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API 571 Literature

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60 Ansichten22 Seiten

API 571 Literature

API 571

Hochgeladen von

amine bouizar
Copyright
© All Rights Reserved
Wir nehmen die Rechte an Inhalten ernst. Wenn Sie vermuten, dass dies Ihr Inhalt ist, beanspruchen Sie ihn hier.
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4.0GENERAL DAMAGE MECHANISMS ~ ALL INDUSTRIES 4.2 Mechanical and Metallurgical Failure Mechanisms 4. Y ) ization Rare, change in microstructure 800—1100F AM- CIS and up to 1% Mo Loss of strength, ductility andlor Creep resitance Carbide phases are unstable and decompose into graphite nadules CF ~ Chemistry, stress, Temp, time of exposure. © Siand Al have negigible influence © 7% Cr helps eliminate © Rate increases with Temp! ‘AMO - Random Graph. itnot tensile © HAZ Graph. (eyebrow) = @ iow temp edge of HAZ, results in band of weak graph. Syrs@1kF © _Non-weid Graph, ~ along planes of focal yielding, chainlke at cold workingiplastic deform FCC, Cat Reforming and Cokers V 42:2 Softening (Spheroidization) -Change in microstuctur, carbon phases into spheroidal form. @: “850-1400F Loss of strength and/or creep resist. ‘AM - CIS and Low alloy CF ~ chem. Micro., time and temp 2 © Failure not likely unless under high stress © _Annesled steels are more resistant than normalized ABU - FCC, Cat, Reforming, Cokers and furnace tubes. ‘AMD = Metallography to detect PIM» Prevent b ong term exposure @ elevated temps. Above 1025F—spher. then graph. / Below - Graph then spher. 4.2.3 Temper Embrittlement_- Reducton in ‘coger due to long term exposure @ 850-1100 Not evident at OP, Temp. — possible brite fracture during SDISU ‘AM ~2.250r-1Mo (some C1), especially pre 1972 CF ~Alloy Comp, thermal history, temp and time © Develops more quickly a 900F" more severe at 850F © Notacommon sole actor ce AUE - Most common in HP - RX and het feed EX and hot HP sep's, © Allacks weld over Base Metal AMD - Can be contrmed wi impact testing PIM - Existing Materials - cannot be prevented if impure —_o_ Forweld repairs, temp. reverse by heating to 1150 for 2 hes. and rapid cooling ‘Now Materials ~ limit acceptance levels of Mg, Si tin, Antimony and arsenic i - Monitor by insaling test blacks inside RX (0. Use pressurization sequence to prevent brite fracture 4.2.4 Strain Aging - increase in hardness and strength, decrease in ducilly and toughness: ‘AM - Mostly affects pre- nd (CF —compositian and manuf. Process, © Bessemer or Open hearth process (BOF) © BOF steels killed with Al not suse. AUE - Older equipment ~ avoid stressing or pressuring equip. until metal temp is above brite fracture P/M -RWHT @ weld repairs or consider buttering \iIM = No inspection or monitoring RIM - Blue britteness is another form, Page 1 of 22 4,2.5 8850F Embrittlement - Metallurgical change, loss in toughness, Increase in hardness = Can ocour in shert period of timefrapidly at B85F * AM Affects feritc alloys (400, duplex, wrought and cast 300) at 600-t000F + CF —alloy comp, (Cr content), amount of ferrite phase and op. temp. ‘© Suscept Increases wi ferrite phase © Most refiners limit the use of ferric SS due to this mechanism. © AMD = Confirmed by bend or impact testing — most positive indicator PIM Reversible by heat treatment @ 1100F but wil re-embrite faster UM. Found in the form of ezacking during T/A, 4.2.8 Sigma Phase Embbrittlement - loss of toughness due to exposure @ 1000-1750F ‘© Ferric, austenifc, martensite and duplex = CF= Steel ceanliness and grain size 2 Thicker has lower resistance due to increase in triaxial stress at crack tip, + AUE ~Pre-ASME 1987 ‘2 Auto-rrigeration events 8 Can occur during ambient hydro. + PIM-New materials can be specifically designed ‘© Control operating conditions (© _ Reduce likelihood by PYVHT or warm hycros. + Inspection not used to mitigate. 4.2.8 Creep [Stress Rupture - Slow and continuous deformation under high temps. All metals and alloys * CF ~ material, bading and temp. 1 Increate of 25F or 15% of stress can cut life 50% or more © Most itely in course grained material % Corroson can inerease stress and reduce time to failure + AUE - Found ir dissimilar welds due to Thermal Expansion (TE) stresses + AMD - Initial stages found by electron micro. > Onee ittiated, cracking progresses rapidly © PAM- Minimizes by careful selection of materials and higher PWHT temps. © UM VT then IT and strap readings to assess heater tubes. SUT, RI, EC, strap and replication. © Confer! wi ME on destructive sample S {Grand 1.25Cr prone to low creep dutty © VT for bulging, blistering, cracking, sagaing and bowing «Threshold temps ~ C/S - 700, C/Mo — 750, Cro ~ 800, 304H ~ 800, 3474 — 1000 Page 2 of 2 4.2.8 Thermal Fatigue - Cycle stresses by varying temps in all materials ‘© CF magnitude of temp swing and #of cycles, Practical rule - suspect if temp swings >200F © AEU--Mgjor problem in Coke Drums Bolles = rigid attachments a tubes in SIH end reheater a Cracks initiate on the surface, are wide and propagate transverse to stress, oxide filled ‘+ PIM design and operation to minimize thermal stress and cycles © Reduce stress cone © Consider TE of dissimilar metals © Avoid rig attachments © _ VTIMT or PT for cracking — or external SWUT 4.2.40 Short Term Overheating ~ Stress Rupture -Permanent deformation @ low stress du to Tocal Ofheating of all fred heater tube materials. Bulging typiea at 3-10% ‘CF = temp, ime and stress © Féme impingement can cause + AUE™ Heaters, HP RX, refract. lined equip © _Fiplures have “ishmouth” w/ thinning at fracture. + PIM= Buyner management ané conto fouling deposits o _Tastall bed THC's in RX. + UM=VT, Rand tubeskin T's © IRand heat indicating paint on refractory lined + _ Related to Creep. 4.211 Steam Blanketing - Rapid tube cuptire due to steam bubbles (Nucleate Boling) that jin when ial fow balance is disturbed in W/W and steam gen. Tubes. * CiSand LA Steels (C-F = Heat flux and fluid flow ‘Gauses = misdirected or damaged burners, water flow restrictions Failure due to steam pressure at elev. Temps beyond haop stress AUE-~ Steam generators ~ can also accur in SIH and R/H during SU when cond. blocks steam flow “Always a knife-edged open burst ‘Microstructure shows severe elongation DNB ~ Departure from Nucleate Boling PIM- VF for bulging Properly maintain burners Similar to short-term O/H Can cause NaOH corr. ( gouging) 4.2.12 Digsimilar Metal Weld (DMW) Cracking — Cracking on fertitic side of C/S-S/S @ 510F and up. Due to widely cifering TE Ferric to 300 by 30% oF more arlicularlyif 200 weld is used - Nifilers cioser to C/S ‘Aggravated by thermal cycling, poor geometry and excessive undercut ‘Crack forms at toe of weld on fer. Sido Most common in welds joining tubes PIM Ni based fillers ‘0 _ Install intermediate pup piece. + VI_MT, PT, UTSW for Enviro cracking on ID Rebled to thermal and corrosion fatigue. 4.2.43 Thermal Shock thermal fatigue over short period of time. All metas ard aloys + Usually when cold liquid over warm metal + CIF - magnitude of temp dif. And coefficient of TE © SIS has higher coefficients that C/S and LA © Fracture related to constraint (D + AVE-FCC, cokers, Reforming and HP and any high temp unt Page 3 0f 22 + AIM Surface initiating cracks may appear as “craze cracks + P/N —prevent flow interruptions, design, thermal sleeves to prevent liquid impingement ‘© Highly localized and difficult to locate. PTIMAT ta ennfirm 4.2.14 Erosion | Erosion-Corrogion - E =the mech. removal due to impact protective fms or scales for more cor. «All melas, alloys and refractories. y+ CF -Pure erosion is rare p ‘Rate depends on velocity and cone. of medium / size and BHN of partclesiBHN of ‘materiallangle of impact © Soft Cu and Al are easily worn © Each situation has a threshold velocity above which loss occurs, © Gorrosivty conditions (temp, Ph, etc.) + AUE~allecuip, © Characterized by loss often w/ directional pattern © Failure can be short + ikl — improved design = best mitgated with more corr. Resist. Alloys ‘o Harder alloys, hardfacing or surface hardening treatments, © Impingement plates or tube ferrules © _ Higher Mo for improved Naptheniec Acid resistance + UM=NT, UT, RT for extent of metal loss ‘© Coupons and online manitering © IRferrefract. Loss + _ Specialized terms include — cavitation, liquid Impingement and fretting 15 Cavitation — Erosion by the formation and instant collapse of tiny bubbles on most materials + CF difference between selual pressure and vanar pressures NPSH (net postive suction head) "Inadequate NPSH can cause - Minimum head required to prevent © Temps approaching the boiling point © Solids or abrasives can accelerate ‘+ AUE=Most offen in pumps (casing, impellers) and piping DIS of erfices and CV's ‘AIM Looks like sharp edged pitting + PIN avoid concitions that allow absolute pressure to fll below the vapor pressure © Change material properties » ©. Accelerated by the mech, disruption of protective fis <) + Mmay sound ike pebbles in the pump © Monitor fuid properties VT, UT, RT for oss in suspected areas. ‘+ _ Related to liquid impingement 4.2.16 Mechanical Fatique ~ Cracking due to cycical stresses for extended periods — All alloys ‘© Sudden, unexpected fellure ‘+ Mechanical or thermal loading + GF geometry stress level, # of cycles and mech. props. © Usually iniiates at stress risers / notches © TI,CIS and LA have endurance limits below which this cracking wil occur © EL— Endurance Limit UTS ~ Utimate Tensile Strength = 4 to 5 © Austenitic and Al have no EL (typically 10, 10;) © Inelusions ean accelerate Quenched ortempered fine grain perform better than course + AUE Thermal Coke drums, queneh nozzles © _ Mech, ~ rotating shafts, small Bore piping + AM: Signature mark is “clamshel" with concenticrings call “beach marks" from initiation point. + PIN Best defense is good design 6 Generous radi / minimize grinding marks f remove burrs + M-PTIME ane SwuT © VTsmall bore piping for oscillation © Vibration monitoring E removes Page 5 of 22, 4.2.17 Vibration-Induced Fatigue -Mech. fatigue cracking due to dynamic loading 0° vibration, water hammer or unstable fuid flow. - All Materials © CF Amplitude and frequency of vibration and fatigue resistance of material (© High likelinjood i input load syncs. wii components natural frequency. © Lack of or excessive suppor / stiffening + AUE —socket welds and small bore piping near pumps / compressors © High pressure drop CVs and steam reducing stations © Usually a crack initiating @ point of high stress: © Visible damage to refractory and anchors is a warning sign + PIM~ can be eliminated or reduced by design (supports or dampening) © Vibration effects can be shifted when one is anchored » UM= on-stream vbration or water hammer (visual and audible) © VT-during SD/SU 2 Check supports and hangers on a schedule 4.2.18 Refractory Degradation Thermal insulating and erasion resistant types. Mechanical and Corrosion + Materials include cerame fibers, castables, brick and plastic * CF selection, design and installation © Anchors - comgatible with Thermal Coefficients of Expansion (CE) * ALE ~FCC, Fluid Cokers, WHB and thermal RX in $ plants + A/M-Cracking, spaling, if-off, softening © Erosion can wash away \VT during SD /1R during run 4.2.19 Reheat Cracking ~creeking due to reaxaton uring PWHT or elev. temps. ‘© Most often in thicker componants © LA, 300 and Nialloys + GF ~ material type, grair size, residual stresses and thickness © Requires high stess © Occurs at elevated temps. © Usually in HAZ © Intergranular w/ittle or no deformation. ‘+ ABU — most ikely in thick components with high restraint (nozzle welds, thick piping) 2 HSLA steels very susceptible. ‘© AMD surface breakingor imbedded ‘o_ Most frequent incourse grained HAZ = PM—Design to minimize restraint during welding and PWHT © Large grain less ductile, more susceplble © Notches from welding are frequently the cause © _Avoid sharp changes in cross section. IM-UT, MT, PT AKA.~ stress relief cracking and stress relaxation cracking, Page 6 of 22 } 4.3 Unitorm or Localized Less of Thickness 4.3.4 Galvanic Corrosion - Corrosion atthe junction of dissimilar metals joined with an electrolyte. ‘= Allmeials excluding the most noble. © CF (3) condition must electrolyte, 2 materials, and electrical connection (© Noble isthe cathode, anode is sacrificed, © Farther apart in series the higher the farce of cor. © Relative exposed surface has significant effect © Same alloy can be anode and cathode (old to new) = AUE—any unit typical locations = buried pipelines, ship huls ‘© AMD — depends on driving force of cor., conductivity and ratio ‘© PM Good design © Coatings helpful if noble is coated © Electric insulating bolts sleeves and gaskets © Zn'tosteel reverses at 150F © IM-VT UT ~may be hidden under batt head, 4.3.2 Atmospheric Gorrosion - corrosion that occurs from atmospheric moisture. Marine and industrial most severe, + CF physical location, moisture, temp, salts, dit and $ compounds © Designs thet trap mossture are mare prone © Rates increase with temp to 250F. >250 too cry unless under insulation © Airborne contaminants can accelerate AUE — Tanks and piping particularly susceptible AANAD — general or local, depends on rapped moisture PM. surface prep and proper coating application are criteal IM -VTIUT 4.3.3 Corrosion Under Insulation (CUI) — cue to moisture trapped under insulation oF fireproofing * AM- CS, LA, 300 and Duplex © CF = insulation system design, insulation type, temp and environment © Corrosion more severe 212-250F © Inmarine, CUI temp can be higher than 250F © Cyclc-and intermittent increase rate (© Aggravated by contaminants in insulation. © Airborne Ci and $02 can accelerate + AUE—AIl AM are subject to localized and pitting © 300te CLSCC (© downwind of cooling towers, steam vents and deluge systems ‘+ AMD = older GaSi's contain chiorides + PM mitigated with proper coating and insulation system © IM—VT, UT, Real time forloss. Neutron backscatter and IR to 1D wet insul. Guided wave UT ‘and Deep EF. 4.34 Cooling Water Corrosion - due to dissolved salts, gases, organic comp.'s or microbiological activity. + AM~CS, ALSS, Cu, Al, Ti, Nibased alloys + CF ~corrosion and ¢ fouling closely related and should be considered together Temp, water type, cooling system (open, closed, 1 pass), O2 content and velocily Corrosion and fouling increase with temp. Low velocities can promote corr. —high can cause erosion 300 gets piting. Crevice ang SCC CuiZn gets dezinctication, SCO if NH4 ERW gets weld HAZ corr. Severe hydriding embrittlement of Ti when connected to an anode @or> 180F + AUE —water cooled EX. piping and towers ‘AND - general loss in CS when dissolved 02 PM - proper design, operation and chemical treatment a © Process inlet <135F * Periodic mechanical cleaning of tubes, © CIW should be on the tubeside to minimize stagnant areas. @ eooncae Page 7 of 22 ‘+ IM—menitor CW for ph, 02, biocide resid, temp and process leaks ‘Measure exchanger performance (U-factor) Ultrasonic flow meters 4.3.5 Baller Water Condensate Gorrosion - general corr. and pitting in boiler system and cond. ret. Pring. ‘+ AM-Primarily in CS. Some LA, 300 and CU based + CF—usually the result of cissoived gases (02, CO) © Concentration of gases, pf. temp and BFW quality ‘© Corrosior protection in boilers is bed of Magnetite (F304) © NH4 SCC of CU and Zn due to hydrazine, amines, and NH4 compounds. + AMD. cissolved 02 tends to cause piting. Aggressive in closed heaters and econ. w/ rapid temp rise. ‘© CO2in cond. return systems tends to be smooth, groovy. * PM=O2 scavencing is typically catalyzed NeS2 or hydrazine. © Amine inhibitor mat be required, + IM~ water analysis > No proacive inspection techniques ©__WFMPT for deareator cracking 4.3.6 CO2 Corrasion— in CS and LA when CO? dissolves in H20 to form carbonio acid (H2C03) ‘+ CF — partial pressure of CO2, ph and temp. ‘© Higher pp = lower ph and higher rates ‘© Liquid phase where CO2 condenses © Rales inctease w/ temps. > _Cr not hebful unt 12% + AUE -BFW and condensate systems ‘© Effluent gas streams in H2 pants {2 OH of gens in CO2 pants + AMD —local thinning or pitting, deeper with turbulence or impingement ‘+ PM corrosion inhibitors © Increase ph >6.0 © 300 highly resistant. 400 and duplex are resistant '¢ IM~focus VT. UTand RT where wetting is suspected. ‘Preferential corrosion of weld seams © May affect bottom surface, ‘© _ Water analysis for ph Fe. 43,7 Flue Gas Dew Point Gorrosion - S and Cl combustion products condense with water to form ‘acid and corredes CS, LAand 300. = CF ~ concentration of contaminants in fuel and OT of fue gas metal Bewpolnt of Sulfuric ocid ~240F, HCL ~120F ‘+ AUE ~econs and stacks ofall heaters and boilers > 300 gets CISCC © AND ~CS genera! wastage with wide shatlow pits ‘* PN maintain metal temp > 280F. © _ Avoid 200 in HSRG if C's in environment *_IM-UT econ tubes and stacks, .8 Microbiologically Induced Corrosion (MIC) - caused by ving organisms in all materials © CF - usually found in aqueous environment, especially stagnant ‘© Can grow in severe conditions - 0-1 2ph, 0-235F, lack of O2, hi salinity, © Allergs. Require C, N and Phosphorous for growth © Leakage of process (HC or H28) can lead to massive growth ‘AUE ~ most often in EX. ST bottoms water, low flow piping. FW possible. ‘= AMO - localized pitting ~ cup-shaped pits in CS / subsurface cavities in SS © PM- biociées © Maintain fow velocities © Cathodic protection © Established organisms require complete removal © Coatings Page 8 of 22 = IM—monitor water treatment © Probes: © Monitor EXC performance ® © Foul smeliing water. Page 9 of 22 Soil Corrosion ~ AM- CS, cast Fe and ductile Fe + CF=OT, moisture and 02 avail, sol resistivity, sol type, CP, stray current, coating, and age. © Hof characteristics used to determine soil covrosivity (© sols with high salt, moisture and acidity are most corrosive g © STA’ are more suscepiible UE ~ anything touching the soi [AMD ~ external thinning with local loss © Poor coating is teltale sign + PM—special backfil, CP © Most effective is combination of coating and CP. + IM~ measure soil potential 10 Caustic Corrosion - due to concentrated caustic sats under evap. or hi heat x-fer conditions. ‘© AM-CS, LAAND 300 + Sources ~ neutralizing or reactive additives (some for sufur) and from leaks «AMD =-accelerated in preheat EX, furnace tubes and xfer ines (© Typically local loss, grooves © Localized along waterline © General corosion of CS >175F, very high >200F + PN —design ~ limit caust adequate water flow, minimize hot spots © Allow proper mixing and dilution ‘© Sand 300 dificult to detect with UT + IM= UT scans and RIT © Local loss dificuit to detect with UT AKA “caustic gouging’ or “ductile gouging” 4: i Dealloving - preferential attack of 1 or more constituents failure sudden and unexpected © AM-= primarily Cu's, alloy 400 and cast Fe * CF alloy comp, temp, aeration, oh and time © Hard to define exact conditions + AUE—UG caste piping (© Water service Cu tubes and TS, bronze and mone equipment + AMD ~ color change or deep etching ‘© Can occur without loss or visible changes = PA —change allay comp. “OP, coating * IM-color change — scale removal may be necessary © Bronze appears reddish *Cast Fe appears charcoal gray © ME to confirm extent of damage © Possible reduction in BHN 4.3.12 Graphitic Corr, — de-alloying corr, of Fe matrix leaving porous graph. Loss of strength. duct. & density Usually low ph and stagnant conditions wi hi cone. of Sulfates AM ~ Gray cast FE © Nodular and mailesble cast Fe tend to erumble when attacked © White Fe has no graphite © CF~alloteomp,, temp... degree of aetation, ph and time © Usually <200F © Graphite is cathodic © AUE—waters and diute acids. Firewater in particular © AMD — widespread or local © Mayrnot be visually noticeable ‘© Damaged area will be sft and easly gouged © _ME to confirm = IM=UT—n0 good © Acoutic (loss of ring") and UT allentilion ate youd Significant reduction in BHN PM= difficult to predict @ Page 10 of 22 © Internal - coatings / cement linings © External — coating and CP Page 11 of 22 4A High Temperature Corrosion [400eF (204C)) 4.4.1 Oxidation - 02 reacts with alloys converting them to oxide scale Tost oft in fred eters and boilers * A= all Fe bated, 09,400 and Ni based on comp. And temp, > ¢ GF =temp and alloy comp 9 CS significant >1000F, rates increase with temp. Resistance cetermined by Gr content © 00 resistant 1500F [AUE ~ fred equipment and combustion equipment / piping > 000° [AND — general thinning, 300 and Ni based have a thin, dark scale PM —upgrade IMM monter process condtions oTubeskin iC oI © Lose usually measure wit UT Related o surface scaling 462 ‘Sulfidation - from reaction with S compounds. H2 accelerates « AM- All Fe, 300, 400 and Ni based = all depend on Cr content *Cu from lower temp. + GF —aligycomp,, temp and concentration of § compouncs on Pe besed >500e S Ineeasing Cr decreases corrosion © Sirom enue, soa ane He “Primary fom #25, + AUE™common FCC, ude, vacuum, coke, vsbeaker and HP AND —mostotlen general thinrng although focal and EI6-can our, Usvaly has sulide scale {IMM= monitor process cond foremp and § levels © Tubeskin T/C or IR 0 _UTIRT for thickness. PM + Ak sutfde corsion 44,3 Carburlzation — C absorbed into the metal at elevated temps. Due to the formation of metal carces, 7M =A, 900, cos 8, aa based w Fo (60 and 600) D + CF @)coniions must expostie fo Cabonizing envi, righ temp (yp.>1 1 OOF) and suscepfte materia 2 inialy high rate of Cetus * CSand LA OC forms hard, brittle structure at surface * AVE —most common in on fired heater tubes. Coke deposits are a source of C (esp. during decoke: cycles) * AMD = depth confirmed by ME ©. Siesta rerease n BHN, loss of dutty, volumetric increase possible + PM" alley selection ‘Resvce © atinty in envio. (ower tmp, higher 21S pp) + IN ~intial stages cities to detect v NEE or FMR of atected sutace o Measure magretic permeability of ASS ©. Cracking in atraneed stages —VT, UT and MT © RM severe form s mata dusting 4.4.4 Decarburization ~C3 and LA loses strength due to removal of C leaving only Fe matrix. OS C= time, temp and C actity of process Must be exposec to gas phase Wow C actly “Extentand depth = time and temp. &Shatow not gerimental + AUE anything ini tenp, neat testes or fred © HOCHS senice (HP and Gatroforing) “Hol fomed vessels + AMD - vertes by ME Damage to exzosed surface but can be trough wall ©. Surface tree af C= CS wil be pure Fe = PM control chem. Of gas phase and alloy selection per RP-941 ® > CReMo steels have more stable C Page 12 of 22 ‘© IM-FMR to confirm “BHN —loss of hardness © Related to HTHA 44.5 Metal Dusting — Carb. W/ accelerated pitting- rapid metal wastage ‘ ® may contain soot or graphite dust © AM LA, 300, Ni based ~ nothing is immune © CF process comp., OT and alloy comp. 2 Preceded by Carb. © Complex series of reactions with reducing gases (H2, meth, prop, CO) © Usually 900-1500F; rate Increases with temp. © AUE~primariy fired equipment © AMID — [Link] be uniform but usually shallow pts wth dust 88 and HA frequently local with deep, round pts = PM-~ S (usually H2S) forms protective sulfide — for protection H2S must ALWAYS be present © Aldifusion treatment can be beneficial @ IM-Heater tubes ~ UT most efficient 9 RT for thinning. VT affected surfaces: © Filer elements may show Fe dust AKA "Catastrophic Carburzation” 4.4.8 Fuel Ash Gorrosion - contaminated fuel combustion products depost melt on surface Typically in fut ol or coal W'S, Na, K, andlor Vanadium. Motten salts dissolve surface oxides. + AM~ all conventional alloys in fred heaters and boilers © 50Gr-S0Ni shows Improved resistance + CF ~Concentation of forming sats, metal emp, alloy comp. © Only occurs if the metal temp > temp of liquid species formed. © Rates depend on alloy, location in heater and increase with temp. © Carburization will increase wastage. + AUE~any fred treater or gas turbine with contams in uel © Tube hangars and supports operate hotter + AMD- severe metal loss associated with slagging — 100 to 1k mpy. © (2) layers of scale with the metal surface resembling alligator hie, + PM prevented by blending or changes fuel sources. ©” Bumer design and management © _Upgrede hangars and supports + IM~VTis usually sufficient, git blast to remove tenacious, glassy seale © AKA= hot ash corr, molten salt cor, el or coal ash corr 4.4.7 Nitriding - nard, bitte surface due to hi temps and hi levels of N compounds (NH4, eyanides) *AM=CS, LA, 300, 400, Ni based more resistant (30-80% Ni) + GF 900F + AVE —anylocation but, rare Steam methane reformers, steam gas cracking, NH4 synthesis plants * AMD — usually confined to surface, dull and dark gray © Inlial only with ME © High surface BHN © Potential for erack development © _TTOF — possible micracracking and embritlement + PM —upgrede to high Ni + UM —colr, BHN (400-500), magnetite, EC ©. RT, SWUT for cracking Page 13 of 22 4.5 Environment - Assisted Cracking 45-1 CLSCC-~ envio. Cracking Of 900 and some Ni! stress, temp and aqueous-C @ GF=Cl content, ph, temp, stress, 02 and ally comp ©. Typically >140F Tendency decreases with increase ir ph (usually 2.0 of cracking) © 8 12%Ni most susceptibie + AMD inter andor transgrenuiar 1 Welds typically more resistant due to ferrite phase (duplex nature) + PM design with proper materials, stress relaf Page 14 of 22 4.5.2 Corrosion Fatigue - cracking occur due to combined cyclic loading and corr. starts at stress conc. (pit) © Am—all metals and alloys © CF— material, corr. Enviro. cyelle stess and stress risers (0 Gyclic = thermal, vib. Or TE differential © AMD - britle at fracture, t-granular wi litle deformation ® PM rotating — coating, inhibitors, materials and minimize galv, Couple © De-ateaiors ~ chem. Control, PWWHT, smaoth contours, © _IM—UT, MT, WEMPT / Boilers — UT, EMATS 4.5.3 Caustic SCC (Caustic Embrittlement — surface initiating cracks in pipe and equip exposed to caustic. 45, a = AM- CS, LA, 300 and Ni based (more resistant) «CF -NaGH and KOH solutions, strength, temp and stress © Can occur at low (50-100ppm) conc. © Residual stresses form welding and cols work Rates increase with temp and can be rapid AUE—H25 and mercaptan removal units ‘AMO ~ typically parallel 0 weld in base metal (some HAZ) © Confirmed w ME, 300 typically tgranutar © PM—PWHT very effective (1150F in CS). / Avoid steam out of no -PWHT © IM~Best= WEMT, ET. RT of ACFM— prep wi grt or water biast © PT not effective © _ UTSW for depth, AET for growth and location 4 Ammonia SCC = SCC in Cu aloys due to NHG in aqueous streams ¢ AM Cu wi wet/CS with dry (anhydrous) NEA + GF ~inGu, Zn affacts susceptibility, 02 necessary, PH> 8.5, any temp, resi. Stress promotes. © InCS~<,2% H2), PWHT eliminates, al or 02 increases + AUE~Cuin X's, CS in NHS storage and refrig. + AMD ~ CU— cracks w/ buish color ciled wi corr. Products. Trans or intergranular © _ CS—non-PWHT welds and HAZ — + PM—CU-Zn content <15%, 90-10 and 70-30 nearly immune. C/S - BEN <225, PWHT, prevent 02 + IM—Cu—monitor ph and NH4. VT, ET tubes, especialy at rolls. /CS~ WEMT, UTSW, AET “255 Liquid Metal Embrittlement (LME) — cracking from molten metals in contact w/ alloys 43. ‘Can be sudden. Affects most common MOC + CF ~very specific conditions. Low meting points of 2, Merc, Cad, Cu, Pb, tin © Tensile stress contributes © AMD ~ brittle cracks filed with the molten metal + PM-~ keep ‘em separated = 300 Zn / Cu = bloic, (Mi Strength = Cad and Pb. + IM—MT in ferite, PT in other / RT inside EX tubes + _RM-Nialloys susceptible to similar mech caused by Nr-NIS eutectic @ 1157F .6 Hydrogen Embrittlement (HE) —loss of ductity & strength from atomic H2 causing brite cracking, ‘Can occur during manuf, welding, or H2 charging services, ‘Am ~ C8, LA, 400, precipitation hardenable SS-and some HS Ni alloys GF =(3) musts - H2 at critical conc., strength and microstructure susceptibility © Stress (resid or applied) > HE threshold. H2 from wet electrodes, acid cleaninglpickling, high temp H2 gas atoms, wet H2S,HF and CP Thicker more vulnerable ‘Ambient to 3O0F. decrease with temp increase. Not likely > 160-180F. Susceptibility generally increases with stength * AUE ~CS in wet H2s (FCC, HP, amine, sour water and alky) © Storage spheres, bolting and springs (resid. Stresses) © GrMolf BHN > 235 * AMD ~ usually surface breaking but can be sub-surface. Inter-granular in HS steels + PM ~alloy comp and PWHT © Use lowH2, dry electors © If diffused H2 expected, bake outat 400F before welding © Goatings of weld overlays in corrosive, aqueous service, * IM=PT, ME, WEMT, UT for cracks, RT not useful, Monitor H2 flux. Page 15 of 22 + AKA~H2 flaking, underbead cracking, delayed cracking, H2 assisted cracking and HIC. Page 16 of 22 oa. > 8.4. [Link] INDUSTRY DAMAGE MECHANISMS, 5.1 Ganeral- Uniform or Lotallzed Loss in Thickness Phenomens 1.1 Amine Corrosion ~ general or local in CS in amine treating from dissolved acid gases (CO2 & H2S) 300 highly resistant © CF design and operating practices, amine type and conc, contams., temp, velocity Closely tied to operations of unit. © Most problems form faulty, design, operations or contams, © Mostto least aggressive ~ MEA, DGA, DIPA, DEA, MDEA © AUE~Coker, FCC, Crude, H2 reform, HP and tal gas. Rich amine service and hot amine service, ‘2 AMD -loss morph, depends on velocity. PM - proper operation is most effective © IM=T, UT for internal, UT scans and RT from external ‘© Goupans or probes ~ target hot areas, 2 Related to ASCC 1.2 Ammonium Bisulfide (NH4HS) Corrosion (Alkaline Sour Water) — aggressive corrasion in HP RX effluent streams and in units handling alk. Sour water. e@ “aay 81. ‘+ AM CS most susc., 300, duplex, Aland Ni (more resist) + CF=NHGHS cone, velocity, turbulence, ph, temp, alloy comp. © Rates increase with cone. And © N2, reacts wi H2S in fed for FCC, HP RX and coker furneces, Precipitates @ 120-180F. © Fouling or plugging unless water washed. ® Other AUE air cooled headers * AND ~general in CS, local turb, or velocty. Underdeposit iow / stagnant 9 Cu alloys corrode rapidly Al tubing highly susceptible © PM good design with balanced flow. ©" Keep CS velocity @ 10-20 fps © Use 825 or duplex if velocities > 20 fps © Water wash injection with ow 02 content + IM-review process with engineers to locate possible areas. o_ UT scan and RT profile in high and low veloeives 1.3 Ammonium Chloride Gorrosion = exposure to NHéCI or amine salt deposits often no water. ‘+ General or local but, often piting + AM in > order~ CS, LA, 300, 400, duplex, 200, 825, 625, 276, TI + CF ~chem.., concentration, temp and water availabilty © Can occur > 300 F (water dewpoint) © Fyaroscopic salts —readiy absorb water. These form aci in solution wth water. © Rates increase with temp. + AUE—Crude tower OM, HP, cat reforming, FOC and Coker Fract’s. ¢ AMD salts are white, green or brown. Water wash or stear-out will move, Pittng under sats + PM=timit saits, add water wash * IM =dificul to detect Rt & UT for thickness / coupons or probes ‘© Monitor feed streams 4.4 Hydrochloric Acts (HCI) Cerrosion — very aggressive on most environments + Refinery damage associated with dewpoint corr where water condenses and forms HCL acid + CF ~acid cone., temp and alloy comp. ‘© Severity increases with cone. And temp. © €[Link] LA when ph < 4.5. 300 and 400 not useful © Alloy 400, Ti and some Ni have resistance to cute © Oxidizing agents incraae rate ‘AUE-~ especially Crude and Vac. Units, HP and Cat reforming. ‘AMD 300 and 400 get piting, 900 can get SCC PM ~ specific neutralizing, upgrade or waterwash. IM~ CS general but, local at Cewpoint ‘© UT scan and Rt profile © Process and corrosion monitoring are important aspects Page 17 0f 22 [Link] High Temp H2/H2S Corrosion — H2 in H2S stream > 500F increases severity of sutide ‘s Unitorm loss in hot areas of HP units + AM-inorder—CS, LA, 400, 300 + CF temp, H2 pressure, H2S cone. And alloy comp. ‘© Rates increase with temp and conc. (© GO desul And Hydracrackers have 2x the rate of Naptha desul. ‘© Aly comp. determines sulfide susceptibility © Increase Cr increase resistance. ‘+ AUE found in all HP units (Gesulf. Treaters and crackers) © AMD ~ accompanied by a form of FeS scale, Seole 6x metal loss ‘©. Tightly adhered, shiny scale. + PM=inerease Cr or go 300. *IM=VT, UT and RT or thickness > Verity operatna temps. [Link] HF Acid Corrosion = general or ical can be accompanied by H2 cracking blistering or HIC / SOHIC. «AM—CS, CuNiand alloy 400, LA, 900, 400 suse. o cracking and corr. And not suitable for HF + GF-HF cone., temp, alloy comp., contaminates (02 and S) © CS forms protective FeS in dry erwiro,. velocity and turbulence remove the scale HF acid phase considered separate fram process stream CS'is OK for -3% water <150F. Rates increase with temps and water content. 02 increases and promotes SCC in Alloy 400 FoF can cause severe fouling «ANID local, Generalor severe, Uniform in Alloy 400 (SCG ifno PWHT) + PNM—monitor thickness in areas > 150F. © Prevented by careful operation © Upgrade to aloy 400, if eracki ga000 try C2T6. © _IM= UT and RT for thickness ® [Link] Naphthenic Acid Corrosion (NAC)- high temp corr,. Typ. In Crude, Vacuum and 2 ‘downstream. + AM-CS, LA, 300, 400 and Ni +) CF — Function of neuralizaion number (Napthenie Acid content), emp, S content, velocity and alloy comp. c Neut, #(TAN) = measure of acidity. © Associated wih hot, dry streams oF outs ‘2 FeS inhibi ta point where Nap, Acids dissolve the scale ‘5 Bigger problem in low S crude. ‘0 Normally 428F but, 350-750. 800 in hot coker 66 streams. 5 Acid destroyed by Cat. In FCC and HP RX's 5 2.25% Mo shows improved resistance ‘© Most severe n (2) hase, high velocity and distilation towers * AMD -local pitting or flow induced greoving at high velocities ‘© Gen and ping lo CS, LA and 400 in ow velocities + PM=reduce by blending erude, metallurgy upgrades and inhibitors * IM-RT then UT ‘© Montor TAN and S content of charge and side streams. © Probes and coupons © Monitor Fe and Ni to assess corrosion [Link] Phenol (Carbonic Acie) Correston — used to remove aromatic compounds form Lube Ol + AM-—in order ~ CS, 304, 316, C276 * OF —temp, water content, alloy comp. and velocty Minima < 250F. CS and 304 repid at 450 © 518% phenol very corosive @ High velocities = local corrosion ® Page 18 of 22 AMD ~ general or local in CS PM — proper materials, control phenol solvent chemistry, 2 OlH piping — max. velocity = 30fps IM - UTIRT for thickness. Probes and coupons Page 19 of 22 [Link] Phosphoric Acld Corrosion — used as a catalyst in polymerization units ‘= Pitting and local corr. Of CS depending on water content = AM—in order —CS, 304, 316 and alloy 20 '® CF —Acid cone, temp and contamination . © Nocarrasion If dry. (© Rates increase with temp, © Most corrosion during waterwash et S/D ‘AUE ~ usually found im low flow. PM — material upgrade ~ 304 good to 120F, 316 good to 225F IM UTIRT for thickness. Sample Fe in water. Probes or coupons 10 Sour Water Corrosion (Acidic) - corr. To CS in water with H2S, ph 4.6-7. CO2 must be present. NH4, Cl or cyanides may affect ph AM—S8, CU and Niare generally resistant CF = H2S content, ph, temp, velocity, 02 cane. © H2Scone. Dependent pp 2 >4.5ph, protective scale begins to form. AEU - O/M in FCCnad Coker tracts, With high H2S levels and Low NHA levels AMD — typically general. Local or underdeposit 02 present. SCC if CO2 present PA — 300 below 140F (SCC). Cu and Ni urgrades IM UT or profile for thickness — focus on high velocity and dewpoint = Monitor process and corr. ~ important © Probes and coupons. [Link] Sulfurle Acid Corrosion = general and local corrosion. Severe in HAZ of CS © AM- in order = CS, 316, 20, hi SiCast Fe, hi Nicast Fe, B-2, C-276 ‘* GF acid conc, temp, alloy comp, velocity, contamination and presence of Oxidizers © CS flaw max = 2-3 fps, Acid conc. Min, = 65% + AUE —sulfunc acid alky units and water treatment ‘© Can become concentrated in bottom of fracts. And rebollers * AMD mostly general. H2 grooving in law low or stagnant. Attacks slag © Nostale of rate and velocity are high c + PA” material selcton ard proper deraton @ + IM-UT and RT in turbulent and hot areas © Coupons and ER prabes. 5.12 Environment-Assisted Gracking [Link] Polythlonie Acid SCC (PASCC) ~ normally during SD/SU or op. where air/moisture is present '* Sulfur acids form from sulfide scale and moisture on sensitized (750-1500F) aust, 300, 600 and 800, ‘+ CF environment, material and stress © Carbon content and thermal history have significant effect. L grades better resistance to sens. AUE - EX tubes, Furnaceiboller tubes and siping, and in FCC, HP and Cokers ‘AMD ~IG, typically in HAZ but can affect base metal PM -—flush equipment with neutralizing soda ash or alkaline ASAP or during S/D. Purge with N2 Idle burners above dewpoint '* _ IM—BT for cracking - flapper disk may be needed. May take days to occur 8 AKA~PTASCC, IGCorr, and IGattack [Link] Amine 8CG - aqueaus amine used to removelabsort» H2s and/or CO2 from HG = AM—CS and LA — esp. non PWHT at or near welds, cold working '* CF tensile stress, amine cone. And temp. © More likely inlean DEA and MEA. AMID ~ 1D surtace cracking parallel to weld in HAZ. IG and trans in weld. PM ~PWHT per RP ~ 945 © Upgrade to solid or clad SS or alloy 400 © Waler wash non-PWHT priaf to welding, HT or steamout, © IM= Best = WFMT (git or waterblast may be needed) or ACFMI (no prep) PT noteffective. © SWWUT for depth, AET for growth and locating 84. Puge20 0f22 [Link] Wet H2S Damane (Blistering / HIG / SOHIC / SCC) - bistering oF cracking of CS or LA ‘© H2 blistering — bulges on ID or OD from H2 atoms that form during sulfide corr, Diffuse into the steel an collect in a discontinuity, building pressure. © HIC— interconnecting cracks between blisters, “stepwise” cracking ‘= SOHIC— appear as arrays of cracks stacked on top of each other, perp. To surface in high stress areas. ‘= SSG — from stress in pres. of H2S and water. Usually non-PWHT. A form of HCC from absorption of atomic H © CF —enrironmental, material prop. And stress. © Ph Allare related to the absorption of H2 into steel minimal st [Link]. H cyanide > absorption In sour water. Permeation increases with pp of H2S. H25 >S0ppm H2s dissolved in water. Temp - Ambient to 300F, SCC <180F BHN < 200 WHT ~ for SOHIC and SSC. Will nat prevent blistering and HIC © AUE—wherever there is H2S. ‘© PM~ cladding and coatings. © Water wash for HCN dilution, inject ammonium polysulfides 2 HIC resistant steels, + IM—Review with engineers and corrosion specialists ‘© Sample, monitor streams, especially injections, © WEMT, ET, RT and ACFM. PT not useful. SWUT for sizing. AET for growth and lecating [Link] Hydrogen Stress Gracking ~ HF = from high BHN in aqueous HF © AM SC and LA ‘OF ~ BHN, strength and stress. Increases with BHN (>237 very susc.). time to failure decreases AUE — HF acid service AMD — only confirmed through ME. I-granular. Usually at welds. PM— PWHT beneficial © Use ow-strength stools <200BHN, ©. Gladding and coating + IM—WEMT, BHN. [Link] Carbonate Stress Cerresien Cracking - form of Alksline SCC in carbonate eantaining systems, © AM=CS andLA * GF —stress and water chemistry © Susceptivilty increases with ph. >9 ph at 100ppm, 6-9 ph at 400 ppm. Nom-PWHT = S0pprn > 7.5ph = AUE —equip and piping in FCC Fract O/H condensing and reflux, wet gas compression and sour H20 * AMD — spider webbed, typically parallel to the weld in base metal but can be weld and HAZ. ‘© Further from toe than SSC or SOHIC and multiple parallel. © PM—PWHT io 1150F Is proven. © Coatings, 300 or alloy 400 clad © Metavandanate inhibitor + IM-=monitor ph and CO3-2 in strems, © WFMT or AGFM, PT not useful © SWUT for depth, AET for location and grows. ‘+ RM - Property termed Carbonate SCC 0000 Page 21 of 22 8.1.3 Other Mechanisms 5.1.4 High Temperature Hydrogen Altack (HTHA) - exposure to H2 at elevated temps and pressures. H2 reacts with carbides to form methane. Loss of carbide = lass of strength ‘© AMIN ofder - CS, Mr-Mo, CrMo ‘GF = specific tu meleral, dependant oftime, temp, H2 PP, time and sess. © 900, Sar, 9Gr and 12Cr, not susceptibe in normal refinery eonivns ‘© AUE~ HP units, cat reformers, H2 producing plants ‘2 Boller tubes in very high pressure steam service AMO ~ Confirmed with ME. Causes decarburization PM— Use Cr-Mo products to increase carbide stability IM- Random damage, dificult to detect © UT with velocity ratio and backscater are most success. © VI-forpassibie bisters © WEMT or RT are severly limited © _AET not proven, [Link] Titanium Hydriding —H2 diffuses into i alloys end Zirconium that reacts to form embeiting inyiride phase. Loss of ductity with no loss of thickness. ‘+ CF = metal temp (°185F), solution chemisiy (ph “9 or 8, Neutral with high H2S) and alloy comp. © Galvanic promotes damage. = AUE primary in water etrippere and amine units in O/H condensers, EX tubes and piping "Can happen in H2 atmos. > a50P. + AND - cracking not readlly apparent and only confirmed through ME or mech. Testing © Tubes may not crack untll bundle is flexed © PM —shioud not use Tl in amina of sour water Electrically insulate the gaivanic couple. ‘¢ IM Speciaized ET techniques. Page22 of 22

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