Metallurgy for Non - Metallurgists

Day 1

• Pre – Test 
• Testing and Mechanical Properties of Metals
• Tensile tests
• Impact tests
• Hardness tests
• Compression of mechanical properties
• The Crystalline Structure of Metals
• Bonding in metals
• Solidification crystal growth and structures of metals
• Defects in metals during solidification
• Specimen Preparation and Microscopic Examination
• The preparation (Mounting Grinding, Polishing and Etching) of metal specimens
• Metallurgical and Electron Microscopes
• Dislocations and Strengthening Mechanisms in Metals
• Edge Dislocation (line imperfections) in crystals
• Strengthening of metals by Grain Size Reduction, Solid Solution and Strain Hardening
• Softening of metals by annealing
• Comparison of Cold and Hot working of Metals
• Binary Equilibrium Diagrams
• Solubility and cooling curves
• Thermal Equilibrium Diagrams (Eutectic Type, Solid Solution Type and Combination Type)
• Case study : Galvanic Corrosion Degredation 

Day 2

• Ferrous Alloys
• Definitions and classifications and some uses of ferrous alloys including:
• Carbon steels
• Alloy steels
• Stainless steels
• Cast irons 
• Fabrication of Metals 
• A selection of metal fabrication methods, including:
• Forming
• Casting
• Welding 
• Heat Treatment of Plain Carbon Steel
• Hardening of carbon steel (by quenching)
• Annealing Normalizing
• Tempering
• Austempering
• Surface treatments
• Heat affected zone (HAZ) in welding
• Non-Ferrous Alloys
• Nickel and cobalt
• Titanium alloys
• Case study: MIC Failure For Activated Carbon Filter

Day 3

• Basic of the Corrosion in Metals
• The electrochemical cell
• Types of electrochemical corrosion
• Theory of Corrosion
• Cost of Corrosion 
• Cause of Corrosion
• Types of Corrosion 
• Uniform Corrosion and Local Corrosion
• Pitting
• Stress Corrosion Cracking (SCC)
• Hydrogen damage (Embrittlement / Blistering)
• Galvanic Corrosion
• Crevice Corrosion 
• Hydrogen Embrittlement.
• Case study: Thermal Chock Leak Failure For  Tube and shell heat exchanger  

Day 4

• Corrosion Control Technique
• Material selection 
• Effect of dissolved gases
• Stream Velocity 
• Fiber Glass Type
• Under Ground GRP Material
• Limitation of Non-Metallic Material
• Cost of material
• Improved Design
• Examples of Impingement Corrosion
• Examples of avoiding crevice corrosion by design
• Incorporation of corrosion allowance
• Chemical treatment 
• PH Control
• Removal of Dissolved Gases
• Application of Corrosion Inhibitor
• Biocides role in corrosion control
• Control of Microbial Corrosion
• Advantages of Corrosion Monitoring
• Corrosion Coupons
• Electrical Resistance (ER)
• On-Line Wall Thickness ( UT ) Measurements
• Case study : High temperature Painting Failure For Heater Regeneration line 

Day 5

• Types of Coatings
• Wrapping
• Protective Coatings
• Heat-Shrinkable Sleeves
• Wrapping & Sleeves
• Surface Preparation
• Water jetting
• Abrasive blasting ( provides surface roughness ): Sand blasting and Grit blasting
• Surface Profile
• Paint Application Methods
• Climatic conditions during painting application
• Paint inspection
• Holiday detector test
• Cross Hatch Adhesion Test
• Dry film thickness ( DFT )
• Cathodic Protection 
• Application of CP system
• Sacrificial anode system
• Impressed current system
• Cathodic protection monitoring
• Potential Measurement
• Reference electrode
• Installation of CP system
• Types of ground beds
• Typical Under-Tank Cathodic Protection System for New Tanks
• Impressed Current Cathodic Protection for Tank Internals
• ICCP for jackets
• Isolating flange kits
• Casings for Road Crossings
• Test Posts for CP Monitoring
• Stray-current corrosion
• Galvanizing, etc.
• Inhibitors, Types and usage
• Case study: Creep Damage For Tube Heater

Upon completion of this course, participants will have gained an understanding of the important principals of engineering involving properties and characteristics of metals and alloys, including fabrication and heat treatment of commercial steels and non-ferrous alloys. Participants will acquire sufficient knowledge and skills to independently evaluate possible metallurgical and design solutions, to recognize crucial metallurgical phenomena and intelligently discuss their metal problems with design engineers, metallurgists and fabricators.

Also they will able to understand how they will make righit material selection decisions  and how to protect metal from Corrosion and Erosion by Several ways as a recomeended Practise around oil and gas industries using Painting, coating, linning, Cathodic protection, Material selection, Improved design and Chemical inhibition.

Knowing the Type of corrosion on all the oil and gas and refinery facilities, and how to rectify and mitigate that Corrosion, and knowing also the Cathodic protection types, damage mechanisms on the refinery facilities, and ensuring that quality assurance standards and procedures are maintained.