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

 General Damage Mechanisms
4.0 - All Industries

Mechanical & Uniform or Localized High Temp Corrosion Environment-Assisted

Metallurgical (19) loss of thickness (12) 400F/204C (7) cracking (6)

Chloride SCC
Graphitization Galvanic corrosion Oxidation
(Cl SCC)

Softening Atmospheric
Sulfidation Corrosion Fatigue
(Spheroidization) corrosion

Temper Corrosion Under Caustic SCC

Carburization (Caustic
Embrittlement Insulation (CUI)
Embrittlement)

Cooling water Ammonia Stress

Strain Aging Decarburization
corrosion corrosion cracking

Boiler water Liquid metal

885 F
condensate Metal dusting embrittlement
Embrittlement
corrosion (LME)

Sigma phase Hydrogen

CO2 Corrosion Fuel ash corrosion
embrittlement Embrittlement

Flue gas dew point

Brittle fracture Nitriding
corrosion

Creep / stress Microbiologically

rupture induced corrosion

Thermal fatigue Soil corrosion

Short term
overheating- Stress Caustic corrosion
rupture

Steam blanketing Dealloying

Dissimilar metal
Graphitic corrosion
weld cracking

Thermal shock

Erosion / Erosion
corrosion

Cavitation

Mechanical Fatigue

Vibration induced
fatigue

Refractory
degradation

Shyam S Ponnada API 571

 Reheat cracking

Shyam S Ponnada API 571

 General Damage Mechanisms -
5.0 Refining Industries

Uniform or Localized Environment-Assisted

loss in thickness (11) cracking (5) Other Mechanisms (2)

Polythionic acid stress High temperature

Amine corrosion corrosion cracking Hydrogen Attack
(PASCC) (HTHA)

Ammonium bisulfide
Amine stress
corrosion (Alkaline
corrosion cracking Titanium hydriding
sour water)

Ammonium chloride Wet H2S damage

corrosion (Blistering / HIC
/SOHIC/ SCC)

HCL Corrosion Hydrogen stress

cracking -HF

High temperature Carbonate stress

H2/H2S corrosion corrosion cracking

Hydroflouric (HF) acid

corrosion

Naphthanic acid
corrosion (NAC)

Phenol (Carbonic acid)

corrosion

Phosphoric acid
corrosion

Sour water corrosion

(Acidic)

Sulfuric acid corrosion

Shyam S Ponnada API 571

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 850 F to 1400 F

Softening Loss in strength, & or creep Steam, FCC, Catalytic Sample pieces, No replica Minimizing long term Graphitization
of steels after exp in 850F CS & LAS (predominantly above Only by Metallography
(Spheroidization) resistance reforming units suggested exposure to elevtd temp REFER 4-5
to 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 metallurguical changes Loss in toughness and checking by Impact
3Cr-1Mo & High 650 F to 1100 F (Reactors, hot feed / eff heat no and impact test REFER 4-9 NONE
Embrittlement due to long term exp in increase in brittleness testing
strength LA Cr- exch components & hot regulary by removal
temp range of 650F to
Mo-V rotor steels HP seperators
1100F

Combined effect of
deformation and aging at
Susceptible materials
intermediate temp in Increase in hardness and Only for old materials. If
Vintage CS and Intermediate temp that have not been Brittle cracks by Blue brittleness
Strain aging vintage CS, result in strength with reduction in -- SR not possible buttering
C-0.5 Mo steels along with deformation stress relieved.(Old metallography (Dynamic strain aging)
increase in hardness and ductlity & toughness to be done.
equpt)
decrease in ductility and
toughness

Reduction in toughness in
400 Series + FCC crude and using low ferritic steels
some alloy steels due to Bend or Impact testing Cracks seen during TA &
885 F temper Wrought & Cast Loss in toughness due to fractionation trays and and avoid exposure to
metallurguical changes 600 F to 1000 F & Hardness start-ups, Impact testing, & NONE
embrittlement 300 series + metallurgiacl change weldings & Duplex HE embrittlement temp
due to exp in temp range measurement Hardness measurement
Duplex SS tubes range
of 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
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 result in a loss of fracture
Series (with 17 high temp exposure heater tubes etc., 4-17 material is below 500 F quenching. For 347
toughness in some SS as
Cr) + Duplex SS ferrite shall be limited to
a 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 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, +
SS also deformation inspected for pre-existing embrittlement
plastic deformation up and Hydrotests micorvoid coalscence PWHT + maintiain
flaws/defects.
MSOT during hydrotest

Shyam S Ponnada API 571 6 of 39

 Heater tubes, tube
Minimize metal temp+
Operating above creep supports, hangers and
UT+ET+RT+Dimensional Minimize low creep
range, Generally, furnace internals + all Initial stages by
At high temp metal meas and replication, + for ductility+ Creep resitant
Increase of about 25F internals operating scanning electron
components can slowly & PV focus on welds of CrMo alloys for heater tubes +
Creep / Stress All Metals & or increase of 15% of above creep range + microscope Creep damage + Reheat
cont deform under load alloys optg in creep range, Minimuze hot spots on
rupture Alloys stress can cut Low creep ductility metallography, + cracking
below yield stress, time + check tubes for diametric heater tubes and
Remaining life in half failures have occurred in bulging of heater tubes
dependent phenomenon growth, bulges, cracks, process side deposits +
or more, depending on weld HAZ at nozzles + before failure
bows, blisters VT and UT acco to API
alloy. dissimilar material welds
RP 580
(fer to aust)

Thourough design to
Mix points of hot and cracks initiate at the minimize thermal
cold streams, de- surface + wide and stresses and thermal
Result of cyclic stresses
No set limit on temp superheaters or often filled with oxides cycling+Controlled rates
caused by variations in
swings, practically Start-up and shutdown attemporators. + coke due to elevated temp + of heating and
temp. relative movement All materials of Corrosion fatigue &
Thermal Fatigue cracks suspected if increase the susceptibility drum shells + coke drum single or multiple _ Visual +MT + PT +SWUT cooling+ravoid igid attch
or diff expansion is construction Dissimilar metal cracking
temp swing exceeds to thermal fatigue. skirts + steam DRAGGER SHAPPED in boilers+drain lines to
constrained under
200F generators + soot + TRANSGRANULAR+ be provided in soot
repeated thermal cycling
blowers + water wall cracks initiate at toe of blowers+provide sleeves
tubes welds. to prevent cold liquid
contacting hot liquid

Localized deformation
or bulging in the order In fire heaters, VI, IR Minimize localized temp
Permanent deformation at
Boilers+coker of 3 to 10% or more montg, TST excursions+proper
relatively low stress levels All fire heater
Short term over untis+hydroprocessing depend on temp, alloy +Thermography to identify burner management and
as result of localized over tubes and Dependent of other Temp, time and stress are
heating - Stress units+refractory lined and stress level + FISH refractory damage + fouling deposit Creep/ Stress rupture
heating, results in bulging common Materials factors critical factors
rupture equpt in FCC, sulfur MOUTH Failures maintian monitor reactor control+bed
and eventaul failure by of construction
plant accompanied by bed thermocouples and thermocouples +Maintian
stress rupture.
thinning at fractured reactor skin thermocouples good refractory lining.
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 will quickly follow, proper
knife-edge + Burners should be properly
when heat flow balance sulfur plants, H2 burner management to SB can cause caustic
Microstructure will maintained to prevent
dusturbs, individual Short term high reformers & FCC units), prevernt flame corrosion (Causit
Steam Blanketing CS & LAS Water wall tubes failure always show severe flame impingement. +
bubbles join to form a temperatures Failures occur in super impingement. + Proper Gouging) + Short term
elongation of the grain Tubes inspection for
steam blanket known as heaters and re-heaters BFW treatment to over heating.
structure due to plastic bulging
Departure from Nucleate during start-up when prevent restricted fluid
deformation that occurs
Boiling (DNB), Once SB condensate blocks flow + Tubes shuld be
at the time of failure.
occurs Tube rupture steam flow. inspected from bulging.
occurs rapidly as a result
fo short term overheating

Shyam S Ponnada API 571 7 of 39

 NI base filler metals
have closer Coeff of
therm exp to CS & LAS,
For CS & LAS:
If 300 SS electrodes are
Carbon diffusion Cracks form at the toe
CS & LAS welded used DMW shud be
Cracking of DMW occurs becomes a concern Cracking occurs because of the weld in HAZ of
to Aust SS as well locatesd in lower temp
in ferrtic (CS or LAS) side above 800F to 950F the coeff of therm exp the ferrtic material, + MT and PT + UT methods
Dissimilar metal as any material DMW (Ferritic to 300 region + in boilers the Thermal fatigue &
of weld between Aust SS Ferritic / Aust joints between Fer & 300SS differ Support lugs or for surface breaking
weld cracking comb that have Series welds) weld at high temp end Corrosion fatigue.
(300SS) and ferrtic can generate by 30% or more, REFER attachements or cast or cracks.
widely differing shud me made in
material optg at high temp. significant therm exp / PAGE 4-38 wrought 300 SS to 400
thermal exp coeff. penthouse or header
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 All metals & have higher coeff of therm Surface initiating cracks sleeves to prevernt liquid
Thermal Shock expansion or (temp embr) are more difficult to locate , PT and Thermal fatigue
restrained stresses above Alloys 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
cooling procedures to
when a colder liquid points for potential
minimize s/d time.
contact a warmer metal thermal shock
surface.

Increasing hardness of the

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

Pump casings, pump

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

Shyam S Ponnada API 571 8 of 39

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

Socket welds and small

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

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

Imp parameters include

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

INDEX - ALL INDEX -

INDUSTRIES REFINERIES

Shyam S Ponnada API 571 9 of 39

Shyam S Ponnada API 571 10 of 39
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
occur at the junction of
met, Presence of baffles particularly if crevice, groove or pitting but more the noble
dissimilar metals when they are All metals with the
Galvanic electrolyte, 2 different salt water cooling is corrosion, at the bolts or Visual inspection & UT materal shall be coated +
joined together in a suitable exception of most N/A Soil corrosion
Corrosion alloys & electrical utilized.+ Buried welds of different materials gauging For piping, electric
electrolyte, such as a moist or noble metals.
connection REFER pg-4- pipelines, electrical REFER PG 4-65 insulating bolt sleeves and
aqueous environment, or soils
65 transmission support gaskets + galvanized steel
containing moisture.
towers and ship hulls.

general or localized,
Critical factors include depending upon whether or
the physical location not the moisture is trapped.
A form of corrosion that occurs
(industrial, marine, rural); + If there is no coating or if
from moisture associated with
Corrosion rates increase moisture (humidity), there is a coating failure,
atmospheric conditions. Marine Surface preparation and
with temperature up to particularly corrosion or loss in
environments and moist Carbon steel, low alloy VT and UT are proper coating application
Atmospheric about 250F. Above 250F designs that trap thickness can be general.+ Corrosion under
polluted industrial environment steels and copper (REFER 4-69) techniques that can be are critical for long-term
corrosion surfaces are usually too dry moisture or when Localized coating failures insulation
with airborne contaminants are alloyed aluminum. used. protection in corrosive
for corrosion to occur present in a cooling will tend to promote
most severe. Dry rural environments.
except under insulation tower mist; temperature; corrosion.+
environments cause very little
presence of salts, sulfur Metal loss may not be
corrosion.
compounds and dirt. visually evident, although
(REFER 4-69) normally a distinctive iron
oxide (red rust) scale forms.

more severe at metal temps

between the boiling point
Design of insulation
212F & 250F where water
system, insulation type, CS, LAS & 300 SS +
is 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 appearace will be loose
steels. environment, industrial susceptible.+ Location (REFER 4-71) Chloride SCC
insulation or fireproofing. be 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

Shyam S Ponnada API 571 11 of 39

 Monitor CW for pH, O2,
cycles of concentration, maintian process side inlet
biocide residual, temperatures below
biological activity, cooling 135F+ water velocities
Fluid temperature, type water outlet temp, HC partcrly in salt water sys.+
of water (fresh, Cooling water corrosion can contamination and metlrgy of HE comp may
Cooling water corrosion
General or localized corrosion Corrosion occurs in Fresh brackish, salt water) and result in many different process leaks.+ Periodic be upgraded esp in waters Microbiologically
Carbon steel, all is a concern with water-
of carbon steels and other water: If process side temp the type of cooling forms of damage including calculation of U-factors with high Cl cont, low induced corrosion
grades of stainless cooled heat exchangers
Cooling water metals caused by dissolved is above 140F & in Sea system (once-through, general corrosion, pitting (heat exchanger velocity, high process + chloride stress
steel, copper, and cooling towers in
corrosion salts, gases, organic water or brackinsh temp open circulating, closed corrosion Microbiologically performance meas) will temps, + Periodic cleaning corrosion cracking
aluminum, titanium and all
compounds or microbiological above 115F may cause circulating), oxygen Induced corrosion, stress provide info on scaling of tube ID’s and OD’s in + galvanic
Ni base alloys. applications across all
activity. scaling. content (high O2), and corrosion cracking and and fouling.+ Ultrasonic order to maintain clean corrosion
industries.
fluid velocities (<3fps) fouling.& Crevice corrosion flow meters can be used heat transfer surfaces.
are critical factors. to check the velocity of f) CW should be
water in the tubes.+ EC preferebly on U-tube
or IRIS inspection of side to minimize stagnant
tubes.+ Splitting sample areas.
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 Monitor water analyses pH above 6 can reduce
dissolves in water to form
Corrn usually occurs may suffer deep pitting and (pH, Fe, etc.) to corr in steam cond sys.+ Boiler water
carbonic acid (H2CO3). The Increasing temperatures The partial pressure of
when the effluent grooving in areas of determine changes in 300 Series SS are highly condensate
CO2 acid may lower the pH and Carbon steel and low increase corrosion rate up CO2, pH and
stream drops below turbulence + Corr generally operating conditions.+RT, resistant to corr in most corrosion and
Corrosion sufficient quantities may alloy steels. to the point where CO2 is temperature are critical
the dew point, approx occurs in areas of UT angle probe + elbows applications. Selective carbonate
promote general corrosion vaporized. factors.
300F. Corrosion rates turbulence & impingement and Tees where upgrading to SS is usually cracking
and / or pitting corrosion of
as high as 1000 mpy and sometimes at the root turbulence occurs required remove CO2
carbon steel.
have been observed.+ of piping welds. removal units+ 400 Series
Overhead systems of SS and duplex SS are
regenerators in CO2 also resistant.
removal plants

Shyam S Ponnada API 571 12 of 39

 Maintain metallic surfaces
at back end of the boilers
Sulfuric acid corr on
The concentration of and fired heaters above
economizers or other
Sulfur and chlorine species in contaminants (sulfur and the temperature of
carbon steel or low alloy
fuel will form sulfur dioxide, chlorides) in the fuel and All fired process sulfuric acid dewpoint At lower
The dewpoint of sulfuric steel components will have
sulfur trioxide and hydrogen the operating temp of heaters and boilers that Wall-thickness corrosion.+ For HRSG’s, temperatures,
acid depends on the general wastage often with
chloride within the flue gas metal surfaces burn fuels containing measurements by UT avoid 300 Series SS in the hydrochloric acid
concentration of sulfur broad, shallow pits,
combustion products. determine the likelihood sulfur have the potential methods will monitor the FW heaters if environment may condense
Flue gas dew Carbon steel, low alloy trioxide in the flue gas, but depending on the way the
b) At low enough temperatures, and severity of Corr.+ for H2SO4 dewpoint wastage in economizer is likely to contain and promote HCL
point steels and 300 Series is typically about 280°F H2S04 condenses.
these gases and the water Since all fuels contain corrosion in the tubes. + Stress corrosion chlorides. corrosion of
corrosion SS. & dewpoint of HCL depends + For 300 Series SS
vapor in the flue gas will some amount of sulfur, economizer sections cracking of 300 Series + In oil-fired boilers carbon steels +
on the concentration of feedwater heaters in
condense to form sulfurous sulfuric and sulfurous and in the stacks.+ 300 SS can be found using when units are water- and chloride stress
hydrogen chloride. It is HRSG’s, stress corrosion
acid, sulfuric acid and acid dewpoint corrosion SS in HRSG- REFER VT and PT inspection. washed to remove ash if corrosion cracking
typically about 130°F cracking will have surface
hydrochloric acid which can can occur if metal 4-84 the final rinse does not of 300 Series SS
breaking cracks and the
lead to severe corrosion. temperatures are below neutralize the acid
general appearance will be
the dewpoint. salts( Sodium carbonate
somewhat crazed.
should be added to the
final rinse)

heat exchangers,
In CW systems,
bottom water of storage
effectiveness of treatment
tanks, piping with
is monitored by
stagnant or low
measuring biocide
flow, and piping in
residual, microbe
MIC is usually found in contact with some soils. Microbes require water to
MIC corrosion is usually counts & visual
aqueous environments + equipment where thrive. Systems that
observed as localized pitting appearance.+ Special
A form of corrosion caused by Carbon and low alloy or services where water hydrotest water has not contain water (cooling
under deposits or tubercles probes have been
living organisms such as steels, 300 Series SS is always or sometimes been removed or water, storage tanks, etc.)
Microbiologic that shield the designed to monitor for
bacteria, algae or fungi. It is and 400 Series 0F to 235F (–17 C present,especially where equipment has been should be treated with Cooling water
ally induced organisms + Damage is evidence of fouling which
often associated with the SS, aluminum, copper to 113C). stagnant or low-flow left outside and biocides such as Cl, corrosion
corrosion often characterized by cup- may precede or coincide
presence of tubercles or slimy and some nickel base conditions allow and/or unprotected.+ Product bromine, ozone, ultraviolet
shaped pits within pits in with MIC damage.+ An
organic substances. alloys. promote the growth of storage tanks and light or proprietary
carbon steel or subsurface increase in loss of duty of
microorganisms. + water cooled heat compounds. + REFER 4-
cavities in SS a heat exchanger may be
REFER 4-83 exchangers in any unit 83
indicative of fouling and
where cooling water is
potential MIC
not 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
Underground piping be minimized through the
operating temperature, external thinning with reference electrodes near
and equipment as well use of special backfill,
moisture & O2 availability, ASTM STP localized losses due to the structure + Cathodic
The deterioration of metals as 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 combination of a corrosion
drainage, coating type, age, corrosion damage. thickness tools, pressure
metal structures resistant coating and a CP
and condition. testing, or
system.
visually by evaluation.

Shyam S Ponnada API 571 13 of 39

 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 exchangers. UT thickness gauging +
burner mangment to as caustic gouging
concentration of caustic or in general corrosion of crude unit charge Injection points should be
minimize hot spots on or ductile gouging.
alkaline salts that usually carbon steel above 175F Major contributing where caustic is added inspected in accordance
heater tubes, and by A related
occurs under evaporative Primarily carbon steel, and very high corrosion factors are the presence + preheat exchangers, with API 570.+ UT scans
Caustic Metal loss, Metal gouging, minimizing the ingress of mechanism is
or high heat transfer conditions. low alloy steels and rates above 200 F + also of caustic (NaOH or furnace tubes and and radiography can be
corrosion deposits, grooving alkaline producing salts known as
However, general corrosion 300 Series SS. Carbon steel and 300 KOH) strength & transfer lines+ Units used.+ Steam generation
into condensers+ caustic Departure from
can also occur depending on Series SS have serious temperature that use caustic for equipment may require
injection facilities should Nucleate Boiling
alkali or caustic corrosion problems in high removing sulfur visual inspection with the
be designed to allow (DNB) as
solution strength strength caustic solutions compounds from use a boroscope.
proper mixing and dilution discussed in
above about 150F . product streams.
of caustic in order to avoid steam 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 Dealloying is often
and cast iron. aeration, pH and exposure time. 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 and graphitic
structure.b) Component failure components including inspection, even where the environment combination,
or 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

Cast irons are comprised of

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

Shyam S Ponnada API 571 14 of 39

 INDEX - ALL INDEX -
INDUSTRIES REFINERIES

Shyam S Ponnada API 571 15 of 39

 4.4 : HIGH TEMPERATURE CORROSION

Damage Affecting
Description Temperature range Affects Affectfing equpt
Mechanism Materials

O2 reacts with CS all CS & LAS + all

for CS - significant
and other alloys at 300, 400 SS
above 1000F and Equpt optg above
Oxidation high temp depending on General thinning
for SS above 1000F
converting metal to compostion and
1500F
oxide scales temp

Piping and equpt

Sulfur compounds
All Fe base alloys (contains sulfur at
reacts with CS &
incl 300 & 400 SS + Iron base alloys Uniform thinning, or high temp.
other alloys at high
Ni base alloys if Cr sulfidation occurs localized corrosion +FCC+Crude+vacu
Sulphidation temperature,
content is less + usually above 500 or high velocity um + Boilers high
Presence of H2
Copper at lower F erosion corrosion. temp where sulfur
accelerates
temp than CS at high comp is
corrosion
present

Shyam S Ponnada API 571 16 of 39

 Carbon is absorbed Typically above Loss of high temp
CS+LAS+300/400 Fired heaters +
into material at 1100F provided creep ductility,loss
SS+Cast SS+Ni Coker units +
elevated temp while exposure to of amb temp
base alloys with catalytic
in contact with carburizing material properties
Caruburization significant iron reformers+ethylene
carbonaceuos environment or (toughness/duct),
content (alloy600 & pyrolosys and
material or carbonaceous loss of weldability
800) + HK/HP steam reformers +
carburizing material and its and corrosion
alloys decoking cycles
environment. susceptibility. resistance.

Condition of loss of Exposed to high

strength in steels temp, Heat treated
due to removal of comp + Fire, + hot
Potential loss of
carbon and H2 untis, Catalytic
room temp tensile
Decarburization carbides leaving CS & LAS -- reformer, fired
strength and creep
iron matrix. Due to heater tubes + PV
strength.
exp to high temp, components hot
Heat Treatment, formed during
exposure to fires fabrication.

Shyam S Ponnada API 571 17 of 39

 Fired heater tubes
+ thermowels +
Form of LAS, 300 SS, Ni furnace
carburization with base alloys, Heat components +
Generally 900 F to Form of
accelerated resistant alloys Catalytic reformer +
1500F increases carburization with
Metal Dusting localized pitting in (Currently no metal Coker untis + GT's
with increase in accelerated
process stream which is immune to + Meoh refor outlet
temperature. localized pitting
containing C and MD at all piping + thermal
H2. conditions) hydrodealkylation
furnaces and
reactors

Shyam S Ponnada API 571 18 of 39

 Fired heater, gas
turbine,+ burning
Accelerated high resulting molten Va & Na
temp wastage of salts (slags) contaminated fuel
materials occurs Various melting dissolve the surface oils or residue in
All conventional
when contaminats point temp oxide and enhance fired heaters +
alloys used for
Fuel ash in fuel form depending on type the transport of O2 Heater tubes some
process heaters
corrosion deposits and melts of service and to the surface to re- times not affected
and boilers are
on the metal contaminants form the iron oxide due to skin temp
susceptible.
surfaces of fired (Refer page 4-121) at the expense of less than threshold
heaters, Gas the tube wall or temp of slag, but
turbines component. hangers and
holders are
affected.

Shyam S Ponnada API 571 19 of 39

 Formation of
hard,brittle surafce
Loss of high temp
layer on some
creep strength, amb
alloys due to Steam methane
CS, LAS, 300 & temp mech
exposure to HT Begins above 600F reformers, steam
400 SS, (Ni base properties
Nitriding process containing and severe above gas cracking (olefin
alloys are more (toughness &
high levels of N2 900F plants) and NH3
resistant) ductility) weldability
compounds such synthesis plants.
& corrosion
NH3 or cyanides
resitance.
under reducing
conditions.

Shyam S Ponnada API 571 20 of 39

 Related
Appearnace Inspection Prevention
Mechanisms

UT, IR temp Cr is more resitant

CS- Oxide scale,
measurement, + to oxidation at high
300 SS thin black Surface scaling
Monitoring of Optg temp, also Silicon
scale
temp and Aluminum

Process cond Upgrading to

monitoring for higher Cr alloy +
Uniform thinning,
increae in Temp & constructing with
localized+Sulfur
sulfur levels + clad or solid 300/
scales depend on
Temp montg + UT 400 SS + Al High temperature
alloy, corrosiveness
& Profile RT for diffusion sulfidation
of stream, velocity
thinning + PMI for treatment for LAS
& presence of
alloy comp check sometimes reduce
contaminats
for any mixing of sulfidation rates
sulfur and scaling

Shyam S Ponnada API 571 21 of 39

 Intiail stages is
Alloys with strong
difficult + If process
Depth confirmation oxide layer or
side accessible
by metallography + sulfide film formers
hardness and insitu
Increase in (silicon and Al) +
metallography +
hardness and loss Reduce carbon
Destruictive and
of activity of
magnetic based
ductility+Volumteric environment thru
tech (ECT) +
increase + Increase lower temp and Metal dusting
determining
in high O2/S partial (Severe
increased level of
FERROMAGNETIS pressures + adding carburization)
ferromagnetism
M of some alloys + S in small amounts
(magnetic
formation of metal into process
permeability) are
carbides depleting streams of steam/
useful for
sorrounding matrix gas crackers of
paramagnetic mat
of carbide forming olefin & thermal
initialy (austenitic) +
element dehydroalkylation
advances stages
units
RT,UT

Control of gas
by metallography, phase and alloy
damage on gas selection + AS with
exposued surfaces Field metallography Cr & Mo form stable
High temperature
and primarly + Hardness testing carbide & more
hydrogen attack
thruwall + free of (Softening) resistant to
carbide phases & carburization. (refer
CS is pure iron API RP 941 for H2
serv)

Shyam S Ponnada API 571 22 of 39

 For heater tubes
in LAS uniform
compression H2S layer forms
wastage usually in
wave UT + RT for protective sulfide
small pits with
pitting and wall layer to prevent
crumbly residue
thinning + VI + carburization,+ Al Catastrophic
metal oxides and
Filtering of cooled diffusion carburization
carbides. In SS
reactor or furnace treatment to
&HAS local attack
effluent may yeild basemetal may
with deep and
metal particles of sometimes reduce.
round pits.
upsterams.

Shyam S Ponnada API 571 23 of 39

 Blending or Hot corrosion, hot
changing fuel ash corrosion,
Corrosion / slag like sources(minimizing molten salt
apparance CR 100 contaminants) + corrosion, oil ash
Visual + Slag
to 1000mpy.+ Burner corrosion and coal
removal and grit
Alligator hide management ash corrosion +
blasting of water
appearance + for reducing flame Circumferential
wall tubes and UT
water walls impingement and cracking in
for thickness
circumferential localized hot spots. waterwall tubes is
measurement
grooves (Refer + Injecting special similar to thermal
page 4-121) additives into fuel. fatigue aggravated
+50Cr 50Ni are by a corrosive
resistant environment

Shyam S Ponnada API 571 24 of 39

 dull, dark gray
Changin to 30-80%
appearance, intially
Dull gray surface + nickel as it is
by metallography
Hardness usually not practical
only + high
testing(400- to modify process Carburization &
hardness at
500HB), Nitride conditions to Metal dusting
advance stage +
layers are reduce N2 partial
increase in vol for
magnetic, + ECT, pressure or lower
12% Cr LAS +
temperatures
crack, flakes

INDEX - ALL INDEX -

INDUSTRIES REFINERIES

Shyam S Ponnada API 571 25 of 39

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

300 series Surface cracks on

Surface initiated cracks Duplex + Nickel base +
components+ water- processside or externally
casued by environmental Visual + PT + Phase when hydrotesting use
cooled condensers and under insulation + no
cracking of 300 series SS All 300 Series are Usually occurs analysis ECT + fine low chloride content and
in the process side of visible signs of corrosion +
and some Ni base alloys highly susceptible. above 140F, Cracking in cracks with PT after allow to dry thouroughly
crude tower overhead branch and craze crack
Chloride SCC under combined action of CS, LAS, 400 series increase in temp stainelss steel specail surface cleaning and quickly + coatings Caustic SCC & PASCC
condensers + drains in appearance +
tensile stress temp and are NOT increases 300 series, methods + UT + NOT RT under insulation + avoid
hydroprocessing units INTERGRANULAR
aqueous cl en, the presence suscepible. susceptiblity. unless cracks are at design where Cl can
are susceptible during cracking of sensitized SS
of dissolved O2 increases advanced stage. deposit or stagnate. + SR
start-up or shutdown if 300 + brittle appearance of
propensity for cracking for 300 SS
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
Corrosion and the pump shaft SCC but NOT branched + Deaerators: WFMT condensate chemical Mechanical fatigue and
initiates at a stress All metals and alloys. --- such as pits,
fatigue where pitting or often propagation of Cycling boilers : control + PWHT + Smooth Corrosion fatigue
concentration such as a pit notches,
corrosion + Deaerators multiple cracks + little buckstays grinding of weld re-
in 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 base alloys more resitant
Increase in H2S & mercaptan
Form of SCC charecterozed parellel to the weld in adj to WFMT+EC+RT or ACFM + Avoid Steam out of Non
caustic Funtction of removal units, equts
by surface initiated cracks basemetal and also in , surface prep by blasting PWHT, where requd
concentrations caustic uses caustic for
that occur in piping & equpt CS, LAS & 300 SS weld deposits/HAZ+ spider is required, + NO PT for water wash before, use Amine cracking &
Caustic SCC with increase in concentration, neutralalization in
exposed to caustic, primarily are susceptible web of small cracks + scale filled cracks+ LP steam for short Carbonate cracking
temp increase metal temp & sulfuric acid alkalyation
adjacent to non PWHT'd Inergrannular + as-welded UT/SWUT + AET for periods. + proper dsgn *
likeihood of stress levels untis and HF alkylation
welds CS fabrications as very fine Crack growth. oprtn of Inj sys requd to
failures units. (Refer page 4-
and oxide-filled cracks ensure 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 as Zn content decrease
for CU alloys: monitor
>8.5 + residual Copper-Zn alloy tubes may show BLUISH <15% + 90-10CuNi & 70-
pH and NH3 of water
stresses + any in HE + NH3 is present CORROSION products + 30CuNI are nearly
draw samples to assess
temperature, as process contaminat Exch tubes shpw single or immune + SCC in steam
Aqueous streams containing Some Cu alloys in susceptibility of Cu alloys
FOR Steels: in some services or highly branched cracks on servei controlled by
ammonia may cause SCC in aqueous NH3 and/or Any + HE tubes by ECT & VI,
Ammonia SCC anhydrous NH3 may be intentionally surface + Cracking can be ingress of air + 300 SS & NA
some Cu alloys + CS iin NH3 compunds + CS Temperature rolled area is highly
with added as an acid either transgranular or Ni base alloys are
anhydrous ammonia in anhydrous NH3 susceptible, FOR CS:
<0.2%water neutralizer + CS in NH3 intergranular depend on immune, FOR CS: PWHT
WFMT welds inside
cause cracks in strge, refrg & some LO env & stress level + for CS or addition of water to
tanks + Ext UT shear
CS, (Refer 4- refining process non-PWHT & HAZ on NH3(0.2%) + weld
wave + AET
144) welds hardness <225BHN +
prevent ingress of O2 in
storage facilities

Shyam S Ponnada API 571 26 of 39

 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 contact with susceptible
nature. alloys +Ti alloys material+ LME couples
LME occurs in (SS300 rub with Galv Brittle cracks in an other Protecting metal
very specific steel)+ In refineries, Hg wise ductile material, by substrates from coming
combinations in crude oils can Metallogarphy only MT + PT + RT for HE into contact with the low
LMC & Ni-Ni sulfide
Liquid Metal od metals in condense embrittling INTERGRANULAR cracks tubes to locate mercury melting metal, + Once
eutectic that forms at
Embrittlement contact with low brass, alloy400, Ti or Al filled with low melting deposits inside because cracking from LME has
1157F
metling point exch components.+ metal. + Spectrography to of high density initiated, grinding out the
metals + High LME of Al components confirm molten metal affected area is not an
tensile stress. has occurred in pieces. 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
H2 @ critical HF alkylation units, + to improve ductility + use
surface cracks
effect is concentration + storage sphere more Surface breaking, intiate low H2 dry electrodes, +
CS+LAS+400 series PT,MT,WFMT + UT + H2 flaking, underbead
pronounce from Strength level, oftne made with slighly from surface + Locations at bakeout metal 400F or
Loss in ductility of high SS + Precipitation NO RT as not sensitive cracking, delayed
amb temp to microstructure higher strength + High high residual and tri-axial higher to diffuse H2 is
Hydorgen strength steels due to the Hardenable (PH) SS to HE cracks + if source cracking, H2 assisted
300F, decrease + Stesses strenth bolts and strsses, brittle fracture +in expected. + heavy wall
Embrittlement penetration of atomic H2 can and some high of H2 is low temp cracking, HIC, Su Stress
with increasing above springs (>150Ksi tensile high strength steels, vessel requires control s/d
lead to brittle cracking. strength nickel base aquesou envir, H2 flux cracking & H2 stress
temp, not likely threshold strength absrod H2 cracking is often and startup procedures to
alloys. can be monitored with corrosion cracking in HF
above 160-180F (REFER PAGE during electro plating intergranular. cotrol pressursation
specail instruments.
4-152) and crack)+ Cr-Mo sequence + apply lining,
vessels in cladding to prevent
Hydorprocessing units surface H2 reactions in
acracks at welds & HAZ corrosive aqueous
ehen exceeds 235BHN reactions.

INDEX - ALL INDEX -

INDUSTRIES REFINERIES

Shyam S Ponnada API 571 27 of 39

5.1.1 - UNIFORM OR LOCALIZED LOSS OF THICKNESS - REFINING INDUSTRIES
Damage Affects/Critical Related
Mechanism
Description Affecting Materials Temperature range factors
Affecting equpt Appearnace Inspection Prevention
Mechanisms

H2S, CO2 and Visual , UT , UT scans or

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

CS is less resistant. Careful design when

Hydroprocessing Units+
+ 300 Series SS, NH4HS concentration, General loss in thickness, + NH4HS concentrations
FCC Units + Sour sampling of NH4HS to
duplex SS, aluminum NH4HS salts precipitate in velocity and/or localized Localised corrosion at increase 2%wt & above
Ammonium Aggressive corrosion occurring Water Strippers (SWS) determine concentration
alloys and nickel base the reactor effluent streams turbulence, pH, bends when concentration 8%wt + maintain velocity
Bisulfide in hydroprocessing reactor + Amine units + + HE tubes insp by ECT
alloys are more when temperatures drop to temperature, alloy above 2% by wt + low 10 to 20FPS for CS,+use Erosion , Erosion-
Corrosion effluent streams and in units Delayed Coker + + UT and profile RT of
resistant, depending within the range composition and flow velocities cause localised alloy 825 & Duplex SS Corrosion
(Alkaline Sour handling alkaline sour water. Aluminum exchanger high and low velocity
on ammonium of 120F to 150F (49C to distribution are all critical corrosion + HE tubes fouling when velocity is above
Water) (Localized corrosion.) tubes aer susceptible areas + monitor water
bisulfide(NH4HS) 66C). factors to + corrodes admiarility brass 20FPS+Water inj to
for erosion-corrosion injection and flow meters
Concentration and consider.REFER 5-4 and copper tubes. dissolve NH4HS+ for SWS
REFER 5-4, 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 Limiting salts and
General or localized corrosion, are susceptible, in and/or steamout will remove
Concentration (NH3, Crude Tower UT thk for wall loss + chlorides through
often pitting, normally occurring order of increasing Above the water dewpoint deposits so that evidence of
Ammonium HCl, H20 or amine Overheads+Hydroproce Montg of feed streams desalting and / or adding
under ammonium chloride or resistance: CS, LAS, 300F (149oC)], Corrosion fouling may not be evident
chloride salts), temperature and ssing + Catalytic and itentifying dew point caustic + water wash to HCL Corrosion
amine salt deposits, often in 300 Series SS, Alloys rates increase with during an internal visual
corrosion water availability are the reforming + FCCU and temp and later temp flush salt deposits, +
the absence of a free water 400, duplex SS, 800, increasing temperature. inspection.+ Corr
critical factors. coker fractionation units monitoring, + Corrosion filming amine inhibitors or
phase. and 825, Alloys 625 underneath the salts is
probes or coupons are neutralizations
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 + Ammonium
The severity of corrosion HCl acid concentration, genrally below 20 PPM in
condense from the overhead constructed in especially crude and attack.+ 300 Series SS and pH & Corrosion chloride corrosion
Hydrochloric increases with increasing temperature and alloy overhead accumulator
stream of a distillation, refineries (Alloy400, Ni vacuum units, 400 Series SS will often monitoring + Water + Chloride SCC &
acid corrosion HCl concentration and composition. REFER PG water + NH3, amine,
fractionation or stripping base & Ti resistant to hydroprocessing units suffer pitting attack and 300 sampling + Corrosion Localized
increasing temperature. 5-10 neutralization into water +
tower. First water droplets that dilute HCL) and catalytic reformer Series SS may experience probes or coupons corrosion
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.

Shyam S Ponnada API 571 28 of 39

 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 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, absence of
of sulfidation usually results in 400 Series SS, and concentration of H2S hydrocracking units.+ metal loss and may be Process simulation
corrosion H2S concentration 316L, 321 and 347 are Hydrogen
a uniform loss in thk associated 300 Series SS. and the alloy comp downstream of multiple layers + tightly checks for H2S levels
highly resistant at service
with hot circuits in REFER 5-13 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
Localized general or severe
unit to minimize water, O2.
Piping and equipment thinning of CS + Cracking
UT and RT are used to Sulfur and other
CS, Cu-Ni alloys, Alloy HF acid concentration in the HF alkylation due to H2 Stress cracking Environmental
monitor for loss in contaminants in the feed.+
400+ LAS, 300 SS and (water content), unit, flare piping and blistering and/or HIC/SOHIC cracking of carbon
Corrosion by HF acid can result Corrosion rates increase thickness.+ Special Controls on the water
400 SS are susceptible temperature, alloy downstream units damage.+ Significant steel and Alloy
in high rates of general or with increasing temperature emphasis programs to content of the circulating
Hydrofluoric to corrosion and/or composition and the exposed to acid fouling due to iron fluoride 400 can occur in
localized corrosion and may be and decreasing HF monitor small bore piping, acid.+ Alloy 400 (solid or
(HF) Acid cracking and are presence of carryover + HE tube & scales + lloy 400 shows HF. R+ Hydrogen
accompanied by concentration (increasing flange face corrosion, clad) can be used to
Corrosion generally not suitable contaminants including bundles + Small bore uniform loss in thk but not stress cracking in
hydrogen cracking, blistering water content). Above blistering and eliminate the problems
for HF service + Other oxygen and sulfur piping + dead legs + significant scaling.+ Non-SR HF + blistering and
and/or HIC/SOHIC 150F HIC/SOHIC are associated with blistering
Ni base alloys such as compounds are the Flange faces + Iso Alloy 400 is susceptible to HIC/SOHIC
recommended as and HIC/SOHIC. A SR HT
Alloy C276 used controlling factors. stripper & de SCC when in contact with damage.
outlined in API RP 751. required to minimize the
propanizers towers moist HF vapors in the
possibility of SCC.+ Alloy
presence of O2
C276 has been used
where there have been
cracking problems with
Alloy 400.

Crude and vacuum

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

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

Shyam S Ponnada API 571 29 of 39

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

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

General but attacks CS weld Corrosion is minimized

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

INDEX - ALL INDEX -

INDUSTRIES REFINERIES

Shyam S Ponnada API 571 30 of 39

5.1.2 - ENVIRONMENT ASSISTED STRESS CORROSION CRACKING - REFINING INDUSTRIES
Damage Affects/Critical Related
Mechanism
Description Affecting Materials Temperature range factors
Affecting equpt Appearnace Inspection Prevention
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
during operation when air and welds, but can also occur in Polythionic Acid
Sensitization: formation of environment, material, on sulfur levels in the
moisture are present. Cracking the base metal (it is usually Stress Corrosion
chromium carbide in the and stress are required. fuel.+ FCC units +
Polythionic is due to sulfur acids forming quite localized and may not Cracking (PTA
grain boundaries of the + Sensization + 300 H 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 are more susc for (heater tubes, hot
corrosion moisture acting on sensitized 600/600H and Alloy appears during start-up or, cleaning during IMPORTANT , REFER Intergranular
occurs in the 750F sensitization in HAZ , 'L' feed/effluent exchanger
cracking Aust SS + Usually adjacent to 800/800H. in 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
+ Cracking may propagate intergranularly + Corrosion Intergranular
dependent), unless temp are less (piping).+ Boilers and
rapidly through the wall thk of or loss in thk is usually Attack (IGA).
than 750F high temperature
piping and components in a negligible.
equipment exposed to
matter of minutes or hours.
sulfur-containing
combustion products.

All non-PWHT carbon PWHT all CS welds in

Amine cracking is a common steel piping and Surface breaking cracks accordance with API RP Amine stress
term applied to the cracking of Cracking has been reported equipment in lean initiating at ID of pipe 945. also to repair welds corrosion cracking
steels under the combined down to ambient amine service including primarly at HAZ and stress and to internal and and is a form of
The critical factors are
action of tensile stress and temperatures with some contactors, absorbers, areas, + typically parelell to external attachment Alkaline SCC.
Amine stress the level of tensile
corrosion in aqueous Carbon steels & Low amines. Increasing strippers, regenerators welds+ Nozzles + similar to WFMT + ACFM + Less welds.+ Use solid or clad Caustic SCC and
corrosion stress, amine
alkanolamine systems used to alloy steels temperature and stress and heat exchangers H2S cracking + found on PT + AET SS Alloy 400 or other carbonate SCC
cracking concentration and
remove/absorb H2S and/or levels increases the as well as any process side opposite to corrosion resistant alloys are two other
temperature.
CO2 and their mixtures from likelihood and severity of equipment subject to external attachment welds + in lieu of CS + Water wash forms of ASCC
various gas and liquid cracking. amine INTERGRANULAR (Oxide non-PWHT CS prior to that are similar in
hydrocarbon streams. carryover.MEA,DEA, 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
Hydrogen
Environmental present.+ Increasing of a weld. HIC damage can
Effective barriers that Embrittlement +
Blistering, HIC, and SOHIC conditions (pH, H2S concentration of occur wherever blistering or with WFMT, EC, RT or
Wet H2S protect the surface of the Amine cracking &
damage have been found to level, contaminants, NH4HS above 2% subsurface laminations are ACFM techniques.+
Damage steel from the wet H2S Carbonate
Carbon steel and low occur between ambient temperature), material increases the present.+ In pressure- SWUT + Evaluation of
(Blistering / REFER 5-41 environment can prevent crackign are
alloy steels. and 300F or higher. properties (hardness, potential for blistering, containing equpt SOHIC wet h2S environments by
HIC / SOHIC / damage including alloy simlair and also
+ SSC generally occurs microstructure, strength) HIC and SOHIC.+ and SSC damage is most Process / Material
SSC) cladding and coatings. confused
below about 180F and tensile stress level Cyanides significantly often associated with the engieers REFER 5-43
REFER 5-43 sometimes withwet
(applied or residual). increase the probability weldments. SSC can also
H2S cracking
and severity of be found at any location
blistering, HIC and where zones of high
SOHIC damage. hardness are found in
vessels or in high strength
steel components

Shyam S Ponnada API 571 31 of 39

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

INDEX - ALL INDEX -

INDUSTRIES REFINERIES

Shyam S Ponnada API 571 32 of 39

 Damag
5.1.3 - OTHER MECHANISMS - REFINING INDUSTRIES Related
e Affecting Affects/Criti Affecting
Description Temperature range Appearnace Inspection Prevention Mechanis
Mechan pressures. The Materials cal factors such as
equpt Ultrasonic
carbon steel, minimize ms
ism H2 reacts with hydrotreaters using a
C-0.5Mo, methane
carbides in steel (desulfurizer combination
Mn-0.5Mo, formation by
to form methane s) and of velocity
1Cr-0.5Mo, INTERGRANU using Cr & Mo
(CH4) which hydrocracker ratio and
1.25Cr- For a specific LAR & Occur alloysteels A form of
cannot diffuse s, catalytic backsacatter
0.5Mo, material, adjacent to also W & Va HTHA can
through the steel. reformers, is most
2.25Cr-1Mo, HTHA is pearlite (iron stabilizers + occur in
The loss of hydrogen suitable to
High 2.25Cr-1Mo- dependent on carbide) areas 25F to 50F boiler
carbide causes producing find fissuring
temper V, 3Cr-1Mo, temperature, in carbon steels safety factor tubes and
an overall loss in units and and serious
ature 5Cr-0.5Mo hydrogen + Some approach is referred
strength.+ Dependent on hydrogen cracks +
Hydrog and similar partial blistering in due when using to by the
CH4 pressure Temperature cleanup Visual
en steels + 300 pressure, to either APIRP941 fossil
builds up, units, such Inspection for
Attack SS, as well time and molecular curves + utility
forming bubbles as pressure blisters when
(HTHA) as 5Cr, 9Cr stress.Servic hydrogen or 300SS overlay industry
or cavities, swing methane
and 12 Cr e exposure methane or clad at H2 as
microfissures and absorption formation +
alloys, are time is accumulating in service for hydrogen
fissures that may units, are all In-situ
not cumulative. laminations in adequate damage.
combine to form susceptible metallography
susceptible the steel sulfur
cracks. to HTHA. + for fissure
to HTHA at resistance +
+ Failure can Boiler tubes cracks (very
conditions decrease in
occur when the in very high limited) + NO
normally partial
cracks reduce pressure AET

Shyam S Ponnada API 571 33 of 39

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

INDEX - ALL INDEX -

INDUSTRIES REFINERIES

Shyam S Ponnada API 571 34 of 39

deg F deg C
0 -17.78
10 -12.222
20 -6.6667
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
emp emb) & 650-1100F (885 F) but occurs in 2.25Cr-1Mo steels & 885F occurs in 400,300SS & duplex HE tubes