APPENDIX A—DETERIORATION MECHANISMS. Table Thinning Daeroration ‘Mechanism Description Betwvior | Key Variables Examples Tidrochiorie Nei | Typically causes lcalzed conosion in ar [Localized] Reid, pl, materials [rade wnit aimosphariecaTame |Conosion bon and lo alloy ste, parcvlry inal Jozcoesiristion.tem- overhead, Hydovrearing event condensation points (<400"F) Attic persue sins, Catalyse reforming eMuent sinless stels experience pitting and crev> end roxnerationsysiems. fee comosion. Nickl alloys can corrode ander oxidizing eondtons. icalanis [Oveurs when ive metals arsjoinedand — |Lovalied — [Yoiredmaterulsor | Seawater ond vome Cooling Ware (Comasion exposed i an eletlyxe Jeonsiuction, cistance [services fn galvanic series [Ammonia Bisal [Highly Tosalized metal ins dacto emmion [Lovallaed ——[NHGIIS % in water | Fonnod by thera or eaalyic ide Corrosion |oorsion in carbon see] and acnialty Kp), velocity pl feracking in hydrotreating, hydeve- bss racking, coking, catalytic cracking, mine treating and sour water ef ent and as separation yes [Carbon Dioxide — | Carbon dione Tea weakly acc gac which Lacillaad [Carbon dioxide oor | Refinery seam condensate sym, [Carbonic Acid) jis comosive when dissolved in water becom Jeenration, process |liydrogen plant andthe vapor evo [Conosion ing earbonie seid (Hs), CO> is eom conations, ery section of easlytie erocking rina foun in peer sections befor emt catmert. Aguscus CO, corrosion of carbon] ard low alloy sce isan eletrochernical process involving the anode dissolution of ron and te ean evoltion af yn gen. The nations are often accompanied by the formation of films of FeCOs (andor Ees0,) tat can be protective or noe-prote>| tive depending on the conditions Sar AT] Wey wrong acd that cases rsa Town Emllad TACHA, pl, mace | Sui ai ayo dem cixrsion ious materials and depends on many ofemstuctin, tem | ined wate cir, perature, velocity, cx ans iparoiers Aad] Vary arong aed tat cast aa TowsinLosavnd J Aad Vo, mara | Hyena aid aligianon wry cemion eos materia foreonsrastion, tem | detinated wate peratie, velo, oxidans Phoponec AT] Wok al Wat causal ows Gonerly | Loolind [Aca pL mate] Waar eonimea pas ceron ded for biel eoroson inition in oreonsrastion, Pal exrboias | Weak onanie ach causing cision aad Locaibed Aci, pi male [Heavy olland evacng pate —| acid) Comosicn mou loss in various alloys Joreosiracion, Anmine Common | Used n ps Gemma io emovedRwavad | Generaat low | Amine hype aid cone_[ATnine Gas weaing Wis ICO, and Th:S acid axes Corosion gener- | velocities, lea eenition, ratril of aly eased by desorbed acid gases or amino} izad at hich constuction, tempers deterioration products, etociies fire, acid gs eading, velocity Timoapherie | The general corowwon proceswoccurTing | Coneral un —[PrevenceaTexyuen, This pease realy apparent [Compsion under atmospheric eendtions where carbon | form comosion [temperature range and |hzh temperature processes where steal (Fo) i converted to iton oxide FesOs. the availabity of carbon stools ave been used wth- watacimoiture cut roteive erxings (seam pip- ing for example). [Conosion Under | CUT Ts peciic exe oTamnamphorc eono: |Geneniio | Prevencoorenyaen, | Msulaed pring nessa Insulation sion where the temperatares and the concer highly temperature range and| rations of watermoisiure can behighar. [localized the avalzbiliey of Onin residaltrace conusive elements ca wateroistce a also be leached out othe inslation msterial corrosive constituents tel creating a mexe corrosne cvironment vith the isuation,40 APL RECOMVENDED PRACHICE 880 Table 1—Thinning Deerionaion Meshonism Desecition Dshavior | Key Vavibles Examples [Soil Comosion | Malle Srucures ta coalae wits oT Hl [Cieneral to | sien of consis | Tank Boioms, underground png comm. located ion, sil charset ics, ype oF coating Tigh Teuperaime [Acarmive process similar oamosphers [Uecal uit —]Sulfor emcentraton | AllTocatians where tise Baul Sulidie Corrosion | corrosion in ihe presence of oxygen. In ths| form conusion [and temperature. | cieaLtemperaiue (4507 inno) sitbout Hy {ease the carbon steel (Fe) i converted in th fn sulfuris prosent m quantities presence of sifurto iron sulfe (Fe). igester than 0.2%. Common loea- [Conversion rate (end therefore eortesion ions are enue, coker, FCC, an rae) is dopendent on temperate a oper hhydroprocessing units vion nd sulfur conseniration, Tigh Tenparature | Wilh the presence of hycrogea, a gui [Genel uni [Sulfur and hydrogen [All localions where taxo Bsa Suinaie Corrosion | cantly more aggrsive case of sulfation | form corrosion |concentatin and tem cient temperate (480°F minima) vith He (sulfdiecommosion) ean exist peveture tnd slurs present in quantities preter than 0.2%, Aroas of hyde processing unite reacier feed down ‘ream ofthe yrogen mix point, the rector, reactor ela td the neeyele hyehogen gas including the exehangers, eaters, separates, Piping, et [Naphihenie Acid | Naphihenieacki cormdion Balak of West |Localiaad | Naphiheniorganie | Mile section of a vasa colar] Corrosion alleys by organic acids that condense inthe [eorosion acid eoncentration and] ina cnade nit (primarilyin the tango 08 350°F to 7S0°F, The prescnoe of temperature MVGO ext), can also oceur in potently harmful amounts of naphthenic seniospherie distillation ais, tbe acids in crude may be signifi by higher ‘maces and waster Hino neutralization suber (Oxidation igh enpetatu corrosion rexaion where Geseal mie | Temperature, pesenee| Ouse of Fomaee ties, mace etl is oomwerzed to anita oxide abows | form corrosion of at atonal oF eon-| rubs hangers, and other eternal fur] poole eraperes seucion. nce eomponenis exposed 10 oo bastion gases containing excessEScAASED INSPECTION a Table 2—Stress Corosion Gracking Deseransion Mechanisi esetipion Behavior Key Variables Examples [Chloride Croking | Cracking bat can jitate irom We ID [Transgranular | Aeid(ehlorde) coneenia- | Exiemally prewat in oqupmeat Wi] forODaatstenitie sainiece steel — erecting. sim, If, material of con- | poor insolation and weatherproofing euiprment, primarily dw fbvica- struction texperature, | downwind of cooling water spray Hon o resid! stresses, Some applic fabrication, tresses and equipment expose to fre water stesces ean also cause cracking. approaching yiekd Incenally wherever chlorides ean bo PrESENE with water such as amo- spheric column overheads of crude its and reactor efliven condensing [Causte Cracking | Cracking primarly tatied rom the | Typically, ier | Couto voncentaiion, pI, | Cansie (wating soto, causa er 1D afearbon sie! qquipmentprimz- granular ako |maeral ofeorsiusion, © | vic, merspean weatmoet, rade Fly duo stricaion or residual [canbe eans- | temperate tess unit eed prebeat destin, sour sess, ranular crack water reatment, steam syst ng [Povihione Acid | Cracking ofumieaiio aainiow oa [lateramlr | Mareral oT consimation, | Gonsrly oecur in austenite Sai Cracking in tie sensitize eonction (due ohigh| cracking, | sensitized mierostrictae,_ less tee! materials in eualytic crak temperature exposure or welding) it presence of water, poly Jing uit reactor and Due was syste the presenceet polythionic aid in wet ‘homie acid, ésulfurzer furnaces and hycepre> ambient conditions. Polthiocic aed essing mits. is formed hy a corversion of FeS in the presmce of water and oxy, (Amine Cracking | Amine is used in gas reament 0 | Inergranalar | Amine iype and concerns: Arnine Wali unis remove dissolved COs ard ILS acid [erseking, | tion, material of eonstrc ses, Cracking generally caused by tion emer, stress. desorbed acid gasex or amine deterio- raion produc. Amnon (Cracking ofarhon seclandadnivaly|Ineagranular | Mareral ofeostniction, | Generally jess amionia pro= Cracking brass ‘racking in ea | emiperatue, sires, ution and handling such as o¥er- bom sive, tans ead condonsation Where ammonia ramalarin sa neutralizer [copper ine alloys Hydrogen Induced [Occurs carbon and low aloy ol Planar els TS conssnlation, wales [Anywho it TS 6 present wilh [Grading Siwss. |materialsin the presence of woterand |(bister), | temperature pH, material | water such as erude units catalytic [Criented Hydto- | Fa8. Deveroruion ofthe material [Transyranutar | ofeonsivetin. eracking compression and yas eco [gen liduced | propeniesiscaused wien atwnie —_|eracks asblis- ery, hydroprocessing, sour water and] [Cracking nyctogen, aenerted throush como- |ters progress eoker units, sion, cies io the material and [toward wel. reas with other alone hydrogen to Toem molecular hydrogen as nino sions ofthe steel, Deterioration ean take the form of blisters and step-wise racking in tess relieved equipment and nonsiress relieved equipment. [Salide Siew | Oceursin carbon and low ally tee! |Tranggranular 11S eonasntaiion, water, [Anywhere tha TTS & present wih [Cracking terials in the presence of wate and |eracking, nor |iemperature, pHmaterial| water such as erude units, catalytic HS. Deteroraion lakes the form of mally asioe:- | ofeonsiuetio, post weld. foracking compression and gas toon Jeacking in non or improperly sess. fated with [heat reatmiem, Condition, fery, hydroprocessing, sour wer and] relieved equipment. fabrication, | hawiress eoker units, lttactiment and repair weldsAPL RECOMVENDED PRACHICE 880 Table 2—Stress Corrosion Cracking Deerionaion Meshonism Pestipion Behavior Key Vavichies Examples Tipcogen ‘Decuria carbon and Tow alley Seer | Planar eracks [JTS concentration, wales [Anyhare Tha HS is present wilh Riisering materia in the presmce of water and |¢blisirs).—_|reraperstire, pH, material | water sich at crede rite, calytic TS. elerioration of the material lof eosiruction racking compression and yas rem properties is caused by atomic hydro- er, hydroprocessing sour wator and Bon generated through corosin di. ooker unit. Fuses into the material and wesc with other atoraie hydrogen to forma soe lar drogen gas in inclusions othe steel Deterioction takes the form of planar blisters an can occa re ‘elioved and aon-stressroeved exuip- Tisosen Presence iycogen cyanide can pao [Planar Gaslw|Prosonss of ICN IES con] Anpwhaw Waa TES Ts present wa [Cyanide Cracking | more hydrogen deercration (SOHIC, (lise) and _|eoniation, water, emper | water such aserode units, catalytic SCC, and blistering) by dewabiliing”|wansgra lar ‘he fon sulfide proietive surface ferocking. scale. ture, pH, raterial of leonstucton, esacking compression and gas reo ex, hydroprovessing sour water a eokcr unis.EScAASED INSPECTION 4 ‘Table 3—Metallurgical and Environmental Failures: Dacian Mechanisn Desetition Batevior Key Vales amples iigh-Temperanrs | OSes n carbon ard alyssa Inagranciar it Mataral oF consniton, —|TVpcaly occurs i rSon ridogen tack [nates nde rewenoe of high |aurecracking, |tydogen paral pressure, | xeon of ydrocaron po ferperctureantydrgen, usally |Accabuzaton, |lempeature, sein ser Jeesirg unis saxh asic asapart of thohydrocbon sear. sie desu, yocracker, /Atelvsted nips (> 500"), roformng and hy dropen eterna of he mete pone podecton uit ies is caused by methane gas fm ing Esse long the rin Bouncares Aton eydrgen i fises imo tae maz ad rots vith atbon from theta, forming frethane gas ar depltng the sel reat ain Growth Gecurs wien deel are hesiad | Lacan Miaimarn tampentare — Paco wes urs fie above acevsin exper, beio= read, deat maximum | damaged equipment oni ing abot I100°F for CS and mos empire materalol [ment sical toruraway promuacedat 1350°F. Austere consration esctions ness secs an High eke chroma alleys dora hace subject ogre aro ntl ested atone 1650" arian [Ovcars when the formal pene | LASS Matsa of consction, [FOC tor gris in sts compos into st empentur and tne of weak erie grairs ane graphite exposure odulss usually dc to long teem exposure inthe 25°F 00°F |. ange Sigma Phare [Gccurs when aaswnlic ad cer | Generalized Maia of constuction, [Cant race bes and compo F:brivemens snes tects rh move ten 176 tempertureardtimeot nen regener eytores chromium arc held in th ange of exposure frocunt. 1W0XF1S00"F for euended tine pels. SSF Embriiomen | Occur aller aging offers can-|aneriznd | Mineral of consnaion, | Gaking of wrought ad sat sing sles sels 630° tenperaue sects rig Stow, 1000°F and produces a loss of ambient ensperatore docu. Temper Enbrc [Occurs when iow alloy sees a | Gcneaiand | Nateral ofconsnichon, | Ditag aio and wap ota fo tong pried em emperaureand time ot onto the problem may peatne rang of 700-1050. exposure appear eine ia der There is alos of toughness that is etnry units at have ope not evident st opens temps td ons enough forth sm tether shows upat ambien ten aon wo devel, erate weave rite Hydrogen fiscons. igus ar of meres because they aro wad a levaad to | _ a perms. aga Neat Form of castoplic bie fare Laci ial of consracton,—| Mercury is ound nse Fbriemene ora normaly dutie metal cae tenson tres presence of [ende ils and alse when isin or has heen in, eons vith igus meal and stressed in sin, Examples inchide sainles | cel and zine combination and cor} per based alloys and mercury com nation. liguid meta. refinery distillation ean con- dense and eonoontrate ita low spois in equipment such as conderser shells Failrcof process instruments that utilize erry hs boon know 0 nnrovhice dhe guid meet iru refinery seams.44 APL RECOMVENDED PRACHICE 880 Table 3—Metallurgical and Environmental Failures iva rolkiphase alloy. ions, material of construe ior. Deterioration Mechanism esetipion Behavior Key Viviables Esanples [Camrzation [Caused by carbon dius tao the] Localized Maeral of constriction, | Furnace tuber having coke stool at ele temperatnes. The temperate anctime of | departs ate god candidate increas carbon content resus in exposure. Fa earburization (ID). sn increase in the hardenablity of forte stools and some stinioss steels, When carried sacl ook a brite structure can esl, Dasviurinaiion [Lassof eachon fom thesurfice of Localized ‘Maieral of censinacion, [Carbon wee frmace thes ferous alloy asa result of heating in| temperature environment, |(OD). Result of excessive over |: madiuen tht rece with carbon beating (re). Nita Dasting Tighly localized earbarvation and’ [Localized Teper, pcs | Deiycrogenaton unit fred sibsoquont wastage of ols ssream composition, | heaters, coker heaters cracking] expose to mixtures of hysogen, its nd gas trbines racthars, CO, CO, ad ight hyiko} earbon ia ke temparaure range of 800" S00°F Sclctive Leasing | Preferential loss aT one ally phase | Localized Process stream fw eondk- | Admialy wibes used ta ook ng eater systems,EScAASED INSPECTION 4 Teble 4—Mechanical Failures Deisionion Mechanisa. Deserption Behavior Key Variables Examples echanieal Fatigue [Faure of component hy cracking] Localized yes eros love, material] Resprosaiing pats in pumps and flor tbe cornined appliewtion of of constveton. [compressors and the shuts of eyclicsress which extsed the vat machinery and associated aerials endure lira, pivina, cycle equipment such os [prose swing assorbers, [Conosion Finis | Form of Talgue wharea camosion | aeilizad’ | Cyelis sro maleral of | Stearn dram headars, Bvet tibos process, ypially ping eorosicn svstrasten, ping poten adds or promotes the mechanical lial ofe process sean. Fatigue process [Caation Caused by the vapid Tornarian and [Taclizad | Prosars head valucalong |acksds oT pump Tpalens, collapse of vapor bubbles in iguid the low of process steam. |ebows st amet surkace ae reel of pe Meshanicat Typical examplesare the misise of [NIA Fquipment design operar | Flange Tacos and her machined Petcroration cols andl squipment, vind deterio- ing procedures scating surfaces may be-damaged ation, careless banding waen wee not price wilh covers or equipment is moved or ected wien aot handled with ar [Overinading [Occurs when loads in exooss ofthe [WA Equipment design, operat | ipeostate esting ean oveoad maxinwen permite by design are ing procedns pporing smeuresducto exe plied to equipment weight applied. Thermal expan sion and oociraction can ae [overloading problems, [ner pressaring Appisaton ofprsmw in eaaso NA Trauipment desian oper | Exooss Feat ara rosll of upew te cnaximumn allowable working ing procedures. process coraition can rest in pressure of the equipment under lover pressing: blocking off feonsderaion. [equipment which isnot desired to handle full process pressure, Bile Friars Tas of dusty Wherein Re Goal is|Lacilizad’ | Maforal oT consiniion, | Daring equipment prosarizaiion ror Wo as having fw note romper. In abwonce of prevationury mea- iughness or poor impact trent somes csp Tigh temperature mechanism ——[Toeallzad | Maeva aTeonsimiction, | Fumace whes and aipporis wtercin continuous plastic defor temperature, applied sess, ation o a mst iakes place While finder stress below the normal yck! srt Sines Rupe Tine failure Tora metalarele|Tacalizad | Maier oTennsimaaon, | Fume wbes vated tempecatures unde applied ‘emperatue, applied sues stoss bolow its normal yiold time of exposure strength. Themaal Show [Secure when large and non-aniform| Localized [Equipment dian, oponi- | Assolnted wih occasional, BST herd stroses develop over a rk ing procadns, ow inierptions or curing aw ively short sit in apiece of esi men doo to diffrontil expansion Jor contaction. Irmovemert ofthe eqaipment i resraned this ean pro} duce stresses above the yield strong of the materia Thernal Fatigue | Thermal faigue isa processot | Lacalizad | Equipment sign, operat | Coke dns ae wbjet to thera] eyelieehanges in stress ina material ite to cycle change in temperune ing predares. eyeing and associat thormal Tkigue cracking. Bypass valves land piping with heavy weld rein- orosment on reactors in ele temporaiure srvice sv also prone to ther fatigue