Chloride - Stress Corrosion Cracking (Cl-SCC)

Description:

 Surface initiated, Environmental cracking, 300 Series SS and Nickel Based Alloys
 Tensile Stress, Aqueous Chloride environment, Temperature
 Dissolved oxygen

Materials:

 300 Series SS (303, 304, 316, 321), Alloy C-276

 DSS (Ferrite-Austinite) are resistant/immune because of low nickel,
 Nickel Based alloys are highly resistant, but not immune
 CS, Low alloy steels, 400 Series SS not susceptible.

Critical Factors:

 Chloride Content/concentration
 pH above 2.
 Temperature above 60 C
 Stress (Applied or residual)- Highly stressed or cold worked components are more susceptible.
 Dissolved oxygen accelerates SCC- No threshold value
 Alloy composition- Nickel content bw 8-12 % is more susceptible.
 Temperature/Chloride increases likelihood of cracking
 Heat transfer conditions allow chloride concentration

Effected Units:

 300 Series Piping and pressure vessels

 Water cooled condensers/ crude tower overhead condensers
 Drains in hydro processing units
 Bellows and instrument tubing, associated with hydrogen recycle streams contaminated with
chlorides.
 Wet insulations- External Cl- SCC
 Boiler Drain Lines

Morphology of Damage:

 Surface breaking cracks can occur from the process side or externally under insulation.
 No visible signs of corrosion
 Branches, Visually detectable- craze crack appearance, spider web appearance.
 Branched trans granular cracks. ( fine branching)
 Intergranular cracking of 300 series sensitized can also be seen.
 Welds in 300 series contain ferrite, producing duplex structure, more resistant
 Corrosion Resistant Nickel Based Alloys also susceptible under severe conditions.
 Fracture surfaces have a brittle appearance.

Prevention/Mitigation:
  Resistant MOC
 Low Cl content water during hydrotest, dry out thoroughly and quickly.
 Coatings under insulation
 Avoid designs that contain stagnant regions
 A high temperature stress relief of 300 Series SS after fabrication may reduce residual stresses.
However, consideration should be given to the possible effects of sensitization that may occur,
increasing susceptibility to polythionic SCC, possible distortion problems and potential reheat
cracking.

Inspection & Monitoring:

 Visually
 PT or phase Analysis EC techniques
 UT
 RT (Not accurate)

Caustic Stress Corrosion Cracking (Caustic Embrittlement)

Description:

 Form of SCC
 Surface Initiated cracks
 Exposed to caustic, adjacent to Non-PWHT’d welds.

Affected Materials:

 Carbon Steels, Low Alloy Steels, 300 Series SS are susceptible. Nickel Alloys are more resistant.

Critical Factors:

 Caustic Strength, Temperature,

 Stress Levels (residual or applied, result from welding or cold working)
Polythionic Acid Stress Corrosion Cracking (PASCC)
 SECTION 5
REFINING INDUSTRY DAMAGE MECHANISMS
5.1.2 Environment Assisted Cracking
5.1.2.1 Polythionic Acid Stress Corrosion Cracking (PA-SCC)
Sulfur+H2O+Air makes polythionic acid

Occurs during Startups/Shutdowns

300 Series SS, Alloy 600/600H, Alloy 800/800H

Sensitized Material

Adjacent to the welds or high stress areas

Through the wall thickness propagation

Environment – Sulfur Containing Environment-

Material – Sensitized (400-815C)

Stress – Residual or Applied

Low carbon grades less susceptible

Appearance: next to Welds/Base Metals, intergranular, negligible thickness loss

5.1.2.3 Wet H2S Damage (Blistering/HIC/SOHIC/SSC)

Stress Corrosion Cracking VS HSC/SSC

SCC can be confused with HSC. Failures of high strength steel under static load are considered a
form of stress corrosion cracking. some of the alloy/ environment

Mild steel/ 10M NaOH ,

1 1 13Cr steel (YS =1500 MPa)/ 3% NaCl ,
18Cr/8Ni stainless steel / 42% MgCl2,
Cu-30Zn/ NH4OH
are not considered SCC, although the crack growth behavior is similar.

Unfortunately, the two forms are still confused. The important differences are that in HSC (other than
SSC), nucleates internally and shows a bright & clean fracture surface however fracture surface of
SCC is covered in corrosion products. Also, as temperature increases, the probability of
HSCdecreases, unlike SCC. Also, CP enhances HSC, while reducing the likelihood of SCC. (In practice,
it is impossible to accurately determine the potential at the surface and the risk of over-protection
resulting in hydrogen generation means that CP would not be used if HSC is a possibility). Table in
picture shows differences between the two forms of environmental cracking.

Hydrogen damage shows the presence of hydrogen within the metal, forming cracks without any
anodic dissolution. While corrosion reactions can be the source of hydrogen, and chemical reactions
can occur on the surface and not by ‘anode-cathode’ corrosion.

Q. When and under what condition Hydrogen Damages due to HSC, SSC, HIC, Blistering, SOHIC, SWC
occur in Sour Wet Service?
Q. what's the difference in PTASCC, Caustic Embrittlement, Liquid Metal Embrittlement, Hydrogen
Embrittlement?

Q. Why aerated environment is required for SCC to occur in sour service, while HSC/SSC does not
require it? 

Q. What’s the difference in HTHA & HE?