Corrosion Engineering 2012

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  • 1. THINKING BEYOND THE OBVIOUSCorrosion EngineeringCorrosion control, durability & life extension techniques18 – 19 April 2012Indaba Hotel and Conference Centre,Corner William Nicol and Pieter Wenning Street,Fourways, Johannesburg, South Africa SETA Accreditation No. 2502
  • 2. MOTIVATION & OVERVIEWAccording to research done by Mintek, corrosion “directly costs the economy about R130 billion a year”due to the damages it does to buildings and infrastructure, as well as, explosions in refineries and factories.In fact, a 2005 study conducted by the University of Witwatersrand which estimated the direct cost ofcorrosion as R154 billion a year. However, several independent studies have also shown that 25% of theeffects and costs of corrosion can be prevented by applying known corrosion technology.Corrosion is natural and inevitable, but it can be minimized and the process delayed. Beyond thesignificant direct costs to repair and/or replace corroded bridges, facilities, and architectural steel; there areadditional costs associated with accidents caused by corroded structures, needless consumption of naturalresources to constantly repair and maintain infrastructure, and lost productivity when delays cause jamsin the production cycle or lost opportunity. Depending on which market sector is being considered, theseindirect costs may be as high as five to ten times the direct cost.From a business perspective, the emphasis is on finding a balance between corrosion control and corrosionprevention. Control and prevention should be seen essentially to complement one another. The margin forerror is usually high because of the human factor. There have been reports of areas being overlooked duringa routine maintenance which has resulted in failure costing more to repair/replace. This 2-day master classwill detail the latest technologies in corrosion control, effective corrosion monitoring and testing as wellas, outline mitigation techniques for internal and external corrosion. Protective coatings methods andcathodic protection measures will be elaborated on at length by the expert panel of speakers. BENEFITS OF ATTENDING• Minimise the cost implications of corrosion damage• Understand the risk of non-compliance with regulatory standards• An overview of design guidelines for corrosion prevention• Receive an understanding of the fundamentals of protective coatings• An update on international standard specifications on hot dip galvanising WHO SHOULD ATTEND• Corrosion Engineers • Mechanical Engineers• Corrosion Specialists • Project Engineers• Corrosion Technicians • Inspection Engineers• Corrosion Technologists • Pipelines Engineers• Chemical Treatment Specialists • Operations Managers• Maintenance Managers/Directors YOUR FACILITATORSBob Wilmot Executive Director, Hot Dip Galvanizers Southern AfricaDave Raath Director, Cathtect EngineeringArmin Schwab Senior Corrosion Engineer, Pipelines Performance TechnologiesGLOBAL PROSPECTUS TRAINING (PTY) LTD. Chief Executive O er - Dhevaraj PillayJohannesburg - Tel: +27 11 781 6222 Fax: +27 11 781 6044 Marketing - m2@globalprospectus.co.za Auditors - Russell Bedford SA (Jhb) Inc.Pietermaritzburg - Tel: +27 33 391 4229 Fax: +27 33 391 5722 Design - www.designmaster.co.za (071 018 8355) Legal - DA Morris & Associates
  • 3. PROGRAMME SCHEDULE All timings are approximate due to the interactive nature of the course. 08:30 Registration & morning coffee 09:00 Start of workshop 10:30 Morning refreshments 10:45 Workshop continues 12:15 Networking Lunch 13:30 Workshop continues 15:00 Afternoon refreshments 15:15 Workshop continues 16:45 End of workshop COURSE AGENDA DAY 1 Session 1: Introduction to design guidelines and latest technologies Corrosion overview • The cost implications • Factors which accelerate corrosion • An overview of corrosion control methods • Corrosion implications on durability of materials • Microbiologically influenced corrosion Design guidelines for corrosion prevention • Identifying corrosion resistant alloys • Life extension of aging plant, equipment and infrastructure • An overview of general classification of environments and engineering materials • Effectively matching a material with an environment Investigating latest technologies in corrosion control • Field Signature Method (FSM) technologies • Overcoming the challenges of implementing green control and prevention strategies - Pressures to follow a more environmentally friendly method of control • Latest update on review of hot dip galvanizing in complying with specifications set by the International Organisation for Standardisation (ISO) Session 2: Corrosion control using Protective Coatings Hot-Dip Galvanizing for steel corrosion protection Examining various types of protective coatings • Coatings thermal spray for corrosion protection • Metallic coatings and metal spray • Liquid applied coatings: epoxies, alkyds, acrylics, polyurethanes, zinc silicate, tape wrappings • Cementicious coatings Identifying the makeup and function of protective coatings • Discussing the practicalities and limitations of various coatings types • Conducting field testing of protective coatings • Test equipment including paint film thickness and paint film integrity • How to avoid premature coating failureGLOBAL PROSPECTUS TRAINING (PTY) LTD. Chief Executive O er - Dhevaraj PillayJohannesburg - Tel: +27 11 781 6222 Fax: +27 11 781 6044 Marketing - m2@globalprospectus.co.za Auditors - Russell Bedford SA (Jhb) Inc.Pietermaritzburg - Tel: +27 33 391 4229 Fax: +27 33 391 5722 Design - www.designmaster.co.za (071 018 8355) Legal - DA Morris & Associates
  • 4. COURSE AGENDA DAY 2 Session 3: Minimising risk factors and increasing durability Mitigation of internal corrosion • Corrosion rate determining parameters • Corrosion control with Inhibitors – types and applications • Corrosion measurement and life protection • The effects of corrosion on chemical treatments, inhibitors and biocides • Internal corrosion direct assessment • Inhibitors, corrosion and scale/deposit Mitigation of external corrosion • Construction requirements – material durability • Coating applications • Determining when cathodic protection is required Effective corrosion testing and monitoring • Direct assessment methodology application • Examining the conventional methods such as condition assessment and non-destructive testing - Weight loss coupon method - Electrical resistance method - Electrochemical method • When, why and how to monitor for corrosion damage • Corrosion probes • Underdeposit corrosion – testing and mitigation Session 4: Cathodic protection Cathodic Protection • The theory and application of cathodic protection and how it interacts with protective coatings • The galvanic table and its role in corrosion protection • Stray current corrosion • Methodology of monitoring cathodic protection • Cathodic Protection of concrete pressure and mortar-coated steel • Cathodic Protection and shielding and root causes of external corrosion of cathodically protected pipelines • Evaluation of cathodic protection performance • Anodic protection Discussion and Delegates FeedbackGLOBAL PROSPECTUS TRAINING (PTY) LTD. Chief Executive O er - Dhevaraj PillayJohannesburg - Tel: +27 11 781 6222 Fax: +27 11 781 6044 Marketing - m2@globalprospectus.co.za Auditors - Russell Bedford SA (Jhb) Inc.Pietermaritzburg - Tel: +27 33 391 4229 Fax: +27 33 391 5722 Design - www.designmaster.co.za (071 018 8355) Legal - DA Morris & Associates
  • 5. Corrosion Engineering ONLY R699 18 – 19 April 2012 Per D eleg 0Registration Form Indaba Hotel and Conference Centre, ex. VA ate, T. Corner William Nicol and Pieter Wenning Street,GPW Fourways, Johannesburg, South Africa Fax Completed Registration Form To: +27 11 781 6044Company Name:Type of Business:Address:Tel: Fax: VAT Number:Delegate 1:Position: E-Mail:Delegate 2:Position: E-Mail:Delegate 3:Position: E-Mail:Delegate 4:Position: E-Mail:Delegate 5:Position: E-Mail:AUTHORISATION: Signatory must be authorised to sign on behalf of Company CREDIT CARDName: Cardholder’s Name: DETAILSPosition: Credit Card Number:Signature: Date: CVC No: Expiry Date:PAYMENT METHODS1. Bank Transfer - Global Prospectus Training (PTY) Ltd. 2. Credit card - Please fill in your credit card details above First National Bank: Randburg 3. Cheques - Made Payable to: Global Prospectus Training (PTY) Ltd. Account Number: 62109 270372 Branch Code: 254005TERMS & CONDITIONSThe following terms and conditions will apply: Substitutions Payment is required in full 5 days from date of invoice Delegates must inform Global Prospectus Training (PTY) Ltd in writing All payments to be made directly to Global Prospectus Training (PTY) Ltd. of any substitutions. No seats will be reserved, unless Global Prospectus Training (PTY) Ltd. receives a signed registration form. There is no charge for substitutions. Global Prospectus Training (PTY) Ltd. reserves the right, due to circumstances beyond our control, to change Global Prospectus Training (PTY) Ltd will not be held liable for incorrect speakers, program content, date & venue. Delegate details on Certi s, etc. in the event of substitutions being The signed registration form is a legally binding contract. made on the day of the conference. In the event of Global Prospectus Training (PTY) Ltd having to cancel or postpone an event due to circum-Cancellations stances beyond our control, delegates will be issued with a credit voucher,All cancellations will be subject to approval by the management of Global Prospectus Training (PTY) Ltd. - which may be used at another of our events.All cancellations made 7 days prior to date of the above mentioned event will be subject to a 50% cancellation fee. -Cancellations made within 7 days of date of the above mentioned event, will be subject to a 100% cancellation fee. Global Prospectus Training (PTY) Ltd will not be held liable for travel and accommoda -The will be no refunds or credit vouchers. tion costs. The conference fee includes: conference material, lunches and refreshments, but excludes travel & accommodation.GLOBAL PROSPECTUS TRAINING (PTY) LTD. Chief Executive O er - Dhevaraj PillayJohannesburg - Tel: +27 11 781 6222 Fax: +27 11 781 6044 Marketing - m2@globalprospectus.co.za Auditors - Russell Bedford SA (Jhb) Inc.Pietermaritzburg - Tel: +27 33 391 4229 Fax: +27 33 391 5722 Design - www.designmaster.co.za (071 018 8355) Legal - DA Morris & Associates