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nde (http://www.nde.com) > NDT for High Temperature Hydrogen Attack (HTHA)
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HTHA is dangerous, difficult to detect and can be missed. HTHA failures have led to severe burn injuries and fatalities.
This inspection should have high degree of reliability. No chances can be taken. We have run into a significant case
where Advanced Ultrasonic Backscatter Technique (AUBT) missed last stages of HTHA in a reactor (see case study
below).
BACKGROUND
Steel suffers from hydrogen damage or high temperature hydrogen attack when a seepage of hydrogen reacts with metal
carbides to form methane gas. This reaction decarburizes the steel, produces micro cracks, and lowers the toughness of
the steel, but does not necessarily cause a loss of thickness. Detection of hydrogen attack is important to ensure the
safe operation of pressure vessels and piping that is susceptible to such damage.
The type of damage caused by hydrogen attack depends on the source. The source of hydrogen in boiler tubes is from a
reaction of steam and steel. Hydrogen damage in boiler tubes is, therefore, always associated with ID corrosion.
However, in chemical plant the source of the hydrogen is from the flow stream (hydrocarbons) and, therefore, there is
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DEVELOPMENT OF NDE TECHNOLOGY BY A.S. BIRRING SINCE 1981
Anmol Birring, President of NDE Associates, Inc., has been involved with the development of NDT techniques for
detection of HTHA since 1981. Most of the inspections at that time used the ultrasonic amplitude technique, the
reliability of which was always questionable. Mr. Birring worked on several projects on this subject with JGC, Japan,
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Idemitsu, Japan, EPRI and Chevron, Richmond. During that period, he identified the relationship of ultrasonic
(https://www.google.com/patents/US4890496) for developing this technology. Since then backscatter technique has
Anmol Birring’s inspection technique depends on recognizing the patterns of backscatter signals in the
time and spatial domains to HTHA. Detection of HTHA is not straight forward and requires skill in
In 2004, NDE Associates inspected a C-0.5 Mo reactor at the Total refinery in Le Harve, France. The reactor was
placed in service in 1972 . The refinery was concerned of any damage by HTHA as the reactor was operating above
the C-steel curve. In 2004 NDE Associates inspected the reactor using the ultrasonic backscatter technique and
found significant levels of HTHA. Follow-up metallurgical, replication and magnetic particle tests confirmed severe
HTHA. Sectioning showed that 60% of the welds were damaged. Based on the results, the refinery took the reactor
out of service immediately after the inspection. The same reactor inspected previously in 2002 using AUBT by
Many technicians conduct HTHA inspections but I am not aware of anyone who has positively found HTHA
during a plant inspection.
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Hydrogen attack (http://www.nde.com/)
in the 18 mm thick pipe from a
failure
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in a Refinery de-suphurization plant (http://www
in Japan. Failure date
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March 31, 1982. Note the depth of HTHA at failure is 70 percent.
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Both the base metal and weld HAZ should be inspected for (http://www.nde.com/consulting/)
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hydrogen attack.
Base metal attack is detected by using a combination of ultrasonic back-scatter and velocity measurements (4, 5,6, 7).
Hydrogen attack increases the ultrasonic backscatter and reduces the ultrasonic velocity in the material. In particular,
HTHA increases the ratio of S-wave to L-wave velocities. The backscatter and velocity ratio measurements are applied to
detect hydrogen attack. The ultrasonic backscatter technique was developed by A. S. Birring in 1989 and was first
applied at the Chevron Richmond Refinery in 1989 (5). Details of the UT techniques for HTHA inspection are given in
references 4 and 5.
Application of the ultrasonic techniques for HTHA detection requires an individual with a good
understanding of the mechanism of HTHA and how it affects the propagation and scattering of ultrasonic
waves. One has to understand that that while hydrogen attack affects velocity-ratio, backscatter and the
frequency of the reflected signal, other material anomalies can influence these ultrasonic parameters as
well and give a false calls. For example, ultrasonic frequency of the reflected signal is affected by grain size,
material microstructure and surface roughness in addition to HTHA. Ultrasonic inspection for this
application is therefore not straight forward and requires a logical test methodology and a skilled operator
to identify specific backscatter patterns related to detect HTHA. It is most important that owners diligently
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Application of ultrasonic backscatter for detection of HTHA. Inspection is performed from the component OD. The ultrasonic
backscatter is ID connected.
Weld HAZ attack is detected using highly focused phased arrays. Since cracking caused by hydrogen attack is in the weld
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HAZ is extremely fine, the inspection is done at a very high sensitivity.
Phased Arrays are not recommended for detection of base metal HTHA. Verification of attack can be done by surface
replication.
High temperature hydrogen attack (HTHA) in the petrochemical is caused when the hydrogen from the stream seeps into
carbon and low alloy steels at high temperatures. Hydrogen reacts with the carbides in the steel, decarburizing the steel
and forming methane gas bubbles at the grain boundaries with no loss of thickness. The methane gas bubbles grow with
time and result in micro cracking. The combination of micro cracking and decaburization reduces the fracture toughness
HTHA is triggered in the components operating at high temperatures and high hydrogen partial pressure. API 941’s
Nelson curves provide information about the safe operating environment for components operating in hydrogen
environments (1). Components operating in the unsafe environments are susceptible to hydrogen attack. The concern is
especially true for C-1/2 Mo steels whose curve has been been lowered and now dropped to the same level as that
carbon steel (1). Because of this drop, some of the C-1/2 Mo components originally operating in the safe region are now
in the unsafe region of the Nelson curves. These components should either be inspected regularly for evidence of HTHA
Hydrogen Attack can occur both in the base metal and the weld HAZ. The attack in the base metal is wide spread and
distributed uniformly. In addition to temperature and hydrogen partial pressure, the susceptibility of attack also also
depends on the microstrocture ferrite/bainite or ferrite/pearlite with quasi M23C6 carbide (2). Weld attack is very
localized and grows along the HAZ. The susceptibility of attack in the weld HAZ depends on the heat treatment. Post-
weld heat treated welds are less susceptible to hydrogen attack compared to the welds that are not heat treated. There
have been several cases where the depth of the attack in the HAZ is greater than the depth in the base metal. It is
therefore imperative that both the base metal and the weld HAZ be inspected for presence of hydrogen attack.
Some of the factors that are important for scheduling inspections are as follows:
operating Home
conditions (partial pressure of hydrogen
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941 (1).
slow cooled C-1/2 Mo steels have less resistance to hydrogen attack than normalized steels (2).
post-weld heat treated welds are less susceptible to hydrogen attack compared to the welds that are not heat
treated.
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A general discussion of HTHA prediction is given in reference 5.
1. The preferred approach should be to replace C-1/2 Mo Equipment operating above the API 941 limits.
2. Reactors, heat exchangers shells and other thicker equipment must be inspected at the earliest if immediate
replacement is not possible. Ultrasonic backscatter inspection must be performed by skilled inspectors who who
understand HTHA backscatter patterns and have a track record of detecting actual HTHA in the plant equipment, not
3. Ultrasonic calibration for backscatter and velocity ratio should be performed/verified on a sample with service
induced HTHA. This is very important as it gives a representative test sample to establish and verify calibration.
4. Selection of inspection locations is critical. Inspection must be performed at the hottest locations of the equipment.
HTHA susceptibility is highly dependent on the heat of the plate and is not very well understood. Just a small difference
in heat input or treatment can make a major difference in HTHA susceptibility. So one plate/spool may be totally free of
HTHA while the adjoining plate/spool operating at the same temp/pressure conditions in the same vessel may have high
levels of HTHA. Each and every plate of the vessel must therefore be tested at both ends. Preferred locations for HTHA
5. Any suspect areas detected by ultrasonic testing must be verified by replication of magnetic particle testing from the
inside surface.
NDE Associates, Inc. has performed several HTHA inspections. Some of our clients are:
failure.
Chevron, Pascagoula, MS
BP, Texas City, 2005
other refineries in US, Canada
Huntsman Chemicals, Melbourne, Australia.
SK Oil, Korea. Conduct follow up inspections after the failure caused by Hydrogen Attack. Failure date: May 13, 1999.
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CF (Fertilizers) Industries, Donaldsonville, Louisiana.
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Conoco Oil Company, Billings Refinery, MT and Denver Refinery, CO.
US Oil and Refining, Tacoma, WA
Note: This website is solely for informational purposes. In no event will this company be responsible for any loss or
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damages resulting from any viewer’s use of these materials.
REFERENCES
1. Steels for Hydrogen Service at Elevated Temperatures and Pressure in Petroleum Refineries and Petrochemical
Plants, API Recommended Practice 941, American Petroleum Institute.
2. T. Ishiguro, H.Yamamoto, K. Kawano, et al, “Metallurgical Effect on Hydrogen Attack Damage in C-½Mo Steels,”
Proceedings, 1996 ASME/ICPVT Pressure Vessels and piping Conference, 21-26 July, 1996
3. K. Kawano, “Recent Activities in High Temperature Hydrogen Attack,” to be presented in 2005.
4. A. S. Birring, et al. “Method and Means for Detection of Hydrogen Attack by Ultrasonic Wave Velocity Measurements”
US Patent, 4,890,496, January 2, 1990
5. A. S. Birring and K. Kawano, “Ultrasonic Detection of Hydrogen Attack in Steels,” Corrosion, March, 1989.
6. A. S. Birring, M. Riethmuller, and K. Kawano, “Ultrasonic Techniques for Detection of High Temperature Hydrogen
Attack,” Materials Evaluation, February, 2005.
7. C Leneve and M Richez, ” Use of the the NDT for the Detection of High Temperature Hydrogen Attack and Assessment
of a Reactor”, Esope 2010, Paris, France, Sep 2010
Birring NDE Inc. provides nondestructive testing (NDT) training and consulting services for petroleum and
power industries. The company specializes in the application of advanced NDT techniques, including
phased arrays, eddy current testing (ECT) and ultrasonic testing (UT)
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