A. Sour Gas Corrosion Testing – Level I

Corrosion of metals has imposed a serious threat on industry, the society and the nation in terms of both money and manpower. General statistics reveals that overall cost due to corrosion of metals amounts to at least 2-4% of GNP. This loss not only included the cost of replacement of metals, but also the damage to products by contamination, shut down of production, loss of efficiency and in psychological factors associated with failure or explosion of equipments. This loss can be reduced effectively to the tune of 20-25% by the application of appropriate and upgraded knowledge of corrosion and corrosion control science. Present course is an attempt in this direction which includes the basics and applied aspects of diffraction forms of corrosion and introduces to the recent developments in corrosion science and Academy with special emphasis on sour gas corrosion.

Module 1: Basics of Sour Gas Corrosion


Module 2: Review of Standards

Understanding of NACE TM0284 - resistance of pipeline and pressure vessel plate steels to Hydrogen Inducted Cracking caused by hydrogen absorption from aqueous sulfide corrosion.

Understanding of NACE TM 0177, EFC 16 and 17 - Sulfide stress corrosion cracking (SSCC) test occurs when a susceptible material is exposed to a corrosive environment containing water and H2S at a critical level of applied or residual tensile stress.

Module 3: Sample Preparation

Module 4: Review Sample under Microscope

Module 5: Hardness Testing

Selection of type of harness based on type of steel grade and geometry of specimen.
Operation of hardness testing Machines.
Calibration of hardness machine .
Selection of indenter.
Standard practice of harness testing as per ASTM E384, E10 , E92 and E18 .
Calculation of hardness number .
Conversion of one hardness to other type of hardness as per ASTM E140.

Module 6: Grain Size Analysis:

Selection of sample for grain size analysis.
Micro constituent of steel.
Standard practice of grain size analysis as per ASTM E112, E930, E1382.
Parameter setting for optical microscope for grain size analysis
Evaluation of Grain size

Module 7: Determination of Inclusion Rating

Basic Knowledge of different type of non metallic inclusions in steel
Selection of sample for inclusion rating
Physical appearance of inclusions in cast steel/iron
Physical appearance of inclusion rolled product.
Standard practice for inclusion rating as per ASTM E45 and ASTM E1245 specification
Calibration of optical microscope
Parameter setting for optical microscope for inclusion analysis
Evaluation of inclusion content in steel.

The duration of this course is for 5 days and it is conducted by a Senior Metallurgist. Students will be given a course completion certificate at the end of this course.

B. Sour Gas Corrosion Testing – Level II

The topics covered in this course include:

Module 1: Hydrogen Induce Cracking (HIC) and Sulfide Stress Corrosion Cracking (SSCC) - 4 point bend Test

Measuring dimension of samples and calculating required test solution volume.
Cleaning and test for degreasing as per ASTM F21. Calculation of deflection based on applied load which depends on steel grade.
Entering required data for the test.
N2 purging and H2S gas bubbling for HIC and SSCC (4 point bend test) .
Idiomatic titration of test solution.
Monitoring and inspection of test.
Neutralization of test solution before deposing to waste tank.
Record of chemical consumption and waste solution.
Evaluate test result .

Module 2: Sulfide Stress corrosion cracking (SSCC) test, Uni-axial Constant Tensile Load

Calculate applied load based on the steel grade.
Loading and un loading of test specimen into the testing machine .
Familiarization with gas management.
Selection of required parameters to enter the test mask.
Evaluation of results

Module 3: Ultrasonic Crack Detector

Setting ultrasonic crack detector's parameters for Ist and 2nd operational level .
Select appropriate speed and resolution to get correct value.
Calibration of machine .
Select proper analysis line for calculating HIC parameters .
Print and save the raw data of scanned samples.

The duration of this course is for 5 days and it is conducted by a Senior Metallurgist. Students will be given a course completion certificate at the end of this course.


Course Need:

• Understating of damage mechanisms prevailing in the reformer tube
• Gain a valuable practical understanding of principles of degradation that occurs in short term and long term operation of reformers.
• Design aspects leading to failures.
• Welding issues related to reformer.
• Metallurgical understanding of the reformer tubes.
• Knowledge to increase the problem solving attitude and take the first hand judgment on the reformer tube failures.
• Attitude to analyze the difference in metal behavior helps to decide better mitigation to the persistent tube failures.
• Recognize general procedures, techniques and precautions in failure analysis and how stress systems relate to fracture of ductile and brittle materials.
• Achieve the knowledge required to conduct or supervise basic failure investigation and effectively communicate with metallurgists & other experts on more    complicated cases. Invention to improve reliability of company operations, cost savings, increase profitability, and enhances safety.

Who Should Attend?:

• Mechanical Engineers of middle management level
• Maintenance / Inspection Engineers
• Process engineers
• Plant Engineers / Managers
• QA / QC Engineers
• Reliability Engineer
• Metallurgical / Materials Engineers
• HAZOP Engineers / Managers
• Other Technical, Laboratory, Sales Personnel, Engineer from other disciplines, management and administrative staff who need a working understanding of    metals and their applications.

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