TIP 0402-22

ISSUED –1995
WITHDRAWN – 2002
REVISED AND REINSTATED – 2003
REVISED – 2008
©2008 TAPPI

The information and data contained in this document were

prepared by a technical committee of the Association. The
committee and the Association assume no liability or responsibility
in connection with the use of such information or data, including
but not limited to any liability under patent, copyright, or trade
secret laws. The user is responsible for determining that this
document is the most recent edition published.

Guidelines for inspecting batch digesters

Scope

This Technical Information Paper (TIP) provides guidelines and procedures for inspecting batch digesters in pulp
mills. It describes damage mechanisms and addresses inspection frequency, planning, methods, damage or
inspection locations, cleaning and preparation, technician qualifications, test equipment and documentation.

The primary focus of this TIP is stationary, vertical, cylindrical welded, carbon steel digesters that make up the vast
majority of the batch digesters in service. Batch digesters may be made from carbon steel or stainless steel. Carbon
steel vessels may be wholly or partially internally protected with corrosion resistant alloy (CRA) weld overlay or
clad layer. Thermal spray coatings also have been used to prevent steel corrosion. Vertical cylindrical digesters
constructed of solid stainless steel are covered in this revision of the TIP.

Digesters of riveted or forge welded construction are not covered in this TIP. Inspection of batch digesters in acidic
(sulfite) pulping service, which are stainless steel or have a brick-lining, is not specifically covered by this TIP,
although the general guidelines herein apply. This TIP does not provide guidance on interpreting inspection
findings, assessing fitness for continued service or designing acceptable repairs. The National Board Inspection
Code (1) and API 579-1/ASME FFS-1 Post-Construction Code provide such guidance (2).

Inspection guidelines in this TIP are to supplement, not supersede jurisdictional and regulatory requirements.

Historical perspective

Hundreds of batch digesters are in regular service worldwide, most seeing 7 or 8 cooking cycles per day. Despite the
possibility of rapid corrosion of carbon steel by cooking liquors, catastrophic failures of batch digesters are rare.
TAPPI is aware of only two catastrophic failures of a batch digester since 1952 in the world. The catastrophic
incident in Florida in 1994 was the first recorded failure of a welded, vertical, carbon steel digester. Explosive
rupture of a stainless steel digester in a sulfite mill in South Africa in 2002 involved unusual metallurgical damage
from a chip fire. Improving this good safety record is the main purpose of this TIP.

To maintain safe operation of digester vessels, corrosion (caused by damage mechanisms that generally are well
understood) must be found and repaired before the mechanical integrity of the vessel is compromised. Modern
vessel integrity management practice involves combining knowledge of damage mechanisms with digester-specific
maintenance experience, plus qualified inspection and NDT methods to systematically manage each digester’s
fitness for continued service. An effective batch digester inspection requires competent and disciplined external and
internal inspection for indications of known damage mechanisms. Easy internal access generally makes it
convenient to internally inspect batch digesters, which is the recommended procedure.

Damage mechanisms

Carbon steel and CRA in batch digesters can be affected by the following corrosion damage mechanisms:

TIP Category: Automatically Periodically Reviewed (Ten-year review)

TAPPI
TIP 0402-22 Guidelines for inspecting batch digesters / 2

Carbon steel

Corrosion of boldly exposed carbon steel occurs in a general or uniform manner by the “hot-plate boiling” corrosion
mechanism (see Section 5.1.1.2 in 3). Carbon steel can corrode at up to 2.5 mm/y (100 mpy) where liquor runs down
or splashes on the shell during digester filling or when liquor continually runs down the hot steel surface. Steel
normally corrodes at < 0.5 mm/y (< 20 mpy) where there is no active hot-plate boiling.

Carbon steel corrodes mostly by pits progressing to a modest depth and then expanding laterally instead of
continuing to deepen, producing a reasonably smooth surface on which the pitting cycle recurs. Each carbon steel
digester has its own pattern of internal corrosion, although corrosion patterns are fairly similar in a fleet of digesters
in a mill. Patterns depend on filling practices; however, hardwood and softwood digesters in the same mill usually
have different corrosion patterns.

Hot-plate boiling corrosion by liquor entering pockets or cavities behind a CRA lining or clad layer can cause leaks
if these conditions are not detected in time. Improper repair of this type of corrosion can lead to serious
consequences, including digester rupture. (“Finger-nail corrosion” can also occur; see description below.)

Another carbon steel corrosion mechanism in alkaline digesters is relatively localized, flow-accelerated corrosion
(see Section 5.1.1.3 in 3) where the passive film on the steel is physically removed by process liquid flow. Common
locations affected are behind extraction screens; in and around nozzles taking liquor to indirect heaters, and in and
around the blow nozzle.

Carbon steel batch digesters in N. America are thermally stress relieved to satisfy ASME Code rules but caustic
stress corrosion cracking (CSCC) of the welds and repair and overlay welds does not occur anyway because the steel
potential changes from active to passive during each cooking cycle and does not reside long enough in the critical
CSCC zone. Cracking of carbon steel welds at internal attachments almost always is due to corrosion fatigue.
Fatigue cracking also can affect external welds at vessel supports and nozzles.

Grinding or corrosion of welds may expose welding defects. Cracks in seam welds are presumed to be hydrogen
cracks from original welding unless metallurgical analysis confirms another cause. [Note: “Critical lengths” for
cracks perpendicular to the primary stress in carbon steel digester shells to become unstable typically exceed one
foot, determined as part of a fitness-for-service evaluation as described in API 579-1/ASME FFS-1 (2).]

Stainless steel

Hot-plate boiling corrosion affects CRAs significantly less than carbon steel. Corrosion rates depend on the alloy
composition: higher chromium content increases corrosion resistance; higher molybdenum content reduces
corrosion resistance (3,4). Duplex stainless steels, used specifically because of their superior resistance to alkaline
liquor corrosion, sometimes experience hot-plate boiling corrosion if directly splashed with cooking liquor.

Hot-plate boiling corrosion of CRA produces rough, frosted or etched surfaces. As with carbon steel, hot-plate
boiling corrosion is more aggressive on surfaces directly impinged by liquor, producing a characteristic corrosion
pattern. CRA welds and overlays can crack from hot-cracking when the welds are made and corroding welds can
acquire networks of fine cracks. Stainless steel and CRA attachment welds can crack due to corrosion fatigue.

“Finger-nail corrosion” produces sharp edges on CRA overlays and welds due to continued corrosion of the carbon
steel. The resulting ditches normally are not structurally significant. Repair is required if ditching is severe enough
to trap liquor behind the CRA layer and local steel corrosion is accelerated.

Thermal spray coatings

Corrosion of thermal spray coatings normally produces an etched surface appearance similar to the as-coated surface
texture. Arc-sprayed coatings, which predominate, are rougher and thicker than HVOF coatings. Coating corrosion
patterns normally appear after a couple of years. Corrosion of the carbon steel concealed behind thermal spray
coatings is less problematic than behind weld overlays, which are strong enough to trap large pockets of liquor.
3 / Guidelines for inspecting batch digesters TIP 0402-22

Thermal spray coatings tend to fail due to local blistering and spalling, which can occur soon after the coating is
installed due to inadequate quality of the coating or due to corrosion of the carbon steel substrate at coating defects.

Inspection frequency

Inspection intervals for carbon steel digesters normally should not exceed two years or 5,000 cooks.

Inspection intervals for CRA digesters or those lined with a corrosion-resistant barrier should be defined by the
highest corrosion rates or the corrosion barrier’s estimated remaining life, respectively. (The corrosion barrier
typically is considered to “fail” when carbon steel is exposed.) Relevant state, local or jurisdictional inspection
interval requirements may require inspection at some maximum time interval.

Factors to consider when determining the inspection frequency for a specific digester should include:
• Age and materials of construction.
• Condition and corrosion rates of the pressure envelope and corrosion barrier(s) as determined in most
recent inspections.
• Process changes made after the previous two internal inspections.

Inspection planning

Safety

Personnel safety and industrial hygiene should be ensured by complying with established mill safety, lockout and
confined space entry procedures.

Some testing described in this TIP involves use and handling of chemicals which present flammability and health
hazards to humans. Procedures for safe handling these materials shall be as stated in the Material Safety Data
Sheets, which must be obtained from the chemical supplier. Prior to using inspection procedures in this TIP, the user
should determine which chemicals to be used are potentially hazardous in order to strictly follow the procedures
specified in the MSDS and to meet local, state and federal requirements for safe use and disposal of these materials.

Review existing information

Inspection starts with an engineering review of the pressure vessel data sheets, drawings, repairs and recent
inspection reports. Drawings must be updated to show vessel modifications, overlays, repairs, etc. Appendix A has
guidelines for setting up a permanent file for a digester. If vessel records are inadequate or incomplete, an
appropriate baseline inspection should be conducted as soon as practical.

Mill responsibilities

The mill should assign management of a digester inspection to someone who, by virtue of appropriate training,
experience and authority can:
1. Manage safety measures for safe vessel entry and worker access.
2. Arrange for the digester to be adequately cleaned and prepared for inspection (see Cleaning)
3. Ensure the digester is thoroughly inspected as outlined in this TIP, and verify qualified NDT procedures
and practitioners are properly used to accurately characterize the corrosion damage.
4. Ensure that conditions found are adequately reviewed and analyzed for fitness for continued service.
5. Ensure the inspection results, repairs, etc., are fully documented in the specified reporting format.

These issues are discussed below.

TIP 0402-22 Guidelines for inspecting batch digesters / 4

Documentation layout and cleaning

Vessel layout

A fixed reference layout system is essential to consistently locate test positions and trend inspection findings. Use
the same "zero" circumferential and elevation location for every inspection. The blow-nozzle flange face is a
commonly used elevation zero. The manway or gas-off (vent) nozzle in the head or thermocouple nozzles are
common circumferential zero points. All internal and external locations in the vessel are identified with respect to
the set zero locations. (Ultrasonic thickness testing (UTT) technically can be done on the inside or outside surface.)

For grid UTT thickness surveys the internal surface typically is divided into eight or ten circumferential segments
(vertical lines), with vertical increments (horizontal lines) between two and four feet. Vertical grid lines usually
continue onto the top head and bottom cone. Reducing the grid spacing obviously increases the UTT data density.

Line-scan surveys typically are done along at least four, equally-spaced, vertical lines. These lines, which normally
must be ground smooth for the UTT line-scans, usually remain visible between inspections.

Cleaning

Internal

The interior surface can be reliably inspected only if it is clean and free of scale and debris. High-pressure water
washing (hydro-blasting) is recommended. Sandblasting also is effective. It is not always essential to clean 100% of
the internal surface provided areas to be inspected are cleaned. Tight rust is acceptable but heavy scale on weld
overlays hides defects that lead to corrosion of the carbon steel.

Some inspection techniques may require supplementary surface preparation such as wire brushing, sanding,
grinding, etc. NDT technicians should specify areas requiring supplemental cleaning or surface preparation.

External

Because most batch digesters are externally insulated and insulation must be removed to inspect the vessel exterior
or to do UTT on the external surface, this is seldom done even though it is technically feasible.

Qualifying NDE technicians and procedures

Only certified NDT technicians should be employed for digester inspection work. Certified NDT technicians must
meet the education and experience requirements of the certifying organization but their technical skill is not assured.

NDT technicians should meet the American Society for Non-destructive Testing (ASNT) Recommended Practice
SNT-TC-1A, for qualification and certification. Canadian General Standards Board (CGSB), via Standard 48.9712,
“Certification of Non-destructive Testing Personnel,” covers technicians in Canada. These standards stipulate levels
of education, training and experience required for various certification levels. However, because each NDT
company administers SNT-TC-1A certification for its own employees, technicians from different NDT companies
may not have met the same certification requirements. [CGSB certification is more uniformly regulated.]

Because of this certification situation, the mill’s above-mentioned inspection manager should review the NDT
contractor’s certification program. As a minimum, the competence of certified NDT technicians involved in each
particular NDT task still should be qualified at the job site to the mill inspection manager’s satisfaction.

Technicians who do UT thickness testing of digester vessels should be certified to at SNT-TC-1A, Level I, or the
CGSB equivalent. Level II or Level III personnel should directly supervise Level I technicians. Manual or semi-
automated UTT procedures or techniques (i.e. spot or scanning) should be described in a written procedure.
Verification of calibration and effectiveness, using appropriate qualification standards, is essential.
5 / Guidelines for inspecting batch digesters TIP 0402-22

Inspection methods and practices

All valid inspections start with careful visual examination. Results from this inspection usually determine what NDT
and supplementary inspections are required. NDT typically includes ultrasonic thickness testing (UTT) to quantify
corrosion damage and testing for cracks with penetrant testing (PT) or magnetic particle testing (MT).

Visual inspection

External inspection.

The external condition should be visually examined when the digester is pressurized. A written report for such a
"walk-down inspection" should be generated annually and signed by the inspector.

Conditions to look for include:

• Liquor leakage from or onto the digester shell and nozzles.

• Water, steam or other liquid leaking from or onto the digester.
• Insulation deterioration and excessive accumulation of chips and chemicals.
• Cracking or looseness of structural supports and all attached piping.
• Unusual vibration, noise or movement.
Safety reminder: Bring problems to immediate attention of the department responsible for digester maintenance!

Locations where wetness or liquor collects on the shell should be investigated for corrosion and cracks when the
vessel is cooled down for internal inspection. This may require removing insulation and cleaning of the external
surface (see Cleaning – Exterior above).

Safety note: External leaks in brick-lined digesters in sulfite service often indicate failure of the internal lining.

Internal inspection

Careful visual examination of all cleaned, internal surfaces is essential. Oblique (low angle) illumination of the
surface increases the sensitivity of the inspection. The inspection scope and supplementary NDT should be based on
the new visual inspection results.

Corrosion damage and flaws found by visual inspection include:

On carbon steel

• Boiling-plate and spreading pit corrosion typically produce rough, pocked surfaces. More severely
corroded steel surfaces can have craze-cracking, the depth of which is determined by grinding to crack-free
condition.
• Erosion-corrosion, which usually produces smooth, flow-related corrosion patterns.
• Preferential corrosion of welds and heat-affected zones (HAZ), including “finger-nail” corrosion of carbon
steel at the edge of stainless steel overlays.
• Cracks, especially fatigue cracks at welds and HAZ’s.
• Deformation or distortion, normally associated with welding or mechanical damage. This is rarely severe
enough to cause problems and should meet API 579-1/ASME FFS1 requirements.
TIP 0402-22 Guidelines for inspecting batch digesters / 6

On CRA plate and weld overlays

• “Boiling plate corrosion,” indicated by matte or etched weld surfaces or ultimate loss of weld bead crowns.
• Rust bleed-out from the overlay - investigate how badly the steel behind the overlay is corroded!
• Erosion-corrosion, which produces smooth, flow-related corrosion patterns.
• Cracks, pores and pits.

The CRA layer on clad plate can crack, corrode, erode and pit like CRA weld overlays. Rust bleed-out, bulging and
cracking at attachment welds should be fully investigated.

Thermal spray coatings

Nickel-rich thermal spray coatings that are widely used can experience slow uniform corrosion and erosion
corrosion, much the same as a CRA weld overlay. Corrosion usually increases the surface texture but can be
difficult to see. Spalling, blisters and cracks are potential liquor paths to the carbon steel substrate.

Thickness measurement

Carbon steel

UTT is done to determine remaining thickness and corrosion rates in the shell, upper dome, knuckle and lower cone.
It is essential good practice to verify the accuracy and repeatability of the measurements. Surface cleanliness and
smoothness affect the accuracy of UTT measurements.

The extent of corrosion damage generally determines if thickness readings are taken at grid points or by scanning.
Scanning data are presented using two formats: B-scan (thickness along a line, displayed as a cross-sectional profile
by assembling many A-scan readings) or C-scan (thickness over an area, displayed as a plan view or contour map by
assembling multiple B-scans). Line-scans define corrosion profiles better than a grid survey, especially if the lines
are thoughtfully located. C-scans are used to investigate small areas.

Reliability of UTT data on CRA overlay or clad plate depends on how the testing equipment deals with the buried
CRA-to-steel interface. As a general rule, all non-destructive testing of corrosion barrier thickness should be
carefully verified, preferably in the actual digester. This especially applies to UTT procedures claimed to reliably
detect CRA overlay thickness because the fusion interface this testing depends on finding is inherently hard to detect
with any UT method.

Thermal spray coatings also present technical problems for UTT: coating density and thickness define how much the
UT signal is attenuated and the coating must be tightly bonded to the substrate.

Thickness of non-magnetic CRA clad layers and thermal spray coatings can be measured with a magnetic lift-off
(MLO) gauge. MLO testing of CRA weld overlays must be determined with a calibrated standard made from the
same materials. However, experience has shown that the amount of magnetic constituent (ferrite) in stainless steel
weld overlay can vary within the same sample, so MLO testing of overlay thickness, even with use of a calibrated
standard, can be problematic.

UTT grid surveys.

Spacing of grid UTT readings should be based on the nature and extent of corrosion in the digester. Grid size also
may depend on whether the inspection is to establish a new baseline condition or simply is the next inspection of a
series of regular inspections. Grid spacing for new baseline inspections normally are spaced at two-foot elevation
steps and every 3 or 4 feet around the ring. Subsequent UT grid surveys can be more widely spaced depending on
operating conditions. NOTE: A ¼” dia. UTT spot reading in a 2-ft x 2-ft grid covers 0.04% of the effective surface.

NOTE 1: A ¼-in. diameter UTT spot reading in a 2-ft × 2-ft grid covers only 0.04% of the surface.
7 / Guidelines for inspecting batch digesters TIP 0402-22

UTT data verification

To ensure the reliability of UTT data, it is recommended that a consistent procedure be established prior to the job to
verify the reproducibility of the vendor's data. All testing instruments must be in calibration. Where feasible,
calibration standards should be made from digester materials. For example, a calibration standard can be made from
nozzle blanks with CRA or thermal spray applied.

UTT data should be verified “blindly” or “specifically”. Blind verification involves statistically contrasting a second
set of readings with the first set; specific verification involves another technician retaking particular readings so the
mill representative can see if both readings match within the specified very tight tolerance (typically ±10 mils).

Verification should include data from different parts of the digester vessel, e.g. shell, top head, bottom cone,
nozzles, etc. and because data from rougher surfaces are more difficult to verify, the degree to which these data are
verified is established ahead of time. Disposition of non-verified data also must be agreed before testing starts.

Where verified data indicates thinning below the mill “flag” limits or where readings are below values predicted by
corrosion rate projections, additional readings or scans are advisable to fully characterize the thinned area.

Surface-exposed cracks

Liquid penetrant testing (PT) and magnetic particle testing (MT) are used to detect and evaluate surface-exposed
flaws like cracks, porosity, etc. PT is used on non-magnetic materials, including CRA overlay and clad layers and on
carbon steel. (Water-washable PT usually is simpler to use for large areas.) MT generally is more sensitive than PT
but only works on magnetic materials.

Sub-surface cracks

Sub-surface flaws include corrosion or debonding behind CRA overlays and cladding; defects in original or repair
welds, and plate laminations. These typically are detected by ultrasonic testing (UT). As already emphasized,
cavities behind a corrosion barrier must be fully investigated right away. This normally requires local
excavation of hidden surfaces and careful surface preparation to repair the corrosion damage and restore the
protective barrier.

Radiographic testing (RT) is limited to evaluating quality of structural welds where required for Code Compliance.

Review and use of inspection results

Inspection results should be carefully reviewed by qualified maintenance personnel with respect to pre-determined
acceptance criteria (typically as described in API 579-1/ASME FFS-1 (Ref. 2)) to determine what repairs are
required to return the vessel to service and to mitigate corrosion. Comparing data from current and previous
inspections defines corrosion rates and identifies new corrosion damage. This information is used to define the scope
and urgency for future inspections and repairs. A copy of the inspection report should go into the vessel file.

Keywords

Batch digesters, Inspection, Overlays, Corrosion, Ultrasonic tests, Thermal spray

Literature cited
1. National Board Inspection Code (NBIC). (National Board, Columbus, OH 43229. www.nationalboard.org
2. API 579-1/ASME FFS-1 Post-construction code www.api.org
3. WRC Bulletin WRB488 Damage Mechanisms Affecting Fixed Equipment in Pulp and Paper Mills (Suppl. to
API 571) www.forengineers.org
TIP 0402-22 Guidelines for inspecting batch digesters / 8

4. TAPPI TIP 0402-03 Guidelines for Corrosion Resistant Weld Metal Overlay of Digester Vessels in Alkaline
Pulping Service (2005), www.tappi.org

Additional references
American Petroleum Institute; API 510, Pressure Vessel Inspection Code: In-service Inspection, Rating, Repair and
Alteration, (API 510, latest ed.). (API, 1220 L Street Northwest, Washington, DC 20005. www.api.org
Loss Prevention Data Sheets 12-6, Inspection of Digesters, May 2003, FMGlobal, www.fmglobal.com
M. D. Moskal,, Non-destructive Testing in the Paper Mill, TAPPI Journal 65 (4): (1982)
Parts of OSHA Standard 29CFR 1910 relevant to aspects of batch digester inspections:
1910.132 Personal Protective Equipment (PPE)
1910.146 Confined Space and Vessel Entry
1910.147 Control of Hazardous Energy (LO/TO)

Additional information

Effective date of issue: July 7, 2008

Working Group:
David Bennett, Chairman, Corrosion Probe, Inc.
Michael Lykins, Smurfit-Stone Container Corporation
Douglas Sherman, Corrosion Probe, Inc.
Harry Dykstra, Acuren Inc.
Max Moskal, Mechanical & Materials Engineering
David Parrish, FM-Global
Michael Perrine, Buckeye Technologies

Appendix A. Batch digester vessel integrity file

The permanent integrity management file on each batch digester should include original design and fabrication
documentation, materials specifications, records of previous repairs and alterations, and inspection reports.

Original fabrication documents include:

• As-fabricated vessel drawings; ASME Form U-1 Manufacturers' Data Report for Pressure Vessels,
• Any other pertinent drawings, radiographs or reports.
• An image of the ASME nameplate showing the vessel manufacturer, design and registration data. The
location of the nameplate on the vessel also should be identified.
• If available, stress analysis reports and ASME min. thickness calculations of head, shell, cone, nozzles, etc.

Operational reports

These describe normal operating conditions and be regularly updated to include details of pressure and temperature
excursions, chemical cleanings, and other significant operational incidents and changes.
9 / Guidelines for inspecting batch digesters TIP 0402-22

Repair and alteration report.

These identify who did repairs and/or alterations; give detailed descriptions of the repairs, and certify compliance
with Code requirements. They should include reports for:
• Repair by welding or other methods, including all overlays (where, when, welding process and procedure,
by whom). NBIC R-1 forms should be filed or a similar report used if NBIC rules do not apply.
• Alterations, including NBIC form R-1A, if applicable, or a similar substitute report.

Inspection reports

Inspection reports document findings from visual observations, NDE and other relevant information. It is very useful
to include photographs, drawings, etc. of areas of special interest and of repairs. Certification documents for the
inspectors and technicians performing the non-destructive examination should be attached to the inspection reports.

Vessel drawings used for inspection reports show the circumferential and elevation reference points, as well as the
mill's designated minimum thickness value for each course or part of the vessel wall.