General Damage Mechanisms in Refining Industries

INDEX
General Damage Mechanisms - All Industries

Mechanical & Metallurgical damages 3
Uniform or Localized Loss of thickness 4
High Temperature Corrosion (204 deg C) 5
Environment Assisted Cracking 6

INDEX
General Damage Mechanisms - Refining Industries

Uniform or Localized Loss of thickness 7
Environment Assisted Cracking 8
Other Mechanisms ( HTHA / Titanium Hydriding) 9

4.0
Shyam S Ponnada API 571

5.0

4.2 MECHANICAL AND METALLURGICAL DAMAGES - ALL INDUSTRIES
Damage Affecting
Mechanism
Description
Materials
Temperature range Effects/Critical factors Affectfing equpt Appearnace Inspection Prevention Related Mechanisms
Change in microstructure of
certain CS & 0.5Mo steels
after long-term oper in
800F to 1100F range
cause loss in strength, Some grades of
Loss in strength, ductiluty & Steam, FCC, Catalytic Sample pieces, No replica Using Cr containing LAS
Graphitization ductility, & or creep CS & 0.5 Mo 800 F to 1100 F Only by Metallography Spheroidization
creep resistance reforming units suggested above 800 F
resistance, At elevated steels
temp the carbide phases in
these steels are unstable
and may decompose into
graphite nodules
Change in microstructure of 850 F to 1400 F

Softening Loss in strength, & or creep Steam, FCC, Catalytic Sample pieces, No replica Minimizing long term Graphitization
steels after exp in 850F to CS & LAS (predominantly above Only by Metallography
(Spheroidization) resistance reforming units suggested exposure to elevtd temp REFER 4-5
1400F range, 1025F)
Reduction in toughness in Primarily 2.25 CR- Hydroprocessing untis &

some alloy steels due to 1Mo @ 900F & optg temp above 650F Install test blocks of same
Temper Loss in toughness and checking by Impact
metallurguical changes due 3Cr-1Mo & High 650 F to 1100 F (Reactors, hot feed / eff heat no and impact test REFER 4-9 NONE
Embrittlement increase in brittleness testing
to long term exp in temp strength LA Cr- exch components & hot regulary by removal
range of 650F to 1100F Mo-V rotor steels HP seperators
Combined effect of
deformation and aging at
intermediate temp in Increase in hardness and Susceptible materials Only for old materials. If
Vintage CS and Intermediate temp Brittle cracks by Blue brittleness (Dynamic
Strain aging vintage CS, result in strength with reduction in that have not been stress -- SR not possible buttering
C-0.5 Mo steels along with deformation metallography strain aging)
increase in hardness and ductlity & toughness relieved.(Old equpt) to be done.
decrease in ductility and
toughness
Reduction in toughness in
400 Series + FCC crude and
some alloy steels due to Bend or Impact testing Cracks seen during TA & using low ferritic steels
885 F temper Wrought & Cast Loss in toughness due to fractionation trays and
metallurguical changes due 600 F to 1000 F & Hardness start-ups, Impact testing, & and avoid exposure to NONE
embrittlement 300 series + metallurgiacl change weldings & Duplex HE
to exp in temp range of measurement Hardness measurement embrittlement temp range
Duplex SS tubes
600F to 1100F
300 series to be de-

Formation of a
300 Series sigmaitized by sol
metallurgical phase known
wrought, cast and Loss of fracture toughness SS piping in FCC & 300 Metallography & Impact Cracks seen during TA & annealing at 1950F for 4
Sigma phase as sigman phase can result
weld metals + 400 1000F to 1750 F in some SS as a result of series weld overalys, SS testing - REFER PG start-ups & s/d when most hrs and followed by NONE
embrittlement in a loss of fracture
Series (with 17 Cr) high temp exposure heater tubes etc., 4-17 material is below 500 F quenching. For 347
toughness in some SS as a
+ Duplex SS ferrite shall be limited to
result of HT exposure
5-9% and 304 still less.
for new equt UCS66 in

Inspection not normally
Sudden rapid fracture ASME Sec 8 Div 1 Straight , non-branch sec 8, + engineering
Old CS & LAS are Sudden rapid fracture under used to mitigate brittle Temper emb+ Strain age
under stress where the vessels before 1987 dec without any elongation, study can be performed
more suseceptible stress, no evidence of failure + susceptible emb + 885F emb + Ti
Brittle fracture material exhibits little or no -- Addm + High thk Limited Intergranular in accord with API 579
and 400 series SS ductility or plastic vessels should be hydriding + Sigma phase
evidence of ductility or materials + during start- cracking and limited sec 3 level 1 or 2, +
also deformation inspected for pre-existing embrittlement
plastic deformation up and Hydrotests micorvoid coalscence PWHT + maintiain MSOT
flaws/defects.
during hydrotest
Shyam S Ponnada API 571 6 of 32

Damage Affecting
Mechanism
Description
Materials
Heater tubes, tube

Operating above creep supports, hangers and Minimize metal temp+
UT+ET+RT+Dimensional
range, Generally, furnace internals + all Initial stages by Minimize low creep
At high temp metal meas and replication, + for
Increase of about 25F internals operating above scanning electron ductility+ Creep resitant
components can slowly & PV focus on welds of CrMo
Creep / Stress or increase of 15% of creep range + Low creep microscope alloys for heater tubes + Creep damage + Reheat
cont deform under load All Metals & Alloys alloys optg in creep range,
rupture stress can cut ductility failures have metallography, + Minimuze hot spots on cracking
below yield stress, time + check tubes for diametric
Remaining life in half or occurred in weld HAZ at bulging of heater tubes heater tubes and process
dependent phenomenon growth, bulges, cracks,
more, depending on nozzles + dissimilar before failure side deposits + VT and
bows, blisters
alloy. material welds (fer to UT acco to API RP 580
aust)
Thourough design to
cracks initiate at the minimize thermal
Mix points of hot and
surface + wide and stresses and thermal
Result of cyclic stresses cold streams, de-
No set limit on temp often filled with oxides cycling+Controlled rates
caused by variations in superheaters or
swings, practically Start-up and shutdown due to elevated temp + of heating and
temp. relative movement or All materials of attemporators. + coke Corrosion fatigue &
Thermal Fatigue cracks suspected if increase the susceptibility to single or multiple _ Visual +MT + PT +SWUT cooling+ravoid igid attch
diff expansion is construction drum shells + coke drum Dissimilar metal cracking
temp swing exceeds thermal fatigue. DRAGGER SHAPPED in boilers+drain lines to
constrained under repeated skirts + steam generators
200F + TRANSGRANULAR+ be provided in soot
thermal cycling + soot blowers + water
cracks initiate at toe of blowers+provide sleeves
wall tubes
welds. to prevent cold liquid
contacting hot liquid
Localized deformation
or bulging in the order of In fire heaters, VI, IR
Permanent deformation at Minimize localized temp
3 to 10% or more montg, TST
relatively low stress levels All fire heater Boilers+coker excursions+proper burner
Short term over depend on temp, alloy +Thermography to identify
as result of localized over tubes and Dependent of other Temp, time and stress are untis+hydroprocessing management and fouling
heating - Stress and stress level + FISH refractory damage + Creep/ Stress rupture
heating, results in bulging common Materials factors critical factors units+refractory lined deposit control+bed
rupture MOUTH Failures maintian monitor reactor
and eventaul failure by of construction equpt in FCC, sulfur plant thermocouples +Maintian
accompanied by bed thermocouples and
stress rupture. good refractory lining.
thinning at fractured reactor skin thermocouples
surface.
In boiler tubes the flow of

energy thru the wall results
in formation of discrete Steam generating units When DNB condition has
Open bursts with the
steam bubbles (nucleate (Fired boilers + waste deveolped, tube rupture
fracture edges drawn to
boiling) on the ID surface, heat exchangers in sulfur will quickly follow, proper
knife-edge +
when heat flow balance plants, H2 reformers & Burners should be properly burner management to SB can cause caustic
Microstructure will
dusturbs, individual Short term high FCC units), Failures maintained to prevent flame prevernt flame corrosion (Causit
Steam Blanketing CS & LAS Water wall tubes failure always show severe
bubbles join to form a temperatures occur in super heaters impingement. + Tubes impingement. + Proper Gouging) + Short term
elongation of the grain
steam blanket known as and re-heaters during inspection for bulging BFW treatment to over heating.
structure due to plastic
Departure from Nucleate start-up when prevent restricted fluid
deformation that occurs
Boiling (DNB), Once SB condensate blocks steam flow + Tubes shuld be
at the time of failure.
occurs Tube rupture occurs flow. inspected from bulging.
rapidly as a result fo short
term overheating

Damage Affecting
Mechanism
Description
Materials
NI base filler metals have

closer Coeff of therm exp
to CS & LAS, If 300 SS
For CS & LAS: Carbon
Cracks form at the toe electrodes are used
CS & LAS welded diffusion becomes a
Cracking of DMW occurs in Cracking occurs because of the weld in HAZ of DMW shud be locatesd in
to Aust SS as well concern above 800F to
ferrtic (CS or LAS) side of the coeff of therm exp the ferrtic material, + lower temp region + in
Dissimilar metal as any material 950F Ferritic / Aust DMW (Ferritic to 300 MT and PT + UT methods Thermal fatigue &
weld between Aust SS between Fer & 300SS differ Support lugs or boilers the weld at high
weld cracking comb that have joints can generate Series welds) for surface breaking cracks. Corrosion fatigue.
(300SS) and ferrtic material by 30% or more, REFER attachements or cast or temp end shud me made
widely differing significant therm exp /
optg at high temp. PAGE 4-38 wrought 300 SS to 400 in penthouse or header
thermal exp coeff. ther fatigue stresses @
SS are also affected enclosure out of heat
temp > 510F
trnsfer zone + Install pup
piece of intermediate
thermal expansiom.
Thermal fatigue cracking

occur when high and non- Prevent interuption in
FCC cokers, reforming
uniform thermal stresses flow of high temp lines +
and HP units + Material
develop over a relatively Design to min severe
that have lost ductility
short time due to diff exp & Temperature cycling (SS restraint+ Install thermal
Differential thermal such as CrMo equpt Higly localized cracks
cont, if exp or cont is have higher coeff of therm Surface initiating cracks sleeves to prevernt liquid
Thermal Shock All metals & Alloys expansion or (temp embr) are more difficult to locate , PT and Thermal fatigue
restrained stresses above exp than CS or LAS) as CRAZE cracks impngment + Min rain or
contraction susceptible. + Equpt MT for confirmation
the yield strngth of material REFER 4-42 fire water deluge sit +
subjected to accelerated
can result. Usually occurs Review hot/cold inj points
cooling procedures to
when a colder liquid for potential thermal
minimize s/d time.
contact a warmer metal shock
surface.
Increasing hardness of the

Erosion: Accelerated Temperature is a factor Localized loss in thk in
metal substrate is not
mechanical removal of which contributes to All types of equt exposed form of pits, grooves, Visual +UT + RT
always good indicator of Specialized terminology :
surface material as a result increase in metal loss to moving fluid and/or gullies, waves, rounded- +Corrosion montg like corr
Erosion / Erosion- All metals, alloys improved resistance where Cavitation, liquid
of relative movement along with other moving catalyst are holes, and valleys. coupons and ER probes + All in page 4-45
Corrosion & refractories corrosion plays a sigf role. & impingement erosion,
between, or impact from parameters of pH, subject to erosion and Often occur a directional IR scans for refractory
Increasing velocities above fretting etc.,
solids, liquids, vapor or any velocity and angle of erosion-corrosion pattern and may fail with erosions.
threshold velocity limits will
combination thereof. impact. in a short period.
increase metal loss
Pump casings, pump

Form of erosion caused by
impellers, (LP side) and
the formation and
in piping down stream of
instanteneous collapse of Sharp-edged pitting but
Inadequate NPSH can result orifices and control Detection of sound
innumerable tiny vapour Temp approaching the may also have gouged Mech mod, desgn, or
Copper, brass, in cavitation. Presence of valves.+ restricted-flow frequencies by montg fluid
bubbles, the bubble may boiling point of liquid appearance in rotational oper change is requ,
cast iron, CS, solid or abrasive particles is passages or other areas properties and Accoustic Liquid Impingement
Cavitaion contain vapor phase of are more likely to result components, DAMAGE MAY NOT be by
LAS, 300, 400 SS not required for cavitaion where turbulent flow subj montg of turbelent areas, erosion
liquid, air or other gas in liq in bubble formation that OCCURS ONLY IN significant material
& Ni base alloys. damage but will accelerate to rapid pres changes UT & RT to check metal
medium, these collapsing lower temp operation LOCALIZED LOW- change, REFER 4-49
the damage. within a localized region loss
bubbles exert severe PRESSURE ZONES.
(ex HE tubes, venturis,
localised impact forces can
seals and bearings
result in metal loss
impellers)

Damage Affecting
Mechanism
Description
Materials
Good design that

CLAM SHELL type
Cracks occur due to PT,MT & SWUT , VT of minimize stress
finger print that has
cyclical stresses exposed small dia piping to detect concentration of
concentric rings called
for an extended period, Geometry, stress level, oscillation or cyclic components + allow for a
"BEACH MARKS"
often resulting in sudden, number of cycles, and Equipments affected by movement, + Vib montg of generous radius along
Mechanical All materials of results from the
unexpected failure, either -- material properties, THERMAL CYCLING & rot equpt to help detect edges and corners + Vibration induced fatigue.
Fatigue construction "WAVES" of the crack
by mechanical loading or (Strength hardness & MECHANICAL LOADING shafts out of balance, IN mimimize grinding marks,
propagation that occur
therm cycling typically well Microstructure)-REFER 4-54 HIGH CYCLE FATIGUE, + good fit-up , mimize
during every cycle
below yeild strenght of the CRACK INITIATION MAKE weld defects + use low
above the threshold
material DIFFICULT stress stamps and
loading.
marking tools.
Socket welds and small

bore bypass lines and Supports & Vibrations
flow loops around dampening, proper side
Crack initiating at a Visual inspection &
Form of mechanical fatigue rotating and reciprocating branching of safety
Amplitude and frequency of point of high stress such Vibration montg, Damage
caused due to dynamic eqpt + Safety relief valves, Vibration has to
Vibration induced All engineering vibration and fatigue as a thread or weld to jacketing can cause wet Mechanical fatigue &
loading due to vibration, -- valves + subject to be removed from the
fatigue material resistance of material are joint. For Refractory insualation resulting Refractory degradation
water hammer or unstable chatter, premature pop- source as the effect may
critical factors. damages, skin temp corrosion below insulation.
fluid flow. off, fretting and failure to shift is anchors are
measurement (CUI)
operate, + HE tubes provided,(design to be
susceptible to vortex studied)
shedding.
Both thermal insu and Excessive cracking, Proper selection of

erosion resist refractories spalling or lift-off from refractory, anchors and
Insulating ceramic
can be Mech damaged. Refractory selection, design the substrate, softening fillers and their proper
fibers, castable Oxidation, Sulfidation and
Refractory (Cracking, spalling & and installation are the keys FCC Reactors, heaters or general degradation Visual inspection during design & Installation are
refractory brick -- Flue gas dew point
degradation erosion) ,as well as to minimize damage, and boilers due to erosion refractory shut downs + IR scans the keys to min ref
and plastic corrosion.
corrosion due to oxidation, REFER 4-62 may be washed thinned damage. Proper curing
refractories.
sulfidation, and other high and anchors may be time as per manuf &
temp mechanisms exposed. ASTM stds.
Imp parameters include type

of material (chemical comp,
Intergranular and can
Elevated temp when impurity elements) grain Heavy wall vessls in Joint configurations in
Cracking in metal due to be surface breaking Surface cracks by UT &
creep ductility is size, resi stresses from areas of high restraint heavy wall sections shuld
stress relaxation during depending on geometry, MT, of CS, LAS ,& 300 SS
LAS, 300 SS & Ni insufficient to fabrication, (cold working, including nozzle welds be designed to minimize Stress relief cracking &
PWHT or inservice at stress, it is mose & Ni base alloys,
Reheat cracking base alloys such accommodate the welding) section thk ) and heavy wall piping + restrain during welding Stress relaxation
elevated temperatures. frequently observed in EMBEDDED cracks can
as Alloy 800 H strains required for the notches and stress High strength low alloy and PWHT, adequate cracking
Most often in heavy wall COARSE-GRAINED only found by UT
relief of applied or concentrations, weld metal steels are very preheat must be applied
sections. SECTIONS OF A examination
residual stresses. and base metal strength, susceptible REFER 4-63
WELD HAZ.
welding and heat treating
conditions. REFER 4-63
INDEX - ALL INDEX -

Shyam S Ponnada API 571 INDUSTRIES REFINERIES 9 of 32
Damage Affecting
Mechanism
Description
Materials
INDEX - ALL INDEX -
INDUSTRIES REFINERIES

4.3 - UNIFORM OR LOCALIZED LOSS OF THICKNESS - ALL INDUSTRIES
Damage Affects/Critical Related
Mechanism
Description Affecting Materials Temperature range factors
Affectfing equpt Appearnace Inspection Prevention
Mechanisms
HE tubes of different
A form of corrosion that can
For GC, 3 cond shall be materils of TS and / or Good design + Coating but
occur at the junction of
met, Presence of baffles particularly if salt crevice, groove or pitting more the noble materal
dissimilar metals when they are All metals with the
Galvanic electrolyte, 2 different water cooling is utilized. corrosion, at the bolts or Visual inspection & UT shall be coated + For
joined together in a suitable exception of most N/A Soil corrosion
Corrosion alloys & electrical + Buried pipelines, welds of different materials gauging piping, electric insulating
electrolyte, such as a moist or noble metals.
connection REFER pg-4- electrical transmission REFER PG 4-65 bolt sleeves and gaskets +
aqueous environment, or soils
65 support towers and ship galvanized steel
containing moisture.
hulls.
general or localized,
Critical factors include
depending upon whether or
the physical location
A form of corrosion that occurs not the moisture is trapped.+
(industrial, marine, rural);
from moisture associated with If there is no coating or if
Corrosion rates increase moisture (humidity),
atmospheric conditions. Marine there is a coating failure, Surface preparation and
with temperature up to particularly
environments and moist Carbon steel, low alloy corrosion or loss in thickness proper coating application
Atmospheric about 250F. Above 250F designs that trap VT and UT are techniques Corrosion under
polluted industrial environment steels and copper (REFER 4-69) can be general.+ Localized are critical for long-term
corrosion surfaces are usually too dry moisture or when present that can be used. insulation
with airborne contaminants are alloyed aluminum. coating failures will tend to protection in corrosive
for corrosion to occur except in a cooling tower mist;
most severe. Dry rural promote corrosion.+ environments.
under insulation temperature; presence of
environments cause very little Metal loss may not be
salts, sulfur
corrosion. visually evident, although
compounds and dirt.
normally a distinctive iron
(REFER 4-69)
oxide (red rust) scale forms.
more severe at metal temps

between the boiling point
Design of insulation
212F & 250F where water is
system, insulation type, CS, LAS & 300 SS +
less likely to vaporize and
temperature, 300 SS are also subject
Corrosion of piping, pressure insulation stays wet longer.+ Visual inspection, Profile
Carbon steel, low alloy environment (humidity, to SCC if chlorides are CS & LAS : loose, flaky Atmospheric
vessels and structural In marine environments or Radiography &
steels, 300 Series SS rainfall and chlorides present, while the scale covering the corroded corrosion +
CUI components resulting from areas where significant Thermography (Generally (REFER 4-71)
and duplex stainless from marine duplex SS are less component. highly localized, Oxidation +
water trapped under amounts of moisture may be appearace will be loose
steels. environment, industrial susceptible.+ Location (REFER 4-71) Chloride SCC
insulation or fireproofing. present, the upper flaky corrosion )
environments containing issues and Design
temperature range where
high SO2) are critical issues (REFER 4-71)
CUI may occur can be
factors. (REFER 4-71)
extended significantly above
250F

Mechanism
Mechanisms
Monitor CW for pH, O2,

maintian process side inlet
cycles of concentration,
temperatures below 135F+
biocide residual, biological
water velocities partcrly in
activity, cooling water
Fluid temperature, type salt water sys.+ metlrgy of
outlet temp, HC
of water (fresh, brackish, Cooling water corrosion can HE comp may be
contamination and
General or localized corrosion Corrosion occurs in Fresh salt water) and the type Cooling water corrosion result in many different forms upgraded esp in waters Microbiologically
Carbon steel, all process leaks.+ Periodic
of carbon steels and other water: If process side temp of cooling system is a concern with water- of damage including general with high Cl cont, low induced corrosion
grades of stainless calculation of U-factors
Cooling water metals caused by dissolved is above 140F & in Sea (once-through, cooled heat exchangers corrosion, pitting velocity, high process + chloride stress
steel, copper, (heat exchanger
corrosion salts, gases, organic water or brackinsh temp open circulating, closed and cooling towers in all corrosion Microbiologically temps, + Periodic cleaning corrosion cracking
aluminum, titanium and performance meas) will
compounds or microbiological above 115F may cause circulating), oxygen applications across all Induced corrosion, stress of tube ID’s and OD’s in + galvanic
Ni base alloys. provide info on scaling
activity. scaling. content (high O2), and industries. corrosion cracking and order to maintain clean corrosion
and fouling.+ Ultrasonic
fluid velocities (<3fps) fouling.& Crevice corrosion heat transfer surfaces.
flow meters can be used
are critical factors. f) CW should be
to check the velocity of
preferebly on U-tube side
water in the tubes.+ EC or
to minimize stagnant
IRIS inspection of tubes.+
areas.
Splitting sample tubes.
Corrosion can occur in Corr from O2 tends to be

Water analysis for pH, O2 scavenging in
external treatment sys + pitting type particularly
concentration of conductivity, chlorine or deaerator + If the
deaerating equp + aggressive in equip such as
dissolved gas (oxygen residual biocide, and total scale/deposit
Primarily carbon steel, feedwater lines, pumps, closed heaters and CO2 corrosion,
No specific temp, depends and carbon dioxide), pH, dissolved solids to check control/magnetite
General corrosion and pitting in some low alloy steel, stageheaters and economizers where there is corrosion fatigue
Boiler water on various factors of pH, O2 temperature, for leaks in the form of maintenance treatment
the boiler system and some 300 Series SS economizers as well as rapid water temp rise. and
condensate , quality of feed water and quality of the feedwater organic compounds. scheme does not minimize
condensate return piping. and copper based the steam generation + Corr in cond return syst erosion/erosion-
temp and the specific + NO proactive insp CO2 in cond return
alloys. system on both the tends to be due to CO2 corrosion
feedwater treating methods + Deaerator system, an amine inhibitor
water and fire sides and CO2 corr tends to be a
system. cracking problems can be treatment might be
the condensate return smooth grooving of the
evaluated by WFMPI required.
system. pipe wall.
BFW & Cond sys in all

units are affected + Corr inhibitors in steam
Efft gas streams of the cond & vapor systems.
shift converters in H2 Localized thinning and/or Vapor + Increasing cond
CO2 corr results when CO2
plants can be affected. pitting corrosion of CS+ CS pH above 6 can reduce
dissolves in water to form Monitor water analyses
Corrn usually occurs may suffer deep pitting and corr in steam cond sys.+
carbonic acid (H2CO3). The Increasing temperatures The partial pressure of (pH, Fe, etc.) to determine Boiler water
when the effluent grooving in areas of 300 Series SS are highly
acid may lower the pH and Carbon steel and low increase corrosion rate up to CO2, pH and changes in operating condensate
CO2 Corrosion stream drops below the turbulence + Corr generally resistant to corr in most
sufficient quantities may alloy steels. the point where CO2 is temperature are critical conditions.+RT, UT angle corrosion and
dew point, approx occurs in areas of turbulence applications. Selective
promote general corrosion and / vaporized. factors. probe + elbows and Tees carbonate cracking
300F. Corrosion rates & impingement and upgrading to SS is usually
or pitting corrosion of carbon where turbulence occurs
as high as 1000 mpy sometimes at the root of required remove CO2
steel.
have been observed.+ piping welds. removal units+ 400 Series
Overhead systems of SS and duplex SS are also
regenerators in CO2 resistant.
removal plants

Mechanism
Mechanisms
Maintain metallic surfaces

Sulfuric acid corr on at back end of the boilers
The concentration of
economizers or other carbon and fired heaters above
Sulfur and chlorine species in contaminants (sulfur and
steel or low alloy steel the temperature of
fuel will form sulfur dioxide, chlorides) in the fuel and All fired process heaters At lower
The dewpoint of sulfuric acid components will have sulfuric acid dewpoint
sulfur trioxide and hydrogen the operating temp of and boilers that burn Wall-thickness temperatures,
depends on the general wastage often with corrosion.+ For HRSG’s,
chloride within the flue gas metal surfaces fuels containing sulfur measurements by UT hydrochloric acid
concentration of sulfur broad, shallow pits, avoid 300 Series SS in the
combustion products. determine the likelihood have the potential for methods will monitor the may condense and
Flue gas dew Carbon steel, low alloy trioxide in the flue gas, but is depending on the way the FW heaters if environment
b) At low enough temperatures, and severity of Corr.+ H2SO4 dewpoint wastage in economizer promote HCL
point steels and 300 Series typically about 280°F H2S04 condenses. is likely to contain
these gases and the water Since all fuels contain corrosion in the tubes. + Stress corrosion corrosion of
corrosion SS. & dewpoint of HCL depends + For 300 Series SS chlorides.
vapor in the flue gas will some amount of sulfur, economizer sections cracking of 300 Series SS carbon steels +
on the concentration of feedwater heaters in + In oil-fired boilers when
condense to form sulfurous sulfuric and sulfurous and in the stacks.+ 300 can be found using VT and chloride stress
hydrogen chloride. It is HRSG’s, stress corrosion units are water-washed to
acid, sulfuric acid and acid dewpoint corrosion SS in HRSG- REFER 4- and PT inspection. corrosion cracking
typically about 130°F cracking will have surface remove ash if the final
hydrochloric acid which can can occur if metal 84 of 300 Series SS
breaking cracks and the rinse does not neutralize
lead to severe corrosion. temperatures are below
general appearance will be the acid salts( Sodium
the dewpoint.
somewhat crazed. carbonate should be
added to the final rinse)
heat exchangers,
bottom water of storage In CW systems,
tanks, piping with effectiveness of treatment
stagnant or low is monitored by measuring
flow, and piping in biocide residual, microbe
MIC is usually found in contact with some soils. counts & visual Microbes require water to
MIC corrosion is usually
aqueous environments or + equipment where appearance.+ Special thrive. Systems that
observed as localized pitting
A form of corrosion caused by Carbon and low alloy services where water is hydrotest water has not probes have been contain water (cooling
under deposits or tubercles
living organisms such as steels, 300 Series SS always or sometimes been removed or designed to monitor for water, storage tanks, etc.)
Microbiologica that shield the
bacteria, algae or fungi. It is and 400 Series 0F to 235F (–17 C present,especially where equipment has been evidence of fouling which should be treated with Cooling water
lly induced organisms + Damage is
often associated with the SS, aluminum, copper to 113C). stagnant or low-flow left outside and may precede or coincide biocides such as Cl, corrosion
corrosion often characterized by cup-
presence of tubercles or slimy and some nickel base conditions allow and/or unprotected.+ Product with MIC damage.+ An bromine, ozone, ultraviolet
shaped pits within pits in
organic substances. alloys. promote the growth of storage tanks and water increase in loss of duty of light or proprietary
carbon steel or subsurface
microorganisms. + cooled heat exchangers a heat exchanger may be compounds. + REFER 4-
cavities in SS
REFER 4-83 in any unit where indicative of fouling and 83
cooling water is not potential MIC
properly damage.+ Foul smelling
treated can be affected. water may be a sign of
+ Fire water systems trouble.
can be affected.
measure soil potential

Soil corrosion of CS can
many factors including using dedicated reference
Underground piping and be minimized through the
operating temperature, external thinning with electrodes near the
equipment as well as use of special backfill,
moisture & O2 availability, ASTM STP localized losses due to structure + Cathodic
The deterioration of metals buried tanks and the coatings and cathodic
Carbon steel, cast iron soil resistivity, soil type and 741 as well as API RP pitting. + Poor condition of a protection (NACE RP
Soil corrosion exposed to soils is referred to bottoms of above protection. The most Galvanic corrosion
and ductile iron. homogeneity , cathodic 580 and Publ 581. protective coating is a tell 0169.)+
as soil corrosion. ground storage tanks + effective protection is a
protection, stray current REFER PAGE 4-91 tale sign of potential guided ultrasonic
Ground supported metal combination of a corrosion
drainage, coating type, age, corrosion damage. thickness tools, pressure
structures resistant coating and a CP
and condition. testing, or
system.
visually by evaluation.

Mechanism
Mechanisms
Proper design + reducing

the amount of free caustic,
by ensuring adequate
water flooding and water Caustic corrosion
Exposure to high solution
Boilers, heat flow + ensure proper is also referred to
Localized corrosion due to strength caustic can result in UT thickness gauging +
exchangers. burner mangment to as caustic gouging
concentration of caustic or general corrosion of carbon Injection points should be
crude unit charge where minimize hot spots on or ductile gouging.
alkaline salts that usually steel above 175F inspected in accordance
Major contributing factors caustic is added + heater tubes, and by A related
occurs under evaporative Primarily carbon steel, and very high corrosion with API 570.+ UT scans
Caustic are the presence of preheat exchangers, Metal loss, Metal gouging, minimizing the ingress of mechanism is
or high heat transfer conditions. low alloy steels and rates above 200 F + also and radiography can be
corrosion caustic (NaOH or KOH) furnace tubes and deposits, grooving alkaline producing salts known as
However, general corrosion can 300 Series SS. Carbon steel and 300 Series used.+ Steam generation
strength & temperature transfer lines+ Units that into condensers+ caustic Departure from
also occur depending on alkali SS have serious corrosion equipment may require
use caustic for removing injection facilities should Nucleate Boiling
or caustic problems in high strength visual inspection with the
sulfur compounds from be designed to allow (DNB) as
solution strength caustic solutions above use a boroscope.
product streams. proper mixing and dilution discussed in steam
about 150F .
of caustic in order to avoid blanketing
the concentration of
caustic on hot metal
surfaces.
Cu alloys (brass, Factors include the composition of the alloy and

bronze, tin)+ Alloy 400 exposure conditions including temperature, degree of
and cast iron. aeration, pH and exposure time. Dealloying is often
Often color change or a
Change in color + Depth referred to by the
deep etched (corroded)
of scale + Dealloying in element removed,
Dealloying is selective corr appearance as one element
brass is visually evident as in
mechanism in which one or is removed from the alloy.
by reddish copper color dezincification,
more constituents of an alloy U/G cast iron piping+ depending on alloy, outward Altering the exposure
instead of yellow brass destannification,
are preferentially attacked HE tubing and TS in appearance of affected conditions or replacing it
color + Graphitic corr turn denickelification
leaving a lower density CW,Sea Water service material may not be with a resistant material.+
cast iron charcoal gray dealuminification
(dealloyed) often porous + BFW and after boiler noticeable upon visual Depending on the alloy-
Dealloying and material can be cut or and graphitic
structure.b) Component failure components including inspection, even where the environment combination,
gouged by knife + corrosion.
may occur suddenly and bronze pumps, monel full wall thk is degraded. + cathodic protection or
Metallography, + Dealloying has
unexpectedly because strainers and brass Attack may be uniform barrier coatings may be
reduction in hardness + also been referred
mechanical properties of the pressure gauge fittings through the cross-section effective.REFER 4-99
"Accoustic tech ("loss of to as selective
dealloyed material are (layer-type) or it can be
metal ring") and US leaching.+
significantly degraded. localized (plug-type) + In
attenuation "NO UT Graphitic
some cases, no dimensional
THICKNESS" + FFS corrosion affects
or other visible changes.
cast irons

Mechanism
Mechanisms
Cast irons are comprised of

Primarily gray cast iron, Graphitic corrosion can
graphite particles embedded in Internal graphitic corrosion Also known as
but also nodular and occur in soft water, salt
an iron matrix. Graphitic can be prevented by selective leaching,
malleable cast irons Factors that influence water, mine waters,
corrosion is a form MAY NOT be noticed in UT NOT A GOOD coatings and/or cement graphitic corrosion
experience graphitic graphitic corrosion dilute acids and in U/G
of dealloying in which the iron Visual Inspection even full METHOD + Accoutstic linings.+ External graphitic is a form of
corrosion. However, include the piping as well as in
matrix is corroded, leaving Damage occurs in the wall thk is degraded + techniques (Loss of corrosion can be dealloying of cast
nodular and malleable composition of the alloy BFW equp. Typical
Graphitic corrosion products and porous presence of moisture or an damage areas are soft and "metallic ring") & US prevented by external irons.+ It
cast irons tend to and exposure conditions examples include
corrosion graphite. b) Attack results in a aqueous phase, usually can be easily gouged with attenuation + significant coatings or cathodic should not be
crumble when including temperature, feedwater piping,
porous structure with a loss of below 200F (93C). knife or hand tool.+ reduction in hardness protection in severely confused with
attacked. White iron is degree of aeration, pH pumps (including pump
strength, ductility and density. It METALLOGRAPHY for although affected areas corrosive soils.+ Knowing graphitization,
not subject to this and exposure time impellers), valves, and
usually occurs under confirmation are localized potential susceptibility of decomposition of
damage REFER 4-101 U/G cast iron pipe. Fire
low pH and stagnant conditions, cast irons is required as carbides at high
because there is no water systems are
especially in contact with soils difficult predict GC temperatures
free graphite. particularly vulnerable.
or waters high in sulfates.
INDEX - ALL INDEX -


4.4 : HIGH TEMPERATURE CORROSION
Damage
Description Affecting Materials Temperature range Affects Affectfing equpt Appearnace Inspection Prevention Related Mechanisms
Mechanism
O2 reacts with CS and other
all CS & LAS + all 300, for CS - significant Cr is more resitant to
alloys at high temp CS- Oxide scale, 300 UT, IR temp measurement,
Oxidation 400 SS depending on above 1000F and for General thinning Equpt optg above 1000F oxidation at high temp, also Surface scaling
converting metal to oxide SS thin black scale + Monitoring of Optg temp
compostion and temp SS above 1500F Silicon and Aluminum
scales
Piping and equpt Uniform thinning,

Process cond monitoring for Upgrading to higher Cr
All Fe base alloys incl (contains sulfur at high localized+Sulfur scales
Sulfur compounds reacts Uniform thinning, or increae in Temp & sulfur alloy + constructing with
300 & 400 SS + Ni base Iron base alloys temp. depend on alloy,
with CS & other alloys at localized corrosion or levels + Temp montg + UT clad or solid 300/ 400 SS + High temperature
Sulphidation alloys if Cr content is less sulfidation occurs +FCC+Crude+vacuum + corrosiveness of
high temperature, Presence high velocity erosion & Profile RT for thinning + Al diffusion treatment for sulfidation
+ Copper at lower temp usually above 500 F Boilers high temp where stream, velocity &
of H2 accelerates corrosion corrosion. PMI for alloy comp check LAS sometimes reduce
than CS sulfur at high comp is presence of
for any mixing of sulfur sulfidation rates and scaling
present contaminats
Depth confirmation by Intiail stages is difficult + If

Alloys with strong oxide
metallography + process side accessible
layer or sulfide film formers
Typically above Increase in hardness hardness and insitu
Loss of high temp (silicon and Al) + Reduce
1100F provided Fired heaters + Coker and loss of metallography +
Carbon is absorbed into CS+LAS+300/400 creep ductility,loss of carbon activity of
exposure to units + catalytic ductility+Volumteric Destruictive and magnetic
material at elevated temp SS+Cast SS+Ni base amb temp material environment thru lower
carburizing reformers+ethylene increase + Increase in based tech (ECT) + Metal dusting (Severe
Caruburization while in contact with alloys with significant iron properties temp and high O2/S partial
environment or pyrolosys and steam FERROMAGNETISM of determining increased level carburization)
carbonaceuos material or content (alloy600 & 800) (toughness/duct), loss pressures + adding S in
carbonaceous reformers + decoking some alloys + formation of ferromagnetism
carburizing environment. + HK/HP alloys of weldability and small amounts into process
material and its cycles of metal carbides (magnetic permeability) are
corrosion resistance. streams of steam/ gas
susceptibility. depleting sorrounding useful for paramagnetic mat
crackers of olefin & thermal
matrix of carbide initialy (austenitic) +
dehydroalkylation units
forming element advances stages RT,UT
Exposed to high temp,

Condition of loss of strength by metallography, Control of gas phase and
Heat treated comp +
in steels due to removal of damage on gas alloy selection + AS with Cr
Potential loss of room Fire, + hot H2 untis, Field metallography +
carbon and carbides leaving exposued surfaces and & Mo form stable carbide & High temperature
Decarburization CS & LAS -- temp tensile strength Catalytic reformer, fired Hardness testing
iron matrix. Due to exp to primarly thruwall + free more resistant to hydrogen attack
and creep strength. heater tubes + PV (Softening)
high temp, Heat Treatment, of carbide phases & CS carburization. (refer API RP
components hot formed
exposure to fires is pure iron 941 for H2 serv)
during fabrication.
Fired heater tubes +

in LAS uniform wastage For heater tubes
thermowels + furnace
LAS, 300 SS, Ni base usually in small pits with compression wave UT + H2S layer forms protective
Form of carburization with Generally 900 F to components + Catalytic
alloys, Heat resistant Form of carburization crumbly residue metal RT for pitting and wall sulfide layer to prevent
accelerated localized pitting 1500F increases reformer + Coker untis + Catastrophic
Metal Dusting alloys (Currently no metal with accelerated oxides and carbides. In thinning + VI + Filtering of carburization,+ Al diffusion
in process stream containing with increase in GT's + Meoh refor outlet carburization
which is immune to MD localized pitting SS &HAS local attack cooled reactor or furnace treatment to basemetal
C and H2. temperature. piping + thermal
at all conditions) with deep and round effluent may yeild metal may sometimes reduce.
hydrodealkylation
pits. particles of upsterams.
furnaces and reactors
Hot corrosion, hot ash

resulting molten salts Fired heater, gas turbine, Blending or changing fuel
corrosion, molten salt
(slags) dissolve the + burning Va & Na Corrosion / slag like sources(minimizing
Accelerated high temp Various melting corrosion, oil ash
surface oxide and contaminated fuel oils or apparance CR 100 to contaminants) + Burner
wastage of materials occurs All conventional alloys point temp Visual + Slag removal and corrosion and coal ash
enhance the transport residue in fired heaters + 1000mpy.+ Alligator management reducing
Fuel ash when contaminats in fuel used for process heaters depending on type grit blasting of water wall corrosion +
of O2 to the surface to Heater tubes some times hide appearance + for flame impingement and
corrosion form deposits and melts on and boilers are of service and tubes and UT for thickness Circumferential cracking
re-form the iron oxide not affected due to skin water walls localized hot spots. +
the metal surfaces of fired susceptible. contaminants (Refer measurement in waterwall tubes is
at the expense of the temp less than threshold circumferential grooves Injecting special additives
heaters, Gas turbines page 4-121) similar to thermal fatigue
tube wall or temp of slag, but hangers (Refer page 4-121) into fuel. +50Cr 50Ni are
aggravated by a
component. and holders are affected. resistant
corrosive environment

4.4 : HIGH TEMPERATURE CORROSION
Damage
Description Affecting Materials Temperature range Affects Affectfing equpt Appearnace Inspection Prevention Related Mechanisms
Mechanism
Formation of hard,brittle dull, dark gray

Loss of high temp Changin to 30-80% nickel
surafce layer on some alloys Steam methane appearance, intially by
creep strength, amb Dull gray surface + as it is usually not practical
due to exposure to HT CS, LAS, 300 & 400 SS, Begins above 600F reformers, steam gas metallography only +
temp mech properties Hardness testing(400- to modify process Carburization & Metal
Nitriding process containing high (Ni base alloys are more and severe above cracking (olefin plants) high hardness at
(toughness & ductility) 500HB), Nitride layers are conditions to reduce N2 dusting
levels of N2 compounds resistant) 900F and NH3 synthesis advance stage +
weldability & magnetic, + ECT, partial pressure or lower
such NH3 or cyanides under plants. increase in vol for 12%
corrosion resitance. temperatures
reducing conditions. Cr LAS + crack, flakes
INDEX - ALL INDEX -


4.5 - ENVIRONMENT ASSISTED CRACKING - ALL INDUSTRIES
Damage Affecting Critical Related
Mechanism
Description
Materials
Temperature rangefactors Affectfing equpt Appearnace Inspection Prevention
mechanisms
300 series Surface cracks on

Surface initiated cracks
components+ water- processside or externally Duplex + Nickel base +
casued by environmental Visual + PT + Phase
cooled condensers and under insulation + no visible when hydrotesting use low
cracking of 300 series SS Usually occurs analysis ECT + fine
All 300 Series are in the process side of signs of corrosion + branch chloride content and allow
and some Ni base alloys above 140F, Cracking in cracks with PT after
highly susceptible. crude tower overhead and craze crack to dry thouroughly and Caustic SCC &
Chloride SCC under combined action of increase in temp stainelss steel specail surface cleaning
CS, LAS, 400 series condensers + drains in appearance + quickly + coatings under PASCC
tensile stress temp and increases 300 series, methods + UT + NOT RT
are NOT suscepible. hydroprocessing units INTERGRANULAR insulation + avoid design
aqueous cl en, the presence susceptiblity. unless cracks are at
are susceptible during cracking of sensitized SS where Cl can deposit or
of dissolved O2 increases advanced stage.
start-up or shutdown if 300 + brittle appearance of stagnate. + SR for 300 SS
propensity for cracking
not properly purged. fractured surfaces.
Rot: Coatings/Inhibitors +
Rotating equpt where Fatugue fracture is minimize galvanic +
cracks developed under the Cracking
galvanic couples brittle+most often corrosion resist,
combined affects of cyclic initiates
between the impeller TRANSGRANULAR as in Rot: UT + MT, Dearators: Proper FW and
loading and corrosion, often concentrations Mechanical fatigue
Corrosion and the pump shaft SCC but NOT branched + Deaerators: WFMT condensate chemical
initiates at a stress All metals and alloys. --- such as pits, and Corrosion
fatigue where pitting or often propagation of Cycling boilers : control + PWHT + Smooth
concentration such as a pit in notches, fatigue
corrosion + Deaerators multiple cracks + little buckstays grinding of weld re-
the surface. Can iniate at surface defects
in later 80's+ Cycling plastic deformation (Refer informcement., Cycling
multiple sites. under cororsion
boilers page 4-135) boilers: Slow satrt-up and
water chemistry
PWHT, for CS consider

SR @ 1150F+300SS litle
advantage over CS + Ni
Equpt handling caustic,
typically propagates parellel base alloys more resitant +
Increase in H2S & mercaptan
Form of SCC charecterozed to the weld in adj to WFMT+EC+RT or Avoid Steam out of Non
caustic Funtction of removal units, equts
by surface initiated cracks basemetal and also in weld ACFM , surface prep by PWHT, where requd water
concentrations caustic uses caustic for
that occur in piping & equpt CS, LAS & 300 SS deposits/HAZ+ spider web blasting is required, + NO wash before, use LP Amine cracking &
Caustic SCC with increase in concentration, neutralalization in
exposed to caustic, primarily are susceptible of small cracks + PT for scale filled steam for short periods. + Carbonate cracking
temp increase metal temp & sulfuric acid alkalyation
adjacent to non PWHT'd Inergrannular + as-welded cracks+ UT/SWUT + proper dsgn * oprtn of Inj
likeihood of stress levels untis and HF alkylation
welds CS fabrications as very fine AET for Crack growth. sys requd to ensure
failures units. (Refer page 4-
and oxide-filled cracks caustic is properly
138)
dispersed before entering
high temp crude preheat
system
for CU alloys: Cu-Zn

alloys show improved res
For CU: pH
Surface breaking cracks for CU alloys: monitor as Zn content decrease
>8.5 + residual Copper-Zn alloy tubes
may show BLUISH pH and NH3 of water <15% + 90-10CuNi & 70-
stresses + any in HE + NH3 is present
CORROSION products + draw samples to assess 30CuNI are nearly immune
temperature, as process contaminat
Aqueous streams containing Some Cu alloys in Exch tubes shpw single or susceptibility of Cu alloys + SCC in steam servei
FOR Steels: in some services or may
ammonia may cause SCC in aqueous NH3 and/or highly branched cracks on + HE tubes by ECT & VI, controlled by ingress of air
Ammonia SCC Any Temperature anhydrous NH3 be intentionally added NA
some Cu alloys + CS iin NH3 compunds + CS surface + Cracking can be rolled area is highly + 300 SS & Ni base alloys
with as an acid neutralizer +
anhydrous ammonia in anhydrous NH3 either transgranular or susceptible, FOR CS: are immune, FOR CS:
<0.2%water CS in NH3 strge, refrg &
intergranular depend on WFMT welds inside tanks PWHT or addition of water
cause cracks in some LO refining
env & stress level + for CS + Ext UT shear wave + to NH3(0.2%) + weld
CS, (Refer 4- process
non-PWHT & HAZ on welds AET hardness <225BHN +
144)
prevent ingress of O2 in
storage facilities

4.5 - ENVIRONMENT ASSISTED CRACKING - ALL INDUSTRIES
Damage Affecting Critical Related
Mechanism
Description
Materials
Temperature rangefactors Affectfing equpt Appearnace Inspection Prevention
mechanisms
Form of cracking that result CS+LAS_High Temp above the
when certain molten metals strenght steels +300 melting point During fire molten
come in contact with specific SS + Ni base alloys + temp of alloy metals may drip onto or
alloys, sudden and brittle in Cu alloys +Al alloys contact with susceptible
nature. +Ti alloys material+ LME couples
LME occurs in (SS300 rub with Galv Protecting metal
Brittle cracks in an other
very specific steel)+ In refineries, Hg substrates from coming
wise ductile material, by
combinations od in crude oils can MT + PT + RT for HE into contact with the low
Metallogarphy only LMC & Ni-Ni sulfide
Liquid Metal metals in condense embrittling tubes to locate mercury melting metal, + Once
INTERGRANULAR cracks eutectic that forms
Embrittlement contact with low brass, alloy400, Ti or Al deposits inside because cracking from LME has
filled with low melting metal. at 1157F
metling point exch components.+ of high density initiated, grinding out the
+ Spectrography to confirm
metals + High LME of Al components affected area is not an
molten metal pieces.
tensile stress. has occurred in acceptable fix.
cryogenic gas plant
comp due to
condensation of liquid
mercury.
CS piping and vessels depend on source of H2,

in wet H2S services in alloy composition & Heat
FCC, hydroprocessing, treatment history, + low
amine, sou water, and strength steels and PWHT
HF alkylation units, + to improve ductility + use H2 flaking,
H2 @ critical surface cracks
effect is storage sphere more Surface breaking, intiate low H2 dry electrodes, + underbead
CS+LAS+400 series concentration + PT,MT,WFMT + UT +
pronounce from oftne made with slighly from surface + Locations at bakeout metal 400F or cracking, delayed
Loss in ductility of high SS + Precipitation Strength level, NO RT as not sensitive to
amb temp to higher strength + High high residual and tri-axial higher to diffuse H2 is cracking, H2
Hydorgen strength steels due to the Hardenable (PH) SS microstructure + HE cracks + if source of
300F, decrease strenth bolts and strsses, brittle fracture +in expected. + heavy wall assisted cracking,
Embrittlement penetration of atomic H2 can and some high Stesses above H2 is low temp aquesou
with increasing springs (>150Ksi tensile high strength steels, vessel requires control s/d HIC, Su Stress
lead to brittle cracking. strength nickel base threshold envir, H2 flux can be
temp, not likely strength absrod H2 cracking is often and startup procedures to cracking & H2
alloys. (REFER PAGE monitored with specail
above 160-180F during electro plating intergranular. cotrol pressursation stress corrosion
4-152) instruments.
and crack)+ Cr-Mo sequence + apply lining, cracking in HF
vessels in cladding to prevent
Hydorprocessing units surface H2 reactions in
acracks at welds & HAZ corrosive aqueous
ehen exceeds 235BHN reactions.
INDEX - ALL INDEX -


INDEX -
REFINERIES

5.1.1 - UNIFORM OR LOCALIZED LOSS OF THICKNESS - REFINING INDUSTRIES
Mechanism
Affecting equpt Appearnace Inspection Prevention
Mechanisms
H2S, CO2 and

Visual , UT , UT scans or
General and/or localized corr Corrosion rates increase mercaptans removal CS & LAS suffer general
profile radiography + Cor
that occurs principally on CS with increasing temperature, Corrosion depends on units + crude, coker, uniform thinning, localized
Mntg with corrosion
in amine treating processes. particularly in rich amine design and operating FCC, H2 reforming, corrosion or localized Proper operation of the
coupons and/or corr
Corrosion is not caused by the service. Temperatures practices, the type of hydroprocessing, and underdeposit attack + amine system is the most
Primarily carbon steel. probes. + Montg should
Amine amine itself, but results from above about 220F (104oC) amine, amine tail gas units. + Regen Thinning will be uniform in effective way to control Amine stress
300 Series SS are target the hot areas of the
Corrosion dissolved acid gases (CO2 and can result in acid gas concentration, reboiler & regenerator + nature when the process corrosion, with particular corrosion cracking
highly resistant. unit such as the reboiler
H2S), amine degradation flashing and severe contaminants, lean/rich exch, hot lean stream velocity is low while it attention to acid gas
feed and return line, the
products, Heat Stable Amine localized corrosion if the temperature and velocity. amine piping, hot rich will be localized for high loading levels. REFER 5-2
hot lean/rich amine piping,
Salts (HSAS) and other pressure drop is high REFER 5-1 amine piping, amine velocities associated with
and stripper overhead
contaminants. enough. solution pumps & turbulence.
condenser piping.
reclaimers
CS is less resistant. Careful design when

Hydroprocessing Units+
+ 300 Series SS, NH4HS concentration, General loss in thickness, + NH4HS concentrations
FCC Units + Sour Water sampling of NH4HS to
duplex SS, aluminum NH4HS salts precipitate in velocity and/or localized Localised corrosion at bends increase 2%wt & above
Ammonium Aggressive corrosion occurring Strippers (SWS) + determine concentration +
alloys and nickel base the reactor effluent streams turbulence, pH, when concentration above 8%wt + maintain velocity
Bisulfide in hydroprocessing reactor Amine units + Delayed HE tubes insp by ECT +
alloys are more when temperatures drop to temperature, alloy 2% by wt + low velocities 10 to 20FPS for CS,+use Erosion , Erosion-
Corrosion effluent streams and in units Coker + Aluminum UT and profile RT of high
resistant, depending within the range composition and flow cause localised corrosion + alloy 825 & Duplex SS Corrosion
(Alkaline Sour handling alkaline sour water. exchanger tubes aer and low velocity areas +
on ammonium of 120F to 150F (49C to distribution are all critical HE tubes fouling + corrodes when velocity is above
Water) (Localized corrosion.) susceptible for erosion- monitor water injection
bisulfide(NH4HS) 66C). factors to admiarility brass and copper 20FPS+Water inj to
corrosion REFER 5-4, and flow meters
Concentration and consider.REFER 5-4 tubes. dissolve NH4HS+ for SWS
5-5
velocity. use Ti & Alloy C276
Salts have a whitish,

greenish or brownish
Loaclised corrosion
All common materials appearance. Water washing
difficult to locate + RT or
are susceptible, in and/or steamout will remove Limiting salts and chlorides
General or localized corrosion, Concentration (NH3, HCl, Crude Tower UT thk for wall loss +
order of increasing Above the water dewpoint deposits so that evidence of through desalting and / or
Ammonium often pitting, normally occurring H20 or amine salts), Overheads+Hydroproce Montg of feed streams
resistance: CS, LAS, 300F (149oC)], Corrosion fouling may not be evident adding caustic + water
chloride under ammonium chloride or temperature and water ssing + Catalytic and itentifying dew point HCL Corrosion
300 Series SS, Alloys rates increase with during an internal visual wash to flush salt deposits,
corrosion amine salt deposits, often in the availability are the critical reforming + FCCU and temp and later temp
400, duplex SS, 800, increasing temperature. inspection.+ Corr + filming amine inhibitors
absence of a free water phase. factors. coker fractionation units monitoring, + Corrosion
and 825, Alloys 625 underneath the salts is or neutralizations
probes or coupons are
and C276 and Ti typically very localized and
useful
results in pitting.+ Corr rates
can be extremely high.
Damage in refineries is most

often associated with dew point CS & LAS suffer general
Water washing + Caustic
corrosion in which vapors HCl corrosion is found uniform thinning, localized UT for general thinning
injection + Chloride control
containing water & HCL All common materials in several units, corrosion or underdeposit and localised corrosion +
The severity of corrosion HCl acid concentration, genrally below 20 PPM in Ammonium
condense from the overhead constructed in especially crude and attack.+ 300 Series SS and pH & Corrosion
Hydrochloric increases with increasing temperature and alloy overhead accumulator chloride corrosion
stream of a distillation, refineries (Alloy400, Ni vacuum units, 400 Series SS will often monitoring + Water
acid corrosion HCl concentration and composition. REFER PG water + NH3, amine, + Chloride SCC &
fractionation or stripping base & Ti resistant to hydroprocessing units suffer pitting attack and 300 sampling + Corrosion
increasing temperature. 5-10 neutralization into water + Localized corrosion
tower. First water droplets that dilute HCL) and catalytic reformer Series SS may experience probes or coupons
Minimize HCL in H2
condense can be highly acidic units.REFER PG 5-10 chloride stress corrosion REFER PG 5-12
streams REFER PG 5-12
(low pH) and promote high cracking.
corrosion rates.

Mechanism
Mechanisms
The presence of hydrogen in In high temp H2/H2S

The corrosion damage is
H2S streams increases the The major factors streams + all Uniform metal loss on
minimized by using alloys
severity of high temperature In order of increasing affecting high temp hydroprocessing units process side and formation UT, RT, VT for metal loss
High Temperature above about with HIGH CHROMIUM High temperature
sulfide corrosion at temp above resistance: carbon sulfidation are the temp, such desulfurizers, of Iron sulfide scale + Scale + Actual temp monitoring
temperature 500 F and increases with content.+ 300 Series SS sulfidation in the
about 500F (260C). This form of steel, low alloy steels, the presence of H2 the hydrotreaters and is 5 times the volume of against design temp +
H2/H2S increase in temperature and such as Types 304L, 316L, absence of
sulfidation usually results in a 400 Series SS, and concentration of H2S and hydrocracking units.+ metal loss and may be Process simulation
corrosion H2S concentration 321 and 347 are highly Hydrogen
uniform loss in thk associated 300 Series SS. the alloy comp REFER 5- downstream of multiple layers + tightly checks for H2S levels
resistant at service
with hot circuits in 13 hydrogen injection adherent gray scale
temperatures.
hydroprocessing units. points.
CS Optg > 150F monitored

for thk loss & may be
upgraded to Alloy 400.+
Careful operation of unit to
Localized general or severe
Piping and equipment in minimize water, O2. Sulfur
thinning of CS + Cracking UT and RT are used to
CS, Cu-Ni alloys, Alloy HF acid concentration the HF alkylation unit, and other contaminants in Environmental
due to H2 Stress cracking monitor for loss in
400+ LAS, 300 SS and (water content), flare piping and the feed.+ Controls on the cracking of carbon
Corrosion by HF acid can result blistering and/or HIC/SOHIC thickness.+ Special
400 SS are susceptible Corrosion rates increase temperature, alloy downstream units water content of the steel and Alloy 400
in high rates of general or damage.+ Significant fouling emphasis programs to
Hydrofluoric to corrosion and/or with increasing temperature composition and the exposed to acid circulating acid.+ Alloy 400 can occur in HF.
localized corrosion and may be due to iron fluoride scales + monitor small bore piping,
(HF) Acid cracking and are and decreasing HF presence of carryover + HE tube & (solid or clad) can be used R+ Hydrogen
accompanied by lloy 400 shows uniform loss flange face corrosion,
Corrosion generally not suitable concentration (increasing contaminants including bundles + Small bore to eliminate the problems stress cracking in
hydrogen cracking, blistering in thk but not significant blistering and
for HF service + Other water content). Above 150F oxygen and sulfur piping + dead legs + associated with blistering HF + blistering and
and/or HIC/SOHIC scaling.+ Non-SR Alloy 400 HIC/SOHIC are
Ni base alloys such as compounds are the Flange faces + Iso and HIC/SOHIC. A SR HT HIC/SOHIC
is susceptible to SCC when recommended as outlined
Alloy C276 used controlling factors. stripper & de required to minimize the damage.
in contact with moist HF in API RP 751.
propanizers towers possibility of SCC.+ Alloy
vapors in the presence of O2
C276 has been used
where there have been
cracking problems with
Alloy 400.
Crude and vacuum

normally occurs above heater tubes& transfer localized corrosion, pitting UT, RT + Monitor TAN upgrade metallurgy, utilize Sulfidation
A form of high temperature 425F, but has been reported NAC is a function of the lines, Vac bot piping, corrosion, or flow induced and sulfur content of the chemical Note: HVGO:
corrosion that occurs primarily as low as 350F. naphthenic acid content AGO circuits; HVGO grooving in high velocity crude charge and side inhibitors+blending crude Heavy vacu gas
Napthenic Carbon steel, low alloy
in crude and vacuum units, and Severity increases with (neutralization number), and sometimes LVGO areas + In low velocity streams to determine the to reduce the TAN and/or LVGO: Light
Acid steels, 300 Series SS,
downstream units temperature up to about temperature, sulfur circuits. also reported in condensing conditions, many distribution of acids in the increase the sulfur content. vaccum gas ,
Corrosion 400 Series SS and
that process certain fractions or 750F (400oC), + however, content, velocity and the LCGO and HCGO alloys including CS & LAS various cuts.+ Corrosion +For severe conditions, HCGO: Heavy
(NAC) nickel base alloys.
cuts that contain naphthenic NAC has been observed in alloy composition.+ streams on delayed 400 SS may show uniform Montg (ER & Coupons) + Type 317L stainless steel coker gas + AGO:
acids. hot coker gas oil streams up REFER 5-19 coking units processing loss in thickness and/or Monitor streams for Fe & or other alloys with higher Atmospheric gas
to 800F high TAN feed.+ pitting. Ni content + H2 probes Mo may be required. oil
REFER 5-19

Mechanism
Mechanisms
proper materials selection

and control of phenol
UT and RT to monitor for solvent chemistry.+ OH
Corrosion of carbon steel can General or localized
In order of increasing Minimal below 250F + CS Temperature, water loss in thickness. piping circuits shld be
Phenol occur in plants using phenol as corrosion of CS + Thk loss
resistance: carbon and 304/304L SS Corrode content, alloy chemistry Phenol extraction b) ER corrosion probes designed for max velocity
(Carbolic acid) a solvent to remove aromatic due to erosion-corrosion NONE
steel, 304L, 316L and rapidly in phenol service and velocity are the facilities in lubes plant. and corrosion coupons of 30fps in recovery
Corrosion compounds from may be observed in tower
Alloy C276. above 450F critical factors. have been used for section + maintian atleast
lubricating oil feedstocks. overhead circuits.
corrosion monitoring. 30F above dewpoint +
316L & for erosion resis
use Alloy C276
Acid concentration, temp Piping and equipment in Selective upgrading to

& contaminants.+ Solid the polymerization unit corrosion resistant
UT and RT for loss of
PA catalysts are not where water mixes with materials is the only option
thickness.+ Sample iron in
corrosive to CS unless catalyst. + low velocity where water cannot be
water from first column
Phosphoric acid is most often free water is present. areas where there is eliminated.+ Type 316L SS
Type 304L SS is satisfactory overhead receiver.+
used as a catalyst in When water is present, little or no circulation and Alloy 20 are effective
In order of increasing for phosphoric acid Online corrosion
Phosphoric polymerization units. It can severe Corr of CS may such as piping at concentrations up to
resistance: carbon concentration of 100% up to General or localized thinning monitoring using ER
Acid cause both pitting corrosion occur.+ CR Increase with manifolds, the bottom of 85% at boiling NONE
steel, 304L SS, 316L about 120F Type 316L SS of carbon steel. probes and/or corrosion
Corrosion and localized corrosion of Incr in temp + Corr can kettle-type reboilers, temperatures.+ Type 304L
SS and Alloy 20. is required from 120F to coupons in the water draw
carbon steels depending on penetrate a 1/4" thk steel partial penetration SS is satisfactory for
225F from the first
water content. tube in 8 hrs+ Most Corr welds, and exchangers phosphoric acid
column overhead
probably occurs during where there is sufficient concentration of 100% up
condenser and the
water-washing residence time to permit to about 120F Type 316L
reboiler.
Operations at S/D + the settling of acid SS is required from 120F
Chlorides increase PAC droplets. to 225F
General thinning. localized

corrosion or localized 300 Series SS can be
Corrosion of steel due to acidic underdeposit attack can used at temp below about
Acid sour water
sour water containing H2S at a Primarily affects occur, especially if o2 is 140F where Chloride SCC
H2S content, pH, corrosion is a concern in
pH between 4.5 and 7.0. (CO2) carbon steel. At a given pressure, the present. Corrosion in CO2 UT& Profile RT + Process is not likely.+ Cu alloys
Sour Water temperature, velocity and overhead systems of Wet H2S damage
may also be present.+ Sour b) Stainless steels, H2S concentration in the containing environments and Corrosion montg of and Ni alloys are generally
Corrosion oxygen concentration are FCC and coker gas and Carbonate
waters containing significant copper alloys and sour water decreases as may be accompanied by pH, + Provide corrosion not susceptible to acid
(Acidic) all critical factors. REFER fractionation plants with SCC.
amounts of NH3, chlorides or nickel base alloys are temperature increases carbonate SCC + 300 SS coupons sour water corrosion.
PG-5-25 high H2S levels and low
cyanides may significantly usually resistant. are susceptible to pitting However,copper alloys are
NH3 levels.
affect pH attack and may experience vulnerable to corrosion in
crevice corrosion and/or environments with NH3
chloride SCC

Mechanism
Mechanisms
General but attacks CS weld Corrosion is minimized

HAZ rapidly.+ H2 grooving through materials selection
may occur in low flow or and proper operation
stagnant areas such as in within design velocities. +
In order of increasing Acid concentration, (for Sulfuric acid alkylation
Sulfuric acid promotes general strge tanks or rail cars.+ Alloys such as Alloy 20,
resistance: carbon CS <65%) units and waste water UT or RT inspection of
and localized corrosion of H2SO4 attacks slag left from Alloy 904L and Alloy C-
steel, 316L SS, Alloy Corrosion varies with temperature ,alloy treatment plants are turbulent zones and
Sulfuric Acid carbon steel and other alloys. welding.+ If CR & velocity 276 resist dilute acid
20, high silicon cast concentration of sulfuric acid content, velocity (for CS, affected.+ DIB OH+ hottest areas. + NONE
Corrosion Carbon steel heat are high, there will be no corrosion and form a
iron, high nickel cast & temp if exceesds> 2-3fps) Caustic treating Corrosion monitoring with
affected zones may experience scale.+ Corr of steel by dilute protective
iron, Alloy B-2 and contamination and sections + Bot of coupons and ER probes.
severe corrosion. acid is usually in the form of iron sulfate film on the
Alloy C276. presence of oxidizers. fractionation towers
overall metal loss or pitting surface. + Acidified
and becomes more severe product streams can be
with increasing temp & washed with caustic to
velocity. neutralize the acid.
INDEX - ALL INDEX -


5.1.2 - ENVIRONMENT ASSISTED STRESS CORROSION CRACKING - REFINING INDUSTRIES
Mechanism
Mechanisms
HE tubes + furnace
tubes and piping.
A form of SCCC normally
+ Fired heaters burning
occurring during S/D, S/U or Typically occurs next to
A combination of oil, gas, coke depend on
during operation when air and welds, but can also occur in Polythionic Acid
Sensitization: formation of environment, material, sulfur levels in the fuel.+
moisture are present. Cracking the base metal (it is usually Stress Corrosion
chromium carbide in the and stress are required.+ FCC units +
Polythionic is due to sulfur acids forming quite localized and may not Cracking (PTA
grain boundaries of the Sensization + 300 H are hydroprocessing units
Acid Stress from sulfide scale, air and 300 Series SS, Alloy be evident until a leak PT after thorough VERY INTERESTING & SCC),
metal. Sensitization more susc for (heater tubes, hot
corrosion moisture acting on sensitized 600/600H and Alloy appears during start-up or, in cleaning during IMPORTANT , REFER Intergranular
occurs in the 750F sensitization in HAZ , 'L' feed/effluent exchanger
cracking Aust SS + Usually adjacent to 800/800H. some cases, operation.+ shutdowns PAGE 5-32 Corrosion (IGC)
to1500F range. (<0.03% C) will not tubes, bellows).+ Crude
(PASCC) welds or high stress areas. Cracking propagates and
(time/temp/composition sensitize while weldign and coker units (piping).
+ Cracking may propagate intergranularly + Corrosion Intergranular
dependent), unless temp are less + Boilers and high
rapidly through the wall thk of or loss in thk is usually Attack (IGA).
than 750F temperature equipment
piping and components in a negligible.
exposed to sulfur-
matter of minutes or hours.
containing combustion
products.
PWHT all CS welds in

All non-PWHT carbon
Amine cracking is a common Surface breaking cracks accordance with API RP Amine stress
steel piping and
term applied to the cracking of Cracking has been reported initiating at ID of pipe 945. also to repair welds corrosion cracking
equipment in lean
steels under the combined down to ambient primarly at HAZ and stress and to internal and and is a form of
The critical factors are amine service including
action of tensile stress and temperatures with some areas, + typically parelell to external attachment welds. Alkaline SCC.
Amine stress the level of tensile contactors, absorbers,
corrosion in aqueous Carbon steels & Low amines. Increasing welds+ Nozzles + similar to WFMT + ACFM + Less PT + Use solid or clad SS Caustic SCC and
corrosion stress, amine strippers, regenerators
alkanolamine systems used to alloy steels temperature and stress H2S cracking + found on + AET Alloy 400 or other carbonate SCC are
cracking concentration and and heat exchangers as
remove/absorb H2S and/or levels increases the process side opposite to corrosion resistant alloys in two other forms of
temperature. well as any equipment
CO2 and their mixtures from likelihood and severity of external attachment welds + lieu of CS + Water wash ASCC that are
subject to amine
various gas and liquid cracking. INTERGRANULAR (Oxide non-PWHT CS prior to similar in
carryover.MEA,DEA,
hydrocarbon streams. filled & branching) welding, heat treatment or appearance.
DIPA
steamout.
H2 blisters appear as bulges

on the ID or OD surface of
Blistering, HIC, SOHIC the steel of a pressure
and SSC damage at vessel. found rarely on pipe
wet H2S environment and very rarely in the middle
Environmental conditions Hydrogen
present.+ Increasing of a weld. HIC damage can Effective barriers that
Blistering, HIC, and SOHIC (pH, H2S level, with WFMT, EC, RT or Embrittlement +
Wet H2S concentration of NH4HS occur wherever blistering or protect the surface of the
damage have been found to contaminants, ACFM techniques.+ Amine cracking &
Damage above 2% increases the subsurface laminations are steel from the wet H2S
Carbon steel and low occur between ambient temperature), material SWUT + Evaluation of wet Carbonate
(Blistering / REFER 5-41 potential for blistering, present.+ In pressure- environment can prevent
alloy steels. and 300F or higher. properties (hardness, h2S environments by crackign are simlair
HIC / SOHIC / HIC and SOHIC.+ containing equpt SOHIC and damage including alloy
+ SSC generally occurs microstructure, strength) Process / Material and also confused
SSC) Cyanides significantly SSC damage is most often cladding and coatings.
below about 180F and tensile stress level engieers REFER 5-43 sometimes withwet
increase the probability associated with the REFER 5-43
(applied or residual). H2S cracking
and severity of weldments. SSC can also be
blistering, HIC and found at any location where
SOHIC damage. zones of high hardness are
found in vessels or in high
strength steel components

5.1.2 - ENVIRONMENT ASSISTED STRESS CORROSION CRACKING - REFINING INDUSTRIES
Mechanism
Mechanisms
PWHT + Low strength Sulfide SCC in wet

Hydrogen Stress Cracking is a Steel hardness:
carbon steels + weld H2S environments
form of environmental cracking Increases with harness Exposed to HF acid + WFMT + Hardness
harndness less than except that HF acid
that can initiate on the surface >22HRC and time to High strength LAS INTERGRANULAR + measurement + Process
Hydrogen 200HB + susceptible is generating the
of high strength LAS & CS with Carbon steels & Low failure increases with (ASTM A 193-B7) bolts SURFACE BREAKING side and attachment
Stress NA above 237BH + CE: <0.43 hydrogen.
highly localized zones of high alloy steels hardness + Strength + and compressor CRACKS USUALLY welds that are not
Cracking - HF + B7M bolts are low Blistering, HIC and
hardness in the weld metal and HF environments + components also B7 WELDMENTS tempered (softened by
strength and softer + Alloy SOHIC damage is
HAZ as a result of exposure to Inadequate heat bolts when overtorqued subsequent passes
cladding or non metallic similar to that
aqueous HF acid environments. treatment
coatings + Alloy 400 found in wet H2S
Post-fabrication SR heat
Surface breaking or cracks that
treatment of about 1150°F
Carbonate occur adjacent to CS welds Montg of pH and
In gas scrubbing units, Cracking susceptibility Typically parelell to weld and for both repair and
Stress under the combined action of carbonate concentration +
cracking may occur when increases with FCC & Main fractionator can also be in weld and HAZ attachement welds also + Amine cracking
Corrosion tensile stress and Carbon steels & Low WFMT, ACFM, NO PT, +
the CO2 content is above increaasing pH and OH condensing & reflux + Spider web of small cracks coatings + clad with 300SS and caustic stress
Cracking corrosion in carbonate- alloy steels SWUT+ Grinding crack for
2% and temperatures corbonate concentration system + CO2 removal + INTERGRANULAR + very / Alloy 400 + water wash corrosion cracking
(Carbonate containing systems. It is a form detection + AET for crack
exceed 200F (93C). REFER PG 5-52 fine Oxide filled cracks non PWHT prior to steam
cracking) of Alkaline Stress Corrosion monitoring
out or HT +
Cracking (ASCC)
METAVANADATE inhibitor
INDEX - ALL INDEX -


5.1.3 - OTHER MECHANISMS - REFINING INDUSTRIES
Mechanism
Mechanisms
HTHA results from exposure to

H2 at elevated temperatures In order of increasing
Hydroprocessing units, Increase Carbide
and pressures. The H2 reacts resistance: carbon
such as hydrotreaters Ultrasonic using a stabilization to minimize
with carbides in steel to form steel, C-0.5Mo, Mn-
(desulfurizers) and combination of velocity methane formation by
methane (CH4) which cannot 0.5Mo, 1Cr-0.5Mo, INTERGRANULAR & Occur
hydrocrackers, catalytic ratio and backsacatter is using Cr & Mo alloysteels A form of HTHA
diffuse through the steel. The 1.25Cr-0.5Mo, 2.25Cr- For a specific material, adjacent to pearlite (iron
reformers, most suitable to find also W & Va stabilizers + can occur in boiler
High loss of carbide causes an 1Mo, 2.25Cr-1Mo-V, HTHA is dependent on carbide) areas in carbon
hydrogen producing fissuring and serious 25F to 50F safety factor tubes and is
temperature overall loss in strength.+ 3Cr-1Mo, 5Cr-0.5Mo temperature, hydrogen steels + Some blistering in
Dependent on Temperature units and hydrogen cracks + Visual Inspection approach when using referred to by the
Hydrogen CH4 pressure builds up, and similar steels + 300 partial pressure, time and due to either molecular
cleanup units, such as for blisters when methane APIRP941 curves + 300SS fossil utility industry
Attack (HTHA) forming bubbles or cavities, SS, as well as 5Cr, 9Cr stress.Service exposure hydrogen or methane
pressure swing formation + In-situ overlay or clad at H2 as hydrogen
microfissures and fissures that and 12 Cr alloys, are time is cumulative. accumulating in laminations
absorption units, are all metallography for fissure service for adequate sulfur damage.
may combine to form cracks. not susceptible to in the steel
susceptible to HTHA. + cracks (very limited) + NO resistance + decrease in
+ Failure can occur when the HTHA at conditions
Boiler tubes in very high AET partial pressures +
cracks reduce the load carrying normally
pressure steam service. Outgassing in shutdowns
ability of the pressure seen in refinery units.
containing part.
Sour water strippers Not to use Ti in Amine and

Hydriding of titanium is a Critical factors are metal
and amine units in OH Specialized ECT may able sour water in hydriding Hydriding is a
metallurgical phenomenon in temperature, solution
Occurs above 165F (74C) condensers, HE tubes, to detect hydriding services + Ti and Non Ti damage
which hydrogen diffuses into chemistry and alloy Only metallurgical change /
and at a pH below 3, pH piping and Ti eupt damage. + No other componenet to be mechanism that is
the titanium and reacts composition.+ Galvanic Mechanical testing.
Titanium above 8 or neutral pH with operate > 165F & also techniques to monitor or electrically isolation to unique to a few
to form an embrittling hydride Titanium Alloys contact + Solubility of H2 Embrittlement only and no
Hydriding high H2S content + above above 350F (177C) in inspect for titanium avoid galvanic couple materials including
phase. This can result in a in Ti alpha-beta alloys ductile, HE tubes crack when
350F in the absence of the absence of hydriding other than the (Eliminating galvanic alloys of titanium
complete loss of ductility with (50-300ppm), beta alloys taken out or during re-rolling
moisture and O2 moisture or O2 + CP metallurgical and/or couple may not prevent and
no noticeable sign of - 2000ppm to for
equpt with potential mechanical methods hydriding in alkaline sour zirconium.
corrosion or loss in thickness. hydriding
values <-0.9v sce water environments.)
INDEX - ALL INDEX -


deg F deg C
0 -17.78
10 -12.2222
20 -6.66667
50 10
100 37.7778
150 65.5556
200 93.3333
250 121.111
300 148.889
350 176.667
400 204.444
450 232.222 deg F deg C
500 260 130 54.44
550 287.778
600 315.556
650 343.333 Enter here
700 371.111
750 398.889
800 426.667
850 454.444
900 482.222
950 510
1000 537.778
1050 565.556
1100 593.333
1150 621.111
1200 648.889
1250 676.667
1300 704.444
1350 732.222
1400 760
1450 787.778
1500 815.556
deg C deg F
260 500
enter here
4.2 Mechanical & Metallurgical damages
4.3 Uniform & Localized loss of thickness
4.4 High temperature corrosion
4.5 Environment assisted cracking
5.1.1 Uniform OR Localized loss of thickness
5.1.2 Environment assisted corrosion cracking
5.1.3 Other mechanisms
Q What is the difference between temper embrittlement & 885 F embritlement
A Phenomenon is mostly similar, both occurs at long term esposure to 600F to 1100 F(Temp emb) & 650-1100F (885
Temp emb) & 650-1100F (885 F) but occurs in 2.25Cr-1Mo steels & 885F occurs in 400,300SS & duplex HE tubes

General Damage Mechanisms in Refining Industries

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General Damage Mechanisms in Refining Industries

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INDEX

General Damage Mechanisms - All Industries

Uniform or Localized Loss of thickness 4

High Temperature Corrosion (204 deg C) 5

Environment Assisted Cracking 6

General Damage Mechanisms - Refining Industries

Environment Assisted Cracking 8

Other Mechanisms ( HTHA / Titanium Hydriding) 9

Shyam S Ponnada API 571

Shyam S Ponnada API 571

Change in microstructure of 850 F to 1400 F

Reduction in toughness in Primarily 2.25 CR- Hydroprocessing untis &

300 series to be de-

for new equt UCS66 in

Shyam S Ponnada API 571 6 of 32

Heater tubes, tube

In boiler tubes the flow of

Shyam S Ponnada API 571 7 of 32

NI base filler metals have

Thermal fatigue cracking

Increasing hardness of the

Pump casings, pump

Shyam S Ponnada API 571 8 of 32

Good design that

Socket welds and small

Both thermal insu and Excessive cracking, Proper selection of

Imp parameters include type

INDEX - ALL INDEX -

Shyam S Ponnada API 571 10 of 32

more severe at metal temps

Shyam S Ponnada API 571 11 of 32

Monitor CW for pH, O2,

Corrosion can occur in Corr from O2 tends to be

BFW & Cond sys in all

Shyam S Ponnada API 571 12 of 32

Maintain metallic surfaces

measure soil potential

Shyam S Ponnada API 571 13 of 32

Proper design + reducing

Cu alloys (brass, Factors include the composition of the alloy and

Shyam S Ponnada API 571 14 of 32

Cast irons are comprised of

INDEX - ALL INDEX -

Shyam S Ponnada API 571 15 of 32

Piping and equpt Uniform thinning,

Depth confirmation by Intiail stages is difficult + If

Exposed to high temp,

Fired heater tubes +

Hot corrosion, hot ash

Shyam S Ponnada API 571 16 of 32

Formation of hard,brittle dull, dark gray

INDEX - ALL INDEX -

Shyam S Ponnada API 571 17 of 32

300 series Surface cracks on

PWHT, for CS consider

for CU alloys: Cu-Zn

Shyam S Ponnada API 571 18 of 32

CS piping and vessels depend on source of H2,

INDEX - ALL INDEX -

Shyam S Ponnada API 571 19 of 32

Shyam S Ponnada API 571 20 of 32

H2S, CO2 and

CS is less resistant. Careful design when