………….. 8

Sacrificial …………………………………………………………………………………….. 10

Common Coatings in Offshore Industry …………………………………………………….. 11

Maintenance of Coating Systems …………………………………………………………….. 12

Coating Defects …………………………………………………………………………………….. 14

Application-related Defects ……………………………………………………………. 14

Normal Aging Defects …………………………………………………………………… 18

Externally Caused Defects …………………………………………………………….. 20

Chapter 5—Splash Zone Systems

Objectives ………………………………………………………………………………………………. 1

Splash Zone Definition ……………………………………………………………………………… 1

Splash Zone Corrosion …………………………………………………………………………….. 1

Common Maintenance Systems in the Offshore Industry ………………………………. 2

Conventional Coatings ……………………………………………………………………. 3

Underwater-curing Epoxy (UCE) ………………………………………………………. 3

Underwater-curing Epoxy Composites (UCEC) ………………………………….. 3

Unidirectional Composite Systems ……………………………………………………. 4

Wax-Based Composites (WBC) ……………………………………………………….. 4

Silicone Gel-Based Composites ……………………………………………………….. 4

Concrete Composite System (CC) ……………………………………………………. 4

Alloy Sheathing ……………………………………………………………………………… 4

Planned Replacement ………………………………………………………………………………. 5

Chapter 6—Cathodic Protection

Objective ………………………………………………………………………………………………… 1

Introduction …………………………………………………………………………………………….. 1

Cathodic Protection ………………………………………………………………………………….. 2

Definition ………………………………………………………………………………………. 3

How Cathodic Protection Works ……………………………………………………….. 4

Cathodic Protection Systems …………………………………………………………………….. 6

Galvanic Systems ………………………………………………………………………….. 6

Impressed Current Systems …………………………………………………………….. 8

Factors Impacting Cathodic Protection Systems…………………………………………… 9

Potential Measurement …………………………………………………………………………… 10

Other Resources ……………………………………………………………………………………. 12

Chapter 7—Study Guide Questions

Chapter 8—Regulatory Guidelines

Objectives ………………………………………………………………………………………………. 1

Federal Regulations …………………………………………………………………………………. 1

BSSE Level 1 Inspections …………………………………………………………………………. 1

Reporting………………………………………………………………………………………. 2

BSSE Inspection Role in Corrosion Protection Systems ………………………………… 2

Required Records ……………………………………………………………………………………. 4

Chapter 9—Corrosion Prevention Maintenance Programs

Objectives ………………………………………………………………………………………………. 1

Introduction …………………………………………………………………………………………….. 1

Maintenance Philosophy …………………………………………………………………………… 2

Program Goals and Objectives ………………………………………………………………….. 3

Grading Systems …………………………………………………………………………………….. 3

Industry Assessment Reference Standards …………………………………………………. 8

SSPC Standards ……………………………………………………………………………. 8

ISO Standards ……………………………………………………………………………… 10

ASTM Standards ………………………………………………………………………….. 11

Facility Breakdown …………………………………………………………………………………. 12

Summary ……………………………………………………………………………………………… 15

Chapter 10—Facility Breakdown

Objective ………………………………………………………………………………………………… 1

Assignment …………………………………………………………………………………………….. 1

Duration …………………………………………………………………………………………………. 1

Chapter 11—Data Collection & Management Systems

Objectives ………………………………………………………………………………………………. 1

Collection Systems ………………………………………………………………………………….. 1

Electronic Data Collection ……………………………………………………………….. 8

Coated Surface Area Data Collection …………………………………………………………. 8

Materials and Equipment…………………………………………………………………. 9

WF Shapes …………………………………………………………………………………………… 10

Tees …………………………………………………………………………………………………….. 10

Angles ………………………………………………………………………………………………….. 11

Box Beam (Tubulars) ……………………………………………………………………………… 11

Channels ………………………………………………………………………………………………. 12

Pipe ……………………………………………………………………………………………………… 12

Cubic Space Concept …………………………………………………………………………….. 13

Shorthand Notations ………………………………………………………………………………. 14

Data Management …………………………………………………………………………………. 14

Hardcopy Systems ……………………………………………………………………….. 15

Database & Spreadsheets …………………………………………………………….. 15

Software Systems ………………………………………………………………………… 16

Web-Based Systems …………………………………………………………………….. 16

Summary ……………………………………………………………………………………………… 17

Chapter 12—Corrosion Protection Systems Evaluation

Objectives ………………………………………………………………………………………………. 1

Introduction …………………………………………………………………………………………….. 1

Efficiency ……………………………………………………………………………………………….. 2

Reproducibility ………………………………………………………………………………………… 2

Accuracy ………………………………………………………………………………………………… 2

Safety …………………………………………………………………………………………………….. 3

Evaluation Philosophy ………………………………………………………………………………. 4

Definition of Visual Inspection ……………………………………………………………………. 4

Deterioration of Coatings ………………………………………………………………………….. 5

Deterioration of the Substrate ……………………………………………………………………. 6

Using Coating Condition as an “Indicator” …………………………………………………… 8

Performance of the Survey ……………………………………………………………………….. 8

Inspection Types ……………………………………………………………………………………. 10

Basic Inspection …………………………………………………………………………… 10

Intermediate Inspection …………………………………………………………………. 11

Advanced Inspection …………………………………………………………………….. 12

Platform Data ………………………………………………………………………………………… 13

Platform Identification ……………………………………………………………………. 13

Element Assessment ……………………………………………………………………. 13

Reason for Assessment ………………………………………………………………… 14

Existing Coating System ……………………………………………………………….. 14

Age of Coating System …………………………………………………………………. 14

Age of Platform ……………………………………………………………………………. 14

Coating System Condition ………………………………………………………………………. 15

Substrate Condition ……………………………………………………………………………….. 15

Cathodic Protection System …………………………………………………………………….. 15

Documentation ………………………………………………………………………………………. 16

Level 1 Inspection Information ……………………………………………………….. 17

Performance of Visual Inspection …………………………………………………………….. 17

Imminent Safety Hazards ………………………………………………………………. 19

Imminent Safety Hazards—Examples ……………………………………………… 20

Active Leaks ………………………………………………………………………………… 23

Extensive Deterioration at Joints/Fasteners ……………………………………… 23

Active Leaks ………………………………………………………………………………… 24

Cathodic Protection Rectifier Issues ……………………………………………….. 24

Grading the Corrosion Protection System ………………………………………… 25

Critical Areas of Concern ………………………………………………………………. 25

Documentation …………………………………………………………………………….. 26

Inspecting Structures ……………………………………………………………………………… 27

Critical Areas of Concern—Structure ………………………………………………………… 28

Perforations …………………………………………………………………………………. 29

Loss of Section …………………………………………………………………………….. 30

Decking ………………………………………………………………………………………. 30

Deformation …………………………………………………………………………………. 31

Missing/Deteriorated Welds …………………………………………………………… 32

Missing Structural Member …………………………………………………………….. 33

Inspecting Piping……………………………………………………………………………………. 34

Critical Areas of Concern—Piping…………………………………………………………….. 35

Loss of Section …………………………………………………………………………….. 35

Indications of Pitting ……………………………………………………………………… 35

Inspecting Equipment …………………………………………………………………………….. 37

Critical Areas of Concern—Equipment ……………………………………………………… 38

Loss of Section …………………………………………………………………………….. 38

Indications of Pitting ……………………………………………………………………… 39

Deteriorated Code Plates ………………………………………………………………. 39

Inspecting Wells …………………………………………………………………………………….. 40

Critical Areas of Concern—Wells ……………………………………………………………… 41

Loss of Section …………………………………………………………………………….. 41

Conductor Deterioration ………………………………………………………………… 42

Chapter 13—Study Guide Questions

Chapter 14—Evaluation Equipment

Objectives ………………………………………………………………………………………………. 1

Introduction …………………………………………………………………………………………….. 1

Testing Coating Integrity by Dry Film Measurements ……………………………………. 2

Introduction …………………………………………………………………………………… 2

Type-1 Magnetic Pull-Off Gauges …………………………………………………….. 3

Calibration Verification and Measurements—Type-1 Pull-Off

Gauges ……………………………………………………………………………….. 4

Type-2 Electromagnetic DFT Gauges ……………………………………………….. 6

Calibration, Verification and Measurement—Type-2 Constant

Pressure Probe Gauges ………………………………………………………… 6

Electronic vs. Eddy Current DFT Gauges ………………………………………….. 7

Electromagnetic DFT Gauges ………………………………………………… 8

Eddy Current DFT Gauges …………………………………………………… 10

Paint Inspection (Tooke) Gauge ……………………………………………………… 13

Description ………………………………………………………………………… 14

Uses …………………………………………………………………………………. 16

Test Procedures …………………………………………………………………. 17

Gauge Calibration……………………………………………………………….. 19

Advantages ……………………………………………………………………….. 20

Disadvantages ……………………………………………………………………. 20

Precision Groove Grinder …………………………………………………….. 20

Adhesion Tests ……………………………………………………………………………. 22

Knife/Micrometer ………………………………………………………………… 23

Measuring Adhesion by Tape Test ………………………………………… 24

Method A …………………………………………………………………. 25

Method B …………………………………………………………………. 27

Pull-Off Adhesion Tests Using Portable Adhesion Testers ………… 29

Self-Aligning Adhesion Tester Type III

(HATE VII Hydraulic Tester) …………………………………………………. 36

Chapter 15—Facility Inspection Planning

Assignment …………………………………………………………………………………………….. 1

Chapter 16—Practice Practical

Chapter 17—Study Guide Questions

Chapter 18—BSSE Inspections and A-B-C Grading System

Objectives ………………………………………………………………………………………………. 1

Introduction …………………………………………………………………………………………….. 1

Grade Definitions …………………………………………………………………………………….. 3

Grade A ………………………………………………………………………………………… 4

Grade B ………………………………………………………………………………………… 5

Grade C………………………………………………………………………………………… 5

Using the Field Guide ………………………………………………………………………………. 5

Chapter 19—BSSE “ABC” Visual Inspection

Assignment …………………………………………………………………………………………….. 1

Chapter 20—Assessment Simulation

Chapter 21—Data Utilization & Planning

Objectives ………………………………………………………………………………………………. 1

Introduction …………………………………………………………………………………………….. 1

Assessing the Enterprise ………………………………………………………………………….. 1

Number of Platforms ………………………………………………………………………. 2

Total Protected Area ………………………………………………………………………. 2

Budget/Area ………………………………………………………………………………….. 3

Average Grade ………………………………………………………………………………. 3

Platform Grades …………………………………………………………………………….. 3

Maintenance Required ……………………………………………………………………. 4

Planning and Budgeting ……………………………………………………………………………. 5

Optimum Coating Maintenance ………………………………………………………… 5

Cost of Deferring Work ……………………………………………………………………. 6

Evaluating Candidates for Overcoating ……………………………………………………….. 6

Monitoring Effectiveness of Corrosion Prevention Systems ……………………………. 7

Planning Follow-On Surveys ……………………………………………………………………… 9

Critical Area Focus …………………………………………………………………………. 9

Altering Survey Frequency ………………………………………………………………. 9

Summary ……………………………………………………………………………………………… 10

NACE Standard SP0169