Designing for Corrosion Control
5-Day Classroom Course
Description
The Designing for Corrosion Control Course reviews the principles of corrosion and corrosion control and provides a systematic method for applying the technology of corrosion prevention to the design process. It offers an overview of the steps involved in materials selection common to many industries. It also covers the economic considerations of including corrosion control in system design and the financial principles used in evaluating alternative materials and designs.
Who Should Attend
Anyone who has a technical corrosion background but is new to design including: civil engineers, mechanical engineers, design and process engineers, consultants, contractors, and architects.
Prerequisites
No prior training is required. However, for those with a limited corrosion background, the NACE Basic Corrosion Course is recommended prior to taking this course.
Course Highlights (include but are not limited to)
- Corrosion Control and Its Importance in the Design Process
- Matching Materials Performance to Service Environments
- Materials Selection (Process, Methodologies and Factors Influencing Materials Selection)
- Effects of Corrosion and Design on Materials
- Optimization of Design
- Economic Considerations and Analysis
Designing for Corrosion Control
Course Outline I. CORROSION CONTROL AND THE DESIGN PROCESS
Cost
Maintenance
Repair
Lost Production
Warranty Claims
Environmental Cleanup
Fuel and Energy
Capital Investment
Function
Product Contamination
Downtime
Loss of Redundancy
Consumer Confidence
Safety
Direct Impact on Safety
Indirect Safety Aspects
Preventive vs: Corrective Control
Advantages of Preventive Control
Advantages of Corrective Control
Integration of Corrosion Control into the Design Process
Roles of Participants in Design Process
Development Engineer
Accountant
Planners and Estimators
Designers
Draftsmen
Production Control
Corrosion Engineer
Research Testing Laboratories
Industry
Professional Societies
Inclusion of Corrosion Engineer in Design Team
Stages Where Interaction is Required
Activities of Corrosion Engineer
Typical Design Process
Education of Design Team
Academic Training
Industrial Training
Professional Society Training
In-house Training
Post-design Corrosion Review
Advantages and Disadvantages
Methods for Analysis of Designs
Design Review Check-off List
Design Review Check-off List
Innovative Versus Iterative Design
Application of Previous Experience
Application of "Good" Experience
Materials and Design
Service Conditions
Documentation
Application of "Bad" Experience
Failure Analysis
Preservation of Surface
Corrosion Products
Microscopic Analysis
Material Composition
Environment Analysis
Cause versus Mechanism Design
Material Deficiencies Fabrication
Environment and Documentation
Corrosion Control in "New" Situations
Performance Predictions
Corrosion Theory
Corrosion Testing
Why Never Before?
Configuration Management
Component Interaction
Importance of Overall Configuration
Importance of Operating/Environmental Factors
Methods for Configuration Management
II. MATCHING MATERIALS PERFORMANCE TO SERVICE
ENVIRONMENTS
Steps in Materials Selection
Define Service Environment
Define Required Performance
Project Material Performance
Match Materials
Definition of Service Environment
Corrosion-Related Environmental Characteristics
Chemical Characteristics
Major Species
Minor Species
Dissolved Gases
Nature of Environment
Combinations
Temperature
Velocity Effects
Pressure
Effects of Time
Additive versus Interactive Effects
Definition of Performance Requirements
Optimum versus Acceptable Performance
Acceptable versus Unacceptable Corrosion
Types of Corrosion
Propagation Rates
Projection of Materials Performance
Based upon Previous Service Experience
Based upon Similar Applications
Based upon Materials Performance Data
Selection Based upon Corrosion Tests
Natural Environment Tests
NACE International
American Society for Testing and Materials
Accelerated Tests
Electrochemical Tests
Materials Selection Process
Matching Performance with Requirements
Iterative Selection Methodologies
Practical Factors Influencing Materials Selection
Availability
Fabrication
Quantity
Joining
New Construction
Modification
Repair
Typical Properties of Materials
Metals
Material Specification
Irons and Steels
Aluminum Alloys
Stainless Steels
Copper Alloys
Nickel Alloys
Titanium
Other Alloys
Organic Materials
Plastics
Elastomeric Materials
Inorganic Non-metallic Materials
Cementitious Materials
Ceramics
Glasses
Composite Materials
Organic Matrix
Metallic Matrix
III. INTERACTIVE EFFECTS OF CORROSION AND DESIGN
Effects of Design Factors on Corrosion
Effects of Geometry
Time of Wetness
Effect on Environment
Drainage
Crevices
Com patibility
Galvanic Corrosion
Effects of Contact with Non-metals
Mechanics
Stress
Vibration
Fabrication
Surface
Exposed Area
Simple Shapes
Smooth Surfaces
Edges and Corners
Design Features for Specific Systems
Structures
Machinery and Equipment
Piping Systems
Tanks and Vessels
Electrical and Electronic Equipment
Ships and Vehicles
Corrosion Control
Protective Coatings
Designing for Coating
Barrier Function
Selection of Coatings
Types of Coatings
Surface Preparation
Coating Application
Coating Inspection
Cathodic Protection
Structural Requirements
Benefit of Combined Use of Cathodic Protection and Coatings
Impressed Current Cathodic Protection Systems
Galvanic Anode Cathodic Protection Systems
Design of Impressed Current Cathodic Protection Systems
Design of Galvanic Anode Cathodic Protection Systems
Change of Environment
Service versus Shutdown
Atmospheric Control
Process Chemical Control
Temperature Control
Inhibitors
Corrosion Allowance
Uniform Corrosion
Localized Corrosion
Maintainability
Ease of Maintenance
Inspection Requirements
Cleaning
Access
Maintenance Procedures/Guidelines
Effects of Corrosion on Function
Uniform Corrosion
Localized Corrosion
Environmental Cracking
Contamination by Corrosion Products
Abrasion
Product Contamination
Environmental Contamination
Protection of Specific Systems
Structures
Machinery and Equipment
Piping Systems
Tanks and Vessels
Electrical and Electronic Equipment
Ships and Vehicles
IV. OPTIMIZATION OF DESIGN
Economic
Direct Costs
Indirect Costs
Methods of Analysis
Cash Basis Method
Life-cycle Method
Payout Period Method
Return on Investment Method
Annual Cost Comparison
Discounted Cash Flow
Economic Considerations for Specific Systems
Structures
Machinery and Equipment
Piping
Tanks and Vessels
Electrical and Electronic Equipment
Ships and Vehicles
Consequences of Corrosion
Safety
Unscheduled Shutdowns
Environmental Damage
Product Contamination
Excessive Maintenance Costs
Esthetics
Methods for Design Optimization
Design Reviews
Use of Checklist
Recommendations
Value Engineering
Combinations of Methods of Corrosion Control
Materials Selections
Compatibility
Geometry
Mechanics
Surfaces
Protection
Maintainability
Economics |
