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MSc Corrosion Control Engineering / Course details

Year of entry: 2024

Course unit details:
Corrosion Control for Industrial Practice

Course unit fact file
Unit code MATS66502
Credit rating 15
Unit level FHEQ level 7 – master's degree or fourth year of an integrated master's degree
Teaching period(s) Semester 2
Available as a free choice unit? No

Overview

This unit provides you with an understanding of the key corrosion processes and mechanisms of prevention or mitigation for the Process and Power industries as well as energy sytems, covering topics such as high temperature corrosion and moving on to environmentally induced cracking and localised corrosion. The unit shows you how these modes of degradation can be encountered in industrial plant environments and inform the best industrial practice for their prediction, mitigation and ideally prevention by design. The corrosion risks for combinations of engineering materials and complex environments including humid air, steam, hot water, acids, and alkalis are presented and discussed. The cross cutting themes are the mechanistic understanding of the processes involved and the prediction of corrosion risks in the different environments, the use of design and materials selection to minimise the probability of corrosion failures, and to encourage an appreciation of the strengths and limitations of the different corrosion control strategies available.

A final set of lectures considers how materials corrosion data is used by engineers from other disciplines, and shows how information from corrosion engineers is used in Failure Assessment Diagrams, where both structural engineering concepts and information on rates of degradation of structures can be integrated to provide robust techniques to assess the integrity and lifetime of industrial plants and equipment.

Aims

The unit aims to:

  • To enable you to understand the corrosion challenges faced by the Process and Power Industries.
  • To enable you to understand how materials selection and the design and use of countermeasures to mitigate corrosion are commonly used in industry and energy sectors.
  • To ensure you understand the specific corrosion challenges in cooling and steam raising equipment
  • To enable you to use the R6 Failure Assessment Diagram framework to integrate data of corrosion risks with mechanical and structural design and assessment methods.

Learning outcomes

A greater depth of the learning outcomes will be covered in the following sections:

  • Knowledge and understanding
  • Intellectual skills
  • Practical skills
  • Transferable skills and personal qualities

Teaching and learning methods

The course is delivered either via face to face lectures or by online modules. This material was originally developed as an online version of the course, but now serves as a parallel resource for revision, with tests and other activities students may use.

There will be a formative online quiz for practise in the third week of teaching, followed by an assessed quiz activity after the fourth week of teaching. The final assessed coursework is a lab exercise, to examine Pitting Corrosion. This will be a group report.

 

Knowledge and understanding

    High Temerature 

    • Describe corrosion processes in high temperature industrial environments such as fossil fuel power plant.

    SCC

    • Understand the most common types of stress corrosion cracking, the effects of stress, metallurgy and environment on SCC rates and occurrence.

    Localised Corrosion

    • Quantify the relationship between pitting and crevice corrosion, and relate this to the effects of deposits

    Intellectual skills

    • Understand both general and localised corrosion/damage processes and the reasons for these occurring.

    Practical skills

    • Understand the method to set up and monitor a localised corrosion experiment.

    Transferable skills and personal qualities

    The summative exercises include teamwork exercises to develop students experience of collaborative working in a virtual leaning environment as well as digital platforms.

    Assessment methods

    Method Weight
    Written exam 70%
    Written assignment (inc essay) 30%

    Feedback methods

    Written and verbal

    Recommended reading

    General texts are listed in the reading list for unit MATS63351. More specialist topics are covered in this unit, but many of these works are also useful for this unit.

    Electrocorrosion and Protection of Metals General approach with particular consideration to electrochemical plants

    Joseph Riskin

    Burlington : Elsevier Science 2008

    Online access available
     

    Corrosion and Chemical Resistant Masonry Materials Handbook

    William Andrew Publishing/Noyes 1986

    Online access available
     

    Understanding how components fail / Donald J. Wulpi.

    Donald J. Wulpi author. Brett Miller Metallurgical engineer, editor.

    Materials Park, Ohio : ASM International, Third edition / edited by Brett Miller. 2013]

    Online access available
     

    Materials selection deskbook / by Nicholas P. Cheremisinoff.

    Nicholas P. Cheremisinoff

    Westwood, N.J. : Noyes Publications ©1996

    Online access available
     

    Handbook of environmental degradation of materials / edited by Myer Kutz.

    Myer Kutz

    Waltham, MA : William Andrew 2nd ed. 2013

    Online access available
     

    Environmentally assisted cracking : predictive methods for risk assessment and evaluation of materials, equipment, and structures / Russell D. Kane, editor.

    R. D Kane

    W. Conshohocken, PA : ASTM 2000

    Available at Joule Library Main Level (620.182 KAN )
     

    Treatment of Cooling Water / by Aquaprox.

    Aquaprox. author. SpringerLink (Online service)

    Springer eBooks

    Berlin, Heidelberg : Springer Berlin Heidelberg, 2009

    Online access available
     

    Selection and use of engineering materials.

    J. Charles F. A. A Crane (Frederick Albert Andrew), 1927-1984.; J. A. G Furness

    Oxford : Butterworth-Heinemann 3rd ed. / J.A. Charles, F.A.A. Crane, J.A.G. Furness. 1997

    Online access available. The library also has physical copies.
     

    Materials for Nuclear Plants From Safe Design to Residual Life Assessments / by Wolfgang Hoffelner.

    Wolfgang Hoffelner author. SpringerLink (Online service)

    Springer eBooks

    London : Springer London : Imprint: Springer, 2013

    Online access available

    For Information and advice on Link2Lists reading list software, see:

    http://www.library.manchester.ac.uk/academicsupport/informationandadviceonlink2listsreadinglistsoftware/

    Study hours

    Scheduled activity hours
    Lectures 30
    Tutorials 3
    Independent study hours
    Independent study 117

    Teaching staff

    Staff member Role
    Fabio Scenini Unit coordinator

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