571 Book Rust Busters1

8/6/20L0
Module o Introduction
ClassAdministration
Scicdulc
.
Classstartsat: =Endsat
.
Brcaks: z\boutevery | - % hour
.
l.unch
One hour - Breakat
[,veningsessions
areavailableif you want.
Rcatroom!
\bur kcyr to clrrr succcsr:
.
Ask Questions- We arc hcreto leam!
o
Participatcin thc discussion- Shareyour stcies
.
Refrain frun profanity
.
fiach niSht review ccncepBooveredin chss
'frcat uhcrs right...inchding thc "Chump"!
o
.
llave fun !
Thc Run 8urtcfl
,t
'o\
Module o Introduction
|.,ffA{-S
Intnxluction
lte API 5Zr Tert Or,ewrfl
RctrncryMstdirlr of Connnrction
thtigrc' Strc!! corrcion CrEhiry (SCt) & HydroFtr
Modulco
Moddc I
Mdlub l
Mddco
l\y r:
Rwiov Malulec e,3

t Iith TemprrtuE Corrosioa
RrfincryOperrtioru lol
MqtuL 4
Modulc I
Dry I
r
.
Hil.h Temp.r.ture (bmion (ootinutd)

C*mnl Drmagc Mccluninru - All loAEtri.
Refineryopcrationrtor
Moduh4
Dlodub s
Moduh 8
Dry +
.
.
lJnifr)m or lnslizal krss of Thic&n'la

(lencral Damatc [techrnilDr - nrfning Indlrtry
R.cfincryt)pcntionr ror
Mfllulc 6
Mqlul 7
Modui. S
D.y S!
Puttint it All ToSetler - Prmesr Unitr

Reriew of aI Modulei
Modul8
Dry 6:
TL|stPreporsti'otr
'fest
MotIuIe9
TheRurt Busterr
,"\
Day r:
.
.
.
8/6l20LO
Module r - The API 57r Test Overrriew
lnlroductior
o What to bring lbr the API tcst - llring sweral perrcils,and your brain. lhis is an cntirely
closedkxrk tcst, and therc are no cnlculationsthat requirea calculator.
. What to expect- By my Estimates,about 75% of thc questionsrcquie deductivc rcasonint.
Ihe other 2595otthe questionssre strsight out ofthe API 571 document.
. I low to preparc. Pa.ssing
thc test requiresa basicknowlalge ot:
o
Mctalhrgt
Thcoccbnicrofcortocimmechaoim
Corrmioo mcchmisos spccific to vrrious uniti,
o
. ltis classWILL NOT teachyou the test"but it will adequatelyprcpareyou tor it. We will
cover thesethreeareasin class.
o Rcadingthe c"ntireAPI J7l is not sunething wc will havetime to do in class. -that will bc
yur respnnsibility.
. Most of this materialy<x will LEAXN antl undcrgtand.Howevcr,therc is still r smalt
amountof dsta that will simply requiremerxrrizslion.
llE Rut Butm
Module r - The API57r Test Ovenriew
lntrudrcti,ol
orrDrs
.
.
.
Prior studentssaid they wantedLOTS of daily tLsts,so that is whst you'll get.
Daily testsstartout easy.
Towardthe end of the week daily tcstswill be more diffifllt. Is not thc materialthat is
diflicult, it's the wny its worded.
t.
z.
J.
,t.
Many of the test questionswill be, "What will be the BEST inspeaion method..."
.[his
is discussedbut not specifiedin the 57 | ,
'festquestionswill askyou wh6t is NOT (useof thc negative)the best . . ...
'l'cstquestionswill not bc specilic. For exampleif thcy arc retbrringto Chnrme
contentin an alloy, they may usethe chernicalsymbol of "Ct'' rathetthan say
chmme.
You bctter know all terms,suchas l{ygroscopic(absorbswatereasily).
,1
8/6/20LO
i'\
Module z - Refinery Materials of Const:uction
Prrt t
I itroduii[
2
Slc6l
(liulm
C'agl lm
{
I
C Mo Stcl
('r-Mo Stal3
Killd stccl
Startrleq!StRlt
stccl
Pr n ll
t.
Ho
9.
:itrcrs Rcliaing.
l0
Areding
||
lHrydrcgmtio.
Prrt lll - ()cnl

Prri lV - (;lcrrt
Slel aDd Crl
lm
i]bfli:
and mlzng
Corrclor
of 'fcrrr
Tlpr
'nr Rurt 8u!t6r
,, rh .
,
l1
Module z - Refinery Materials of Constmction
Introductior
. :itcl is a matcrial comptncd primarily of iroo. Most slccl conlsins morp lhan (X)o/oiron. Many
lypcs of cartxm stecl (CS) contain more lhan 9'9cloiron.
- ,l \
stccl-lrn+cata
\i"t
&
All typcgof stcclcontaina sccondelcmant- carhrn. ManyothcralloyingelcmenBrre uscdin
moslstccl,but iron Nndcarb<rn
arcthconly clcrnc'rtstbundinALL stccll Thc pcrccntagcof
carhn in stcclrangcsf'rumjust above0% to appmximately2%. Moststeclthavcbetwccn0. 15%
andl%carbon.Stcd with lcsscarb<nis morcllcxiblc (ductilc)thm high-carhn sled, but it ig
alsowcalcr. As thc cartxmcontsnl incrcascs,so docastrcngth,hardncss& brinlcncss.
Whcnslcelrsmade.the rrondissolvesthc carbon.Approximatcly2o/ocubon is thc mostlhst crn

hc dissolvcdin thc inrn. l}c lbllowing tigureshounthc relationshipof stcclto crst ircn. l-hc
ditlercnccis primarilybascdon thc cartrunconterrt.
Steel
2o/o
ic
li Carbon
ThcRust Buts!
'i
Cast Inrn
8/6/2010
Module z - Refinery Materials of Construction
(hrton F,quivalcnt (CE) of a stoel alloy refers to mtthod of mtasuring the wddrbt[ty
of the alloy, boscd on the chemical ctmp<xition of the allrry.
l-lighercnncentrationsof carbonand other alloyingelementrsucha.sruu8aog1E"

chromium. silioon molybdenum.ranadium- cpppr.and nickeltend to incrcasetlre
hardnessof the HAZ and decreasethe weldabiliw of the material.
The resulting equivahnt carbon cocfficient allows the alloy to be categorized alongside plain
,:arhrn,$ecle and have their weldability ompared with thcm.
CE (Carbon Equivalent) = C +Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/r5
Steel
0Yo
Cast Inrn
I
2V.
3Yo
9( Cerbon
Tlt Rurt Bullcf!
'.?|,
|:il
Module e -Refinery Materials of Constmction
Alloying Elcmtr - Most stcels contain other ingrcdicntl in additim to imn and carbon. Thcse
ingredicntsare commontycallcd alloyrng elcmenB. M(xt of thc alloying clernentsin stecl arc
prcsntin smail amount,but thcryh|vc I grcrl cffcct on thc propcrticr ofthc stccl.
Mctalr can bc sclcctcdfor thcir mochanicalpropcrtics,suchas:
.
.
.
.
.
.
Strcngrh- Ability to wilhstandlords

Ductility - Tc{dcncf to bulgc rr tcar ratherthm to burstor brcat
Ioughncss- Ability to absorbimpalr without britt c Facturc
llardncas-An indicatorofgoodwearresistance
Elasticity- slight dcformationis rccovcrablc
Crecpstrbility - bw llow ratc undcrload.
Metalsand thcir alloys are alsosclcctcdfor thcir chernicalandphysicalpropcrlics,suchas:

.
Oxidationrcsistancc- tor scalingrcsistanccat elcvatcdtcmpcratures
.
Conosion rcsistancc- For dutability undermany advcrscenvironmcnts
'Ihe RBt 8ust6
8/6/20tO
f]%
Mctals and thcir alloys also must bc selcctcd 1'orthcir t-abricationcapobilitics,

rncluding:
Weldability - Ftr casc ofjoining and alloy ovcrlaying
Formablc - Drrwing, bending, upscnin& and rulling
Caslable - lix maling complex shapcs.
Machinablc - (lutling shcaring and grinding
I leat treatablc * Pcrmits changc of mcchanrcd proprtica.
)
)
!
('rrbor Stccl
l,css cxpengivc
Fcweralloys
Fcwcr spccialpropcrrics
,llloy Stccl
>
>
>
Mora expensivc
Morc alloys
Spccialpropcrtics
Thc Rutt Btstdr
fh
Stccl - is a gcncral term ussl for iron-basedalloys containing inm, cartxn and ohcr alloying clcrncnts. Ilrc
carboncontcntof mort rcfincry stcclsis betrwcn 0.03% to 0.3O% to Bssurductiliry and wcldability.
(lrrbor stccl - Sincecarbonstccl(CS) is typic8lly welded,the carboncontcntmust bc reluivety low,
bctru:cn0. I i% ald 0.35 %.
(lut lror - lron ( Fc) ac{ounB tbr nrcrc thrn 957c of thc alloy mat rid, whilc thc main alloying elorrcnts are
carbon(C)andsilicon(Si). lhcamounlofcarbonincastironsisl.l-4eh. Clstrronstcndtobcbrinlc.
With its low melting point, gmd tluidity, castability,cxccllcat mrchinabrlityard uar resistancc,cart ironr
haw bccomca cngrnctnng malcrralwith a wi& rangeof applicatiom.
C'-MoSlccl-Thisisoldtehoologr. Inthepost,itwasbclievedtharC-l2Mosteclhedbnerresistrncc
than carbon steel to hrgh-temperaturehydroget anack ard was otlen specified in hot FI2 (hydrogen) scrvice.
llor,r,tvcr, tlrc ltmg-term exposurctrnhigh ternpcratureH2 scrvicc is now qucstiomblc.
C-Mo stcclg,cxhibit improvcr!high-tcmpcraturcslrcngthand crecprcsistanccovcr carbonstccl, capociallyst
temperatuGtbctwcnt00 - 100F. flowever, molyMcnum aridition providesNO signrticantincrcalc n
corm3ron resislancover carbon slecls.
'It Rurt lutter'
i '&
8
816/20rO
Module z - Refrnery Materials of Constmction
provrdcasstrst4llory.lnctrlity antl rcrlurcqlthc hkclih<xxllir tcmpcr l.lnbrrnlcrncnt.

Cr-Mo su:el wtth less than .l% Cr provr& rnly a mrxlcsl Incrcrsc rn cun\tkxr resrstancrover CS. Cr-Mo
slcclt contdning up to 9?6 Cr arc gerrllty rua c6t ellbc-tivc lhn CS .t tempcrrturE! above 9(x) F.. Sec
the Mtxftlied Mc{rrrmy curves(pg +lll) &, Coupcr-Grrman!'urv6 (p8 5-15). Also sc the Nelsoocurvc
on pg 5-5t.
Gcsenl sdc - Chnta addlton- fl'c ad&ln dafu

A7'1 Cr (Chro;dta)
Io,rnd lo gaUtlu ctrbn aigrdlaa ol ,hc g?dr bo,tad6rla,
to a d
olloy ho ba
Ttlc Rud Burtdl
lair1
I
Cr-Mo Slccl
rYpc
%c
Carbon Steel
1-.3 %
%Cr
%Nt
% Mo
2.25 Cr
o.$ Max
2.?$
o.5
5cr
o.r5 Max
o.5
9cr
o.15Max
4-6
8-ro
l.o
ThcRut Brat6
8/6/2OLO
{"i%
Module z - Refrnery Materials of Constmction
Killcd stccl
I'hir ir "clem stlrl- with minimd wrdr ud incluionr. KilH stccl is F(drrcd whib rh. moltcn stcel ir still in thc
lirmre Jurl fru to bcint poucd into a mold. A dcoxidizing atnl ir illdd to rcmovc gr.scB,srrh ar c.abondioridc
as it ir b.ing pourcdinto thc moH. Ihc rcgljt of killcd stccl i!. prcdrr,.lthat hs morc rnrl'orm chcmicalsontrxitioo
andpropdrisr. ()m imprtafi result ig thc krllod stcel her grcalcruil'miry m mgarxp to corrsiw rttek.
'ftp
flr dcorrdizing agmt would rcult rn quienng lbc powing opcratron.
nrch would likc quicily in thc mold, hcmc,
rhclem KILLED STF-EL.
Bcocfitr:
l.
2.
Minmal voidr arxl irrclusiom, ard

Mfi? M6ivc
rcslstut.
Thc Rurl burtd
r'"''\
Module z - Refrnery Materials of
Dwint dr stccl mrking proccq oxytd nry bccans rli*r$rcd in tho liquit racol, Drrbg solidifrc*ioo. dro
dirrolval orygcn ca! cqnbir witi cu&n to ftm czbrn mxi&
bubbhs.'fnc cr$oo ir addEdto tlrc cccl
aam alloying clcrrd. Ibc cahr oomri& hrbblcs arc oftco rrycd in dta caltir4 andcstr aci ar initi|lioo
pulr fr teilw.
Hc Xilltd Srcb rrt Prodrcd ud Ttcir Acvrrtryor
r Ftmtim of tlrc csrbonmxidc
bubblcrcao bc climindcd tlrmgh thc additim of danidising Egcnt!$Eh er
rlnniriur
rrd rilku. ln thc crsc of alurunium, thc disrohrcdoxyt. ru6i! with it to form aluinium ori&
{Alumina Al:O!). It fmutrm of alumur mt only prwcntr thc lbrmrtion of bubblcr u prxolty, hrt Sc tiny
partrclcr or inclwions also pin grarobflDdsric &nnB hcrl [cabncrn ptrcsrcr, prevalug gratngtow6.
o Alminum b a bctLr gran rcfining clcrmnt lhan silicon (it mal(ertighEr/smdlrf gratm).
Hor lilhd h tinGd ??

. TlErc arevriationr uf thc pnxess,wbich ar! tenndscmi-killcd gcel, rimmedsteelandcuppedsccl. Thcsc
lariantt nay rchicrc mly p{rtrsl {tr noc d all) rcrultr of firlly tillcd slccl!.
''ih
10
8/6/2070
Module z - Refinery Materials of Constnrction
Str|llcs Slccb - l'hrs rs an alloy wrth flt lcrrt l l.5% Cr. fhcre ar* MANY drllbrrnt gradcsol SS.
l hcre arc lbur categoriesof SS that are charartcnzcd by their rnaallurgicsl Btructureat flx)m tcmpcrsturr:
.
Auslenrtrc
.
lerrlttc
.
Mdrfisltic, an{l
.
Duplex.
,ft-1
.+aI
*1
.f'
l'errtrc - Founrl
rnt'"rt.-,1'i1un-o,-;**doo**.*$,rr*lornufu4;*mpu
\urrcnitic- thrsrsrhc .F .{
normagncric.
are{{)5.{)e. {10.{42.
und {;16.
Mrrtcesitk * A melc{rsrtr ste-turE tirund rn srrnc ,lO0 series SS. llat trErhnl anrVor uclding tbllorrrcd
b1'raprdcurlrng can pnxluce this gtnroturern carbonard lor alloy stccb. Exampb3arc 410. {10S, itl6, 't2O,
{.10A. 140 tJ, and.l40C.
slructurE. Comnon typca ar. ?2O5,23o4 &.
l)upla - A t'amrly of SS thsf {jt'nlrin r mixcd luslrnitic-ttfiitic
2507. 'fhc wcldr ol'l0O sricsSS may also cxhibrt a duplcx $lrul'turc.
-fhc nut burt6
Module z - Refrnery Materials of Consbmction
Tr?
%c
%Cr
%Ni
304
(Austenitic)
o.o8 Mex
18-2()
8- rz Max
304L
(Austenitic)
o.o3 Max
18-eo
8- rz Max
316
o.oB Max
r6 r8
to-14
4o5 (Ferritic)
.o8 Max
11.5- r4.5
o.5 Max
4ro
(Martensitic)
o.15 MaJ(
r1.5- t3.5
416
(Martensitic)
o.l5 Mil)(
L2-14
Duplex
o.o3 Max
18-eo
3-7
% Mo
2-3
l-3
i 't
11
816/20to
f"\
Module e - Refinery
Materials
of Constnrction
o
Prra ll
llor Slccl rnd (-zrt lmr Dillcr
ll rs tmponarn to understanl the rlillbrcncc bctwen slel and casl rron.
Whm stcel rs prtxJucal.the carbondrssolvesrn thc irtn- Eventually,as )ou
adl cnouglt carbon,thc irm canmrtdrssolvcall ol'rt and sonE ol'thc carbm
precrprtalas
oul.
Stecl is inn wilh th. cartm in silutroq which tr,curs below I 6 - 2%. Carl iron is rrsr in which scrrc of
thc carboo has prucrprtatal mt and appcan ai llrk6 (x liulc sptrcr6. TlE cllirts of thc precrprtatcd
catnn are both good and bed.
fhc gtxtd - f'ttc llslca providc a cushioorng ell'er,r lbr irtn when ,t recarvql high comprelsion lo.&. n.
Dod- I}|e tlalcs makc thc (nalrirl m<re bflnlc than stccl, ard har very pflr stlngth whcn 3ffichcd in
tcnslon. l-hc prcciprlaledflakesncouratc the lbrmatronof cracksand cawc breekag,c.
ThRult Buttn
f""\
ee
sbesRelirri4 - (PoawctdHcrrTrc+marr-PwFI) 1--
r--r-5q**1'
Stror relieving is pnmlrily pertbmcd !o rclicvc stascr that hrvc bccn rmport[Ob iccl dE to lorming
rolling, mrhining, or weldrng. Ihc pnrccssinvolves hcating thc stccl to a prorxtablishal tcrnpcraruE
kng enrugh to rqJuc.eresrdttd sttesscso an acrccgablc lcrcl. Itir ie a trmc ard terperaturc dcpcndcrn
o;rration, which is tbllowcrl try slow cooling to svoid crcationol'ncw sltcs3rs.
'lhc amountol'rcsidul sr6r playr a cntical rolc rn tlcterminrnSits ru$egibility to marry
t'ormsof strcas
con6ro{r crar:king(SSC). fhcrt'tbre, strcssrclievrngcan bc spouitiul to improv ! nulcnd's rcsisuncc
to a oartlqulu corrogionmechanrsm.
<lqeoctras
l"hts is a lbrm ol' hed treatrnent that uscs raprd ctnling to rnatc mclal harder srd strongcr, Honrever, it
also males il morc trinlc and less ductlc. {.}uro*hing can bc &mc l'rom any clevaled temperaturc.
llowevcr it hardncss is rmpot'tant. thc malcnal rlruuld be heated to a ternpcraturE abovc thc transfcr
remprarure
mngc.
The Rwt Busten
i'h
L2
816/2OtO
h
Module z - Refinery Materials of Constr-uction
ol*--
emdh3rd
mujizinjcan
b{h bc dclirsl ar hcatingI nErd lbovc a cnt&d tcrnpcrsnn and slnrty curliog
rn rrdcr to obraror mllcr rutcnal. Jrd ac a t'Bct$nsh puircr a herd Inrl skp c(x)ling pwc*rcr pnrda r
rulla ul w,xc dwtih pdt.
Amli4ir
thr involvcr hcuing a marl arl than slowly rcduing thc mling
a crntrulbd ctrling prwg
lt i! cffiilnooly
m a trvcn of funre.
tcmpcrarurc to anain a hi3! rlagrcc of rthcrr.
In an'Edrng dE mdrl is 6rg hcrtcd rbryvc thc tsrycr tralsfrrmaioa
tcmpcrrturr Nrd lc0 lo so* d frr
tmpcranr fir a pcnod of tnrc. llrcn tlr tmpcmhrc is slowiy knercd to cu{ thc nrdd.
Nanrlbiry
- lhis involrrs a m(rc rapd cmlrng pacss tho aunling.
D
)
>
Slow c'rxrlingpu;css
Soltcns and urcatcru mctd
('awcaducrility
>
Reducg intrrnal strJse3
)
Rapidcrnlint procat
)
Har&nsandstrcn$hcnsmc[l
D Causcsbnttlclx
> Caucainlernrlstrcass
D Increag chanccsof crackine and dirrdion
Thc Rurt Buttcrt
,.h
1
Module z - Refinery Materialc of Construction
t:ffect of Grain Sizp - Grain sie hrs ! profoundelfcct m thc strcngttl har&rcasbrinlenessmd
ductilityof ms{all
Pnccl
Anrcottng
Normoltda
Qucncung
Mtttod
Slowcooling poces
This involv! a morc raprd unling proces
thanannealing
L"te"
Rr3Lil|lccto
Frrta.c
Easy to tcar,kcal ,r
Grain Sizc
tirr'turc.
Sfiull Grain
SizD
Highcrresisunr to
tiacture.
Rapid cooling proocss
ALE
.fhe
GnirSirc
(take it easy)
Ruqt 8ut6
i''"1
13
8/6/2010
,\
i4{^'+
Dchydrogcnrtiotr - (llake Out) - Outgassing
llcat frcamc'|t is rxxmally applicd to stecls prirr to rcpair welding of refinery cquipmcnt
crp<xcd to scrvicg that csr causc hydrogcn-induccd crautin& Ilrcgc scrvices includc wct
ll"S scrvicc, higharcssurc/high tempcrature hydrogen scnicc, and aminc scrvico, ltc
typicrl proccdurc is to balc<rut any rcsidual alomic hydrogcn in thc stcel by hesting it to
400 F and holding t'or 2 - 4 htrurs. T}c procedurc is intcftlcd to help avoid dclaycd
hydrogcn cracking during or allcr rcpair wclding
Thc RrBt Bwtd
f'T\
Module z - General Corrosion fips
o}--Test Your Knowledge
Ttre Rust 8u'tffs
i1
L4
816/29ro
"h
Prrt lll
Wcrvs. Dry rxmxion

'Ihc prsivc hycr
Facton which cfti:c1wei cor<xioil rst6.
Effcct of Oxygcn Conccntration& Tempcraturcrm Crrrosion Ratc
(irain txrundarics- lnlcrgrnnulucrrking
llH of HAZ
fhc Rutt Sutd
.:.-
Module e - General Corrosion Tips
Wet vs. Dry Corrosion

a
Corrosion can be dividd into to distinct pntcesses.

Wet Corrosion
o Eletlruchemir:al reactions which rcquire an elec'trotyte to be
preqrnt (ucually water).
Dry conuion
o Chemical reactions which occrurin the absenceof any electmlyte.
f'"'B
15
8/6/2OrO
t'"\
Module a - General Comosion Tips
Damageto the PassiveLayer

When the passive laycr is dissohrcd or disnrptcd at a given point a
very active antxlic site ie set up which catrsBactlerated cormsion.
Reduction of lonr or oxlgcn

\/
I
Metd lonr Fe++
\/
C- r th o d e cethodet
tr'{fi
/
-^-^L-,
Anode '***--+cathode
î}o*=-
{ .q
ffi'o""
Module z - General Conosion Tips
GalvanicCorrosion
c"ttt"dffi----,ni*o
fr,c"tn"a"
The rate of corrosionresulting from galvanicaction

dependson - the relatiae eqtosed urea:s of the
ttuo meto,ls in contoet!
If there is a largeratio of anodeto cathodeare4 the crthodc will effectivelybe
protec'tedand may not corrodcat all! Howevera small rnodc arcawhen coupled
with a largecethodc areawill corroderapidty. ,ri(.ffil
'lleRstBwt6
,. -\{
!i
16
8l6lzoLo
fVfodtrt. z - General Corrosion Tips
{\
llighFlowVelocidecCanBrodcPa.ssivel,ayerrandAccrclerateCorro!.|on
,tft
U"aU" z - General Conosion TiPs

A'
Ttris faPh
illustrate" q" t'?igtl

fresh metal.
corrosion rate of
a
B
'thc Ruli Butert
,h
, ";*
Y
L7
8/6/2010
---l
Module z - General Corrosion Tips
Primary Factors Which Effect Wet Comosion Rates

.p H
r Concentradon
of Dlcoolved ionic epeciec (cdtr,
grscc)
. Tempcrature
. Presaure
. Velocity of the flutd
T}!c Rut Eut"n
r'\
Efitct
of Orygen C-onentration
& Tempcrature on Cotrocion
of C-anton Stcd ln Tap Water
f,nb
lo.
!o
I
a
lo
?o.
I
E
;o
c
!o
o
5o
a5a
FnortF
ThcRutBut6
i1
18
816/z0to
Module e - General Corrosion Tips

('curl
TYDi
ha6tnlds
aTlu{ru.lrF
Cmcfing along thc Bmin bomdaria ir calkrd intcrg'mrlr

frfrkins.
tgically in tha hu rutd at th rcld'r llesl Aftc'rcd Zo.r ( HAA.
Th*
crelt
!E wlly
miatcd
with rcIte ard rc
JA
rds-
.<.:-
f-t
(
tdw
6fra
H
I
I
Module 2 - General Corrosion Tips
Closelook at a HeatAffectedZone ifF,ltrj).
The Rust ButE!
r]
19
8/6/?OLO
{,-h

General
Refinery
flow.
i-
)*"
:&,..1
f,l,h
Module z - General Corrosion TiPs
0
.-1
A
{)'"s
OF-.o.
Iv-\
l1
..,__*r* 1r.,1
.-:-rc
ffi
{4
L J'-a:,-
-rJ
a/ 1
n"ar*t**
ir,
20
816l2Or0
----o
\'/''
FCCUCat UnitYields
Yteld %
Coke
8.o
Butane& lighter
35.o
Gasoline
55.o
Kerpsene
l2.o
Diesel
Lo
Fuel Oil
L2.o
rF,
'i J
Module s - General Corrosion fips
--o
SectionfV - Glossaryof terms
t:f;.
F
2L
816/2OrO
t-\
Module s - Gneral Corrosion Tips

Glocca.ry of terms
'{lloy stcel - Ordinary Carbon steel to which has bccn added allo/int elment', such us chmmium,
nluktrl, ctf.{nncrllng
- A genric term denoting a treatmnt consistint of hr:ating to and holding at a suitsble
temperatuFe,follorvedby crnling at a suitablerate, uccd primarily to soften metsllic materials, but al6o
to simultaneowly producg deeired changeein other propertier or in micrGtnrlture. 'l-he purposc of
suh changer may bc, but is not mnfined to: imprsvem"nt of machinability, facilitation of cold wort,
impmrement of mcl;hanil or electrical pmpcrtieg, and/or incn asc in stability of dimcnsionc.
.{urtcnldc - A term applied to t}rat @ndition of imn assaiated with a change in cryrtd silructure,
that aleo maktr it non-magntic, fhis ours with ordirury imn at an elewted temperatu. Wlrcn
sulficient chmmium and nickel ar" pledent, iron be(oms audenitic at atmapheric tcmprstuE. 'Ihir
ie thc cac with thc many rtainlcer stccle that contain about r8l chromium and 8% or morc nickcl.
Brclcftll - Materisl placrd in a drilled hole to fill space around anoder, vent pipe, and buried
romponentr o{ a cathodic prute.tion s}atem.
B.tnlb
- A agtrr8rtc of frrrite and cemcntitc resulting from the transformrtion of auatenitc at
temperaturee below the pearlitc ranse but abo,c the martensite strrt temp.rstun, Beinite formed in
the upper pan of thc bainitc transfodDation range has a feathery appr:rrarrr; bainite formed in thc
lowe,rpsrt of the range har an *icrlar appesrancc resembling that of temperad msrtensitc. Thir ir
one of soreral paeiblc mirro*nrcturcr ohaioed byttr aandormction of austenite on urling
(norrnslly astaisted with Cg and low alloy rtecb).
The Rst ButeF
1\
Gloccary of terrru
pryEEion marlr on a [rtigu ftrtw

lrukirB lurfa tlEt iry.li.rtr
BcaA mrtr
6 ctw'.{:troio
- Mqffipic
suauriw poritioru of tlrc rdnncing srck hdrt. Tb clsric app.enrE ir of Inqulrr elliptical or unidliptical
riryp"
(ako
lnm
mdiating outwrd from onc o morc origiil. Bceh mrt6
u clarohdl marts d arElt Esrk!) N typically
whm ih. part is loelcd mdomly, intcrnitteotly, d with periqlic wiationt in mcan rtrera
found m sdie frraw
or altmatlnS *u
Blo. brldslra
ahibitRl by mc nftk sftu beir8 hdtcd to a temDcntul! wlthin tha mntc of about
- Brittlod
26 to 3pC 4m to fmn, particuledy if the rtal ir mrlcd at thc el,6nlcd topdanE.
.
.
T\'trelv,
Britdcltstur
- Sepsrationof arc[daccmprniedbylitrlcornomxltropicplasticilcfmtionpidmcl pmpaplimwithlsspqditwof
cmrEr than htdxtihftrnm
lrrittle fractw (ruby
Crrildr
- A compound of carbql with oc q mm mctallic elcmtr, ruh u ircIr' e.htwim or tutttd
Certon Stel
or fom
cutuddn!
- Thc uborption ol carbon rtoro by a metal at hith temFnturEs; it roy re@b dislwtl
itr
dloF bt' hatin!. to a hith tmpentw
rutd carbida .rbrcrprion and difirsim ol carbm into rcUd hru
dtdlinS
mntacl with a nitabh erbcrmur
mt6ial. A f(]m of 6c hardaiq that product t 6rton trtdiet
qmchingdictly
ftom thc cartuizin3
inward ftom thc surfc, emblng the rufrc latu to bc hanlcncd eitha by
tupcatw
tlEa E autoitidry
ard qwu:hiry.
temlxntw
G by @ling to m
Crrtulatlon
- stel that doer not sntain ritnillfft
amut!
of alloyint clcmnts {)ther tha carton.
- The abcorption of carboD into a rutd srfacci ey
or uy
rct be dsinblc
The Rut Bsten
i1
22
8/6l2OrO
'L
jF

Glocgarr of termc
C
Carc hardening
- A generic term cxrveringsweral proceseesapplicable to steel that
changcthe chemical composition of the surface layer tn' absorption of carbon, nitmgen,
or a mixture of the wn an4 by diftrsion, createa concentrationgradient, The outer
portion, or c:I.se,is made suhstantialty harder than the inner portion, or core. The
pn)cessescornmonly used are carburizing and quench hardening; cyaniding: nitrifring;
and tarbonitridiry. 'fhc usc of the applicable specific pro<*ss name is preferrerl
Crrt lron
I.
Grey Cact lrrrn - A mst iron containing a - 3% Carbon und approxirnately

of flake graphite. Often
r -5%silicon. lt givesa gray fracture, duc to the prLrsence
called gray imn. (ircy crst iroa is namedafrerits grey tiacturedsurl'ace.which
th Brlphitic tllkes dflccta passingcrackandinitiatccounllessnew
occursbecause
cracksasthe matcrialbreals
Whitc Crst lron - Cast imn that gives a white frachrre, becausethe r:arbon Ls
in combined form. Wbiic cmt lror is namcdatlcr its whitc surf'rc whcn fractured
dueto its carbideimpuritieswhich sllow cracksto pBssstraightthrough
Ib. Rwt ButeF

Gloccery of terrnc
Causdc cmbrittlement
- A term denoting a form of strs'ss-eorroeioncracking most
frcquently encounteredin carbon steelsor inrn-chromium-nickel alloys that are exposed
to concentratedhydroxide solutrons .
Crvitation
- The formation and instantaneous mllapse of multiple tiny voids or
cavities within a liquid subjerted !o rapid and intense presstue changes.
.
Cavitation conocion
- A processinvohing both corrosion and cavitation.
lhe R[rt BusteB
23
816l2OrO
(1
I
I
Gloeeery of terrng
Qi
flrd metd - A trmpcitc metal ontainiry
t*o rr more laycc thrt hsrc bcn bordcd ttrgsthcr.
"Ihe bonding mry hne bccn accompliehed by rn-rolliry er:rtrusion, wdding, diftreion bondiry
curting, heavy chcmiel depoeition, or heny electroplating .
-l
l
I
Cold worlln;
- Deforming metal plosticallyunder conditions of tempemtw and strain that
induE strain hardening. Usually, hut not nessirib, cpndu(ted !t r@m temperatum. Contrast with
hot working
Concsrtnddt
ccll - An cledmlytic r.rll, the elcrtmmdive force rrf which b caurcd by u diffetencr
in (Dnoentration of romc urmporcnt in thc electmlytc. 'Ihir diffarmcc lca& to the formation d
diecrte cathode and anodc regionr.
Conoclon-eroclon
- Corroeion which is incruosed h$ugc of the sbrasile action of a moning
strrrm; thc prcecncc of arrpended particlec grretly accclcratcs abrasiw sction. Sceenrcion-rprroeion.
Conoclon hdguc
- The procre in which a melal fratula prrnsturely undcrconditionr of
simultaru:our r:orroaion and repetted cydic loodint 8t lorwr $ret8 lwdr rr fercr cydce tlun wurld be
nquired in thc abcern of the corraiw envimn ncnt
-fhe Rut
But6

Gloccery of terrnt
...-r-
r.".- tr*
.yclct tr hrulb of dm in r dH
('otndm
ffitu
' lell nitc onlidoro
t
*t * *, o.r"r*. "r*J";;
dvimmL ".9;
Se mio
".miE "-***
-, fati|u rtruttth .
drmffh
npelted ltrcs thrt cu he endursl brya metal withNt failw sdet
- The muimu
of comiiron aal fatigu aml fior i spsiflc nub6 of stns c?cls drid a sp*iEal perict of time .
Cndna
( lG.D - Tlm{qpcillnt
6ain wrrirg
pnury (EI,; urtt Mnt
rt I llltmu
erdmunS mt!' tqtruy s!!p.
oallov|||
o( ot! c |rlft cumDonotr d | $lid mlutim elby, urudlv in thc fm
- SehctlE omdm
rlo daruburir:doo, deobelrificzud!
dad.Hitu-ti(il,lrimi[etloo,
ard gephift mi<n
Dcqrtclatlo
acarbsr$tainintalloydutoructimwithoncm
- lmofcarbonftoothcorfclarrof
morc chcoical rubaanca in a malim that contactr the'nr{a:. Sccalo dcailoyiig
lh&:ftllv
Btlll (47sC) cnHttlma[t

o{ rtainlaa steb upon qtcndcd aD6N
to temrntwr
t ctHEr
- Emlrittl@t
pmipita-la ttri srrrtc
ir urd brytnc, chmniu:rich
lre anl 5toC (73o arxl g3oF). T hk tyr of mbritthmt
Jt Bmin boudarla: timc st tcmlmtw
dircdy inllwrr
Ar munt of rqrtgrtion- Gnid-bau-lery scgrqado'i of
the chrcmim-rich preipitatd inr:reoscr strtngth and hetncJ, dmaa
dwtifity ad turgbr6,
and chrrya
(ffinmt&r.
glatd.lty -Th prcpe$y of.e rutaiel by vtrtrr of

,which ddonnation causl by rtrefl^disppsrs
ffi.
A pnHry egmc my mmpldly E'deE lu onSlnal slEpe and dremm
an6 Ele&
- A neiwl
of s&clr appearing on tl|e surhc.

uuhr mr.
ffil dmn
- Teodcry to bulgc or tear Ethrr thm to bwi
'l}c crcp stnin oc+rrw rt r ,tisini(hirB ntt ic sallal

mrutmt 6t!, scondsrt (Ep; rDd that ffiint
et m
d im
Sc
,)r brc6l
lrpon rcmovdl of rhc

ol 3tru.
llE Rut DutcF
(h
24
8/6/20rO
=b
Gloecera of terrns
O)-
'Ite rwerc loer of dutility rx

Ernbrltdcrncnt
- LocEof l@d carrying czpsciB of a metal or alloy.
bughrrcss or btll of s mstrrisl, ruually a mc,trl or alloy. Many formr of Ernbrittlcmcrt can leed to
brittle frarture. Many formr can ocorr during thermal tnntmcnt or elsl'8ted-tempcrature scrrrcc
(thermally induced embrittlement). Some oI ther formr of embrittlernent, whici effect steel!,
includc blue brittleneas,885,F(l7s9 embrittlement, sigma-phaceembrittlemnt, and temper
r:mbrittlement. In addition, steels and other metab and alkrye can be embrittled by environmental
conditioru (ewimrunentrlly assisted embrittlcment). Thc forror of emrimnmcntrl ernbrittlcment
includc, cautic embrinlement, lrydrr4en embrittlement, liquid metal embrittlernrrt, and *r*
corraion crocking,
Endurrncc llrnft - The meximum strat thst r matcrial cen withaand for en irfnitely laryc number
of fati$uc ryclea; maximun $Tlic drer8 ls/el a metal can withctand withor-t fatigue failune. Seealso
fatigue strength.
. Brinle fracture of a nornally duttile matcrial in wfiich thc connsi\c

cechq
Environmcntd
effect of th sn/ironmcnt ir n caurative fector. Ennimnmcntal crackirg ir a gencral term thd ittcludct
cnnuritm fatiguc, high-temperaturt trydrogen attach hydmpn bli.*eriry hydmgm eobrittleoert,
liquid meal embrittlement, stre6!-con6ion cr8ckin& and sulfi& 6trat crufiry,
nrc Rut Buterr
,i?r
Module s - General Corrosion fips
Gloeeery of termr
o!-
Eroclortcotroclon
- Action irwoMng corraion ard erodon in thc prtcncc of a morring corraiw
fluid, leodiq to the a<xclcnted loc of rneterid.
Fedguc - The phenomenon lealing to fizcturc undcr rtpcate<I or fluctuating rtreases having a
nnximum ra.lue leaathan thc tensile rtrcngth of th matenal. Fatigue fracturec are pmgressivt and
grow un&r th artion of thc fluctuatint strrss.
Frdgrrc lifc
condition
- 'Ite numbcr of cydec of s,treaathat @n b. custsincd prior to ftilure un&r a st[ted tegt
Fadgue llmit - 'Ihe maximum stn:ss thst leads to fatigue fracturc in a sper:ified number of stress
c1rek:r..Compare with endurance limit.
Fcrldc
- Pertainint to the body-centered cubic cryetal stnrcture (8CC) of many fermus (iron-base)
metalr.
tlatcr
- Sho.t, diEcDntinuorrsintcrnd fisrrrflr in wmught mctab atfihrted to strcsscs produed by
lrrnlized transfrmstion and dccrea*d solubility of trydrosen during mling sfter hot mrkinS. lo E
fracture surfar, flakec app(nr ac brigltt silwry 6rcos; on an etcbcd gurbce, tht? appear as short,
discontinuour cracks.
The Rst 8uteil
's;
L -":ti
25
8/6l2OrO
t\
(;rrin bound&1r - A narrtny zonc in a maal orrt-.rpondint to thc tnndtion fmm orr
crrrnallngrapNc orientation to anotlrr, thu seperating o[e gr:ain from another: thc stornr in mch
grain arc orrangedin an or&rly pottern; thc irrtgular jurrction rrf two adjacentgrainr ie knrwn os I
grarn hrundary.
- Deterioration ril gray cast iron in which thc metlllic $nstitucnt! are
Cnphidc
cornrrion
seledirrly leachcd or conwrtcd to corrosion productr lewing the gaphitc intsd. Secabo deolloying
and se/edrrr?leoching.
Orrphttiadon
- A maallurXjcal rcrm dccribing thc formation of g:rphit
fnrm drrumpocition o{ irun ortidc st la/atcd tcmprrrtunr.
in iron or sted, usudly
Crry (-'rd inrn - Grc;r cert irrrn ir nanred aftcr itr grta fnc'tured surfacc, which ncrurt br:cau,r the
rraphitic flakca derlrrt a passing cracl and initiate eountkxs nw cracks as th rnaterial breals. Whitc
trrt iron ir narned afier its white surfae whcn fracturud duc to its erbidc imptrities which allow
cracks to pels streight through.
Hrdcnrbilfg
- Ttrc reladw abi[ty of r fermu dloy to form martemite wlren qtrencied ft,oar a
temFEtuac abd! the uppcr sithal temprratrre.
Herdnes
- Resictanccof a material to plastic dcformation, usually inrLntion.
(o
Glocerrly of terrns
,"..o* on*-^-;;
Hatrfi..t
d EF
of th. b.*
- Tht Fnid
prcF ikr w
mimndn
rnd rEtunirl
ou*l
micmnrdunl
whii tcenlly
chr.{g
"*,,* *QJ
rfiuiq broirg,
mrtrl th|t w fftltrd
rttrRi by ih" h.a.
R'frr to rm rliml
rftc min
bchrvir.
oniq.
c rcklirq, brr rlxc
io. rld rh.F thc th"ml
HtHmpanen
hydnla
rtrrA - A lB of rtFluth a.d rlucility of .nccl by hith-tmFnturc
wrh 6.biL. ir th. nFl nrultin6 in &turburiarioa rod int md fforina.
}lot thortnd
- 8.ittlM
F{ti.n
ctdc hr
of rborb<d hydmgcn
ir trr.td in thc hot fumlr|3 nntc.
tfydrof:a bllattl
- Th. ftr.n.tb. of blLto m or bdw r ottd orfioc from aoin
of blitq-lil. b.rlta on r drnilc nanl orfu 6rKl by intcrul hydmao p|q.|rm
intrnrd hfln;rn
9ra6
Fomrti.n
fb,&otrobrfflo-t
- AtffiF$ltir|in.dFldoftlr.6gt,uaqAuilqc,.nr.tddrtoth.lruruofrtmic
hvrlrt4n Hytrqm cmbrittl"ffi
h! bcn Fo[nird chgiqlly.r b.ltrt of M tytfl
r. Intend hvtlmgrn embriRlcEnt, ru
whenthc hydrogcncntaE molt?n Dctd whit'h bcom rupmrrtai
with hytrqcn
imm(lirtdy rftcr sli(li6otion. T
hwlfti?n embrittLmrrt, 6ult! fmm hydro!.n bring aborbcd by rdid m.tda 'Iti! 6n @r rhrrirq clcwtalr. Frvimtlmrd
trmp.ntur rh.rmd tFsmot! ard in sryic? &rrin! clcctrcddiri3 mt$t with miil.FE
c+.miCr, @mrkh Esdioos,
qth<nic protetin, Id opcretirq in hiFpttsa
hntrss. tn rh. !b*E
o( si.id
iE
or dtrmel lordlrg cnviunntel
hvdmgcnembritdcmrt ir |mifonql in hriu
funE, sdr E blidrrirq. nturnd cfitt.
hydrU" {orDtim, lnd E&ad
,lu(iility. with r t.Biic ro
with rha trGd
c rtm-intcmity firor aclirg
r qcific thEhol4 th" rtmic hydqn hoar
ln th. .bcna o{r o|ilbn
to indrp subqiti$l (nt gnth lodiq to hrtw,
racbo (polrriad ethodblly), th! ud tlm
rml ir hyko6croirtcdfflingHAc)qhydrltcnGmliDt(H8Cl
ln th.Iffi
otdiEmin,srdfy
u pitrq
(rris
(tpluirrd anodiolly), thc lnf iq ir 3mnuy @&d rtEruin
crqft4c($C), hr lhdfd |@ pogcdy bc ellcd
gcl
hyd.ogndirtld
ct@|ubn
mctinj (HSCC).lts HSCend cletchcoiclrll
loodic
6n ogcEtl *gaotcly or in
ombiortidHsCC). In pru rrtdr. ruh a hLlF.trntth neb, tM rehenbn ir bd'ped to bc rll, or narly dl, HSC.Tlrc
psnidFtint trrchinirm of HSCir m{ aluyr rruSnial ud mry b( ?vilurtcd unld th. 3cmrb halirg of sCC.
-ItE Rust 8wt6
,r'".h
26
8/6l2OrO
B
*3

Gloccan of termc
HvrcoDic
r mrrtat abiliB to qrdcntc thr onrbnrltion of Frter vlDoc apolhl to
- ( l ) PlGim
co'nderurn6nnuchi r:ompocfof s&lt! th.rt yiclil s<1lrout srlutiotrr of r very lov equlibriuri wpoi prtcaut
trrmnnrcd witlr thrt of Durcnter rt tltc srBa tem[ErstuE. (2) Pertriniru to r suixtrncc *{rooc ohviicrl
eharirrcristhr arc appicclablyahcrtd by eftctr ofwatcr rnpor. (3) Pertoiningto wltcr lbeorbcdby drv soil
rnrnenb from tbc ulmmphert; thc omountsrlcpcill on tbc phyrimhcmicol chomc'lero{ thc aurftcer, ond
rncaar nti rising rclstiw hmdity
lnclurionr - Particler of foreirn mrtcrid in a rncirllic mltrir. 'tlc prrndcc arc usuully crmDoundr (swh as
rr$drr, sulfidcr, or silkrtr), but-mry bc of any subetanccilut ir fiorcitn to (and er-ntirtry inrblubb io) lh.
rnrtrir.
(bntr'rt
lnlcrtruula
Intcrlruulrr
orrocloo
- Cormrion auurrin|
negligibla eneck on tlro sdjrcent ErsiD!.
lntcltrrDolrcrrcfha
tmn-sgmnu/0.r cta*ing.
Mlrtanrlta
formed bv tlifhrionlcar
in whict lhc
Dhr* trrruformstkm
- A rerrcdc tcrm for misoatnrturcr
parcm and pmturi phas hew o.sperfc crynallo;raphic
nilatiooehip.. 'tti .arnrum of higb-tcmpcraturt
phc thal tnnslDru
to mrteutr
on o@lrnt dapult to r trgrtc qtttrt on iba towlt tempartturC Ntttmcd,
ihero tring a nther dirtirrt be;innng
- Batrlca
cryrtrb
or ErriE
with tmns3nonuhr.
pr{rrntidly
usually with slight or
st train boun&ricc,
- Craclingorfnctuin8thrtrourrbrtwenthetninr.
Cuntrastwith
Thc Rurt BurtcE
".{Elt+
|
..

Glocsrrv
of termc
Or
.
!t elc\.atrd tcmrrrturE
Mctd dutlru
&teriormjon of mctrb in rrbonactous
- Agrkrltal
d durt-lih comion pmrlrrt: a uniorr form of hirh temDastun smion'lrca which formr a furt-lih
pitr
nrtal
sgmaim'ea_doehpr
hcinirpherir:al
oo
f
suarptiblc
surfrcc;
cimultrnou!
ard
ln$u't
carDunzaboo |l Seoerory oocryo(L
oH - A meq3urc of the uditv or slldinitv of a solution. lt denotr thc derrec of acidiw or basicity of a
ruluer belor 7.-o indicrte rnircosuU ecidity;
iolutio$. At 2SC (ZF), Z.o isilr ncutrol 'ioluc. Decrqriq
incrcaring raluca obow 7.o, incrcatiot boricity (sllsllnc).
Plrrtlc
urtcrirl
Plrrtlctty
Oumhint
mnptishCd
Raidurl
Burly rt Irris .
scnritiatioo
- In austmitic naiDlelr stelr tbc preripitation of chromium erbid!,
boun&rier, oo exprure to tempraturs of abouf SiSoio SSoC (obout tooo to tSSofl), levii|t tlie grio
(EidrrinS)
to prftrcmid
etef by e srodrU
hxndrriee deplatd of chmmium end tberefrxc slrE6iblc
mqliun
&formrdo
- Thc pconuctrt
bcmul ilr eb-*X linit.
(iELsdc)
- Thc prcperty that enablcr a mterid

- Raoid tulinr
by immcrsioo
rtrco
- Stress
diriortion
to uderSo
cf rnctab undcr applid
permsnent drformation
strffi
to fuE
$mosion
thlt 3trrin tbc
without ruptw.
Thir renerallv is
of nrtals (oftcn stek) from a suitsbh elartod temDcntw.
b wrtu, oil polymcr solutioa, or sah, although for<itl air is mctimes
wid
thst rcmrin within r body u a rerult of phst c defbrnotkn.
Thc Rut BuneF
_:",..
27
8/6/20L0
ft\
t,

Gloccrry
of terrrrc
Sifrne-phera crnbritdcrncnt
- Embrittlcrncnt tf irgn-chmmium allrSa (moc notrbly aurtenitic
stainlecc stceb) couscd ln prer:ipitatidr ot trlin borndaricr rn thc har4 brinlc intermetrllic sigru
pharc during long pcnuil ofexpocurc to temp.raturcr bctwecn appmximately 56crBnd 98oC (toso
and tSor;F). Sigma-phnrcembrittlement rtrultr in sel'ereloeein torrghnerrond ductility, and can
rnake the embrittled nraterial cuscrptible to intergranular corrogioo" Seeoho ecnsitir,stion.
Strrln
llbcr
- 'the interuity of tllc interndly dlrtntuted forcca or componcnt| of forccr that n-irt r change
in thc volumc or shapc d r mrtrrial tbst ir or her hcn rubjettcd to stc'nrl forttr. Stn:$ ir
expnxeed in fortr per unit area and is rnkulrtod rxt thc buis of thc fiigitul dimemiom of the cns
w'tion of tbe spcr:jmen, Stredr (rr be eithcr dinct (tension or eompruddon) rr chrr. ScrlD
rtrgidusl stresa.
(tlOC) - A crackint pmccer thet raluirur thr combincd action of e

SEcr-corrrrion
crxllqg
eomxlcnt and surtErncd tendle strera Strr:$-c0rraion crarling may mur in combrnation vnth
hydrogan embrittlemcnt,
Sulfidrdon
- Ttp reaction of e metd or alloy with a eulfur-containinS spc{ict to producc a arlfur
ctm6xrnd that formr on fi betuth thc rurficr on thc mctal or alloy
r5in3 - ,rging inducul by cold workiry.
TheRuiBBt6
(,*
Glocorry of tcrmr
Sullt& rtrer cncHnS - Brittlc hilurc by rrm.kin8 und.r thc tnmbincd action of tenrilc Etrrs. snd
coroeion in the preccncc of watcr and hydrogen sul6&. Seeabo envimnmentel cracking.
Tcnpcr crnbr{ttlcmcnt
- Embrinlcncnt of alloy stt'cb trurcd by holding within or cuoling slrnvly
thmugh a temperstur! rangc just belorv th transformation rant. F.mbrittlcment is the rerult of the
segrepption at grain boundrrice of impuri'tice nrch ae arrcnic, antimony, phocphorur, nnd tin. lt ir
usualty manifeeted ee an upward ehiff in ductile-ta'brittb transition tcmpcmturc.
Tcndlc 6tnt$
- In tensilc testkr& thc ratio of marimum lmd to origfud crc-sc<tionel
AlEo(ilkd ultimrtc tcnsilc srtn$h-
Tcnrile rtrcrr - A strss that caueectuo pertr of an elastic body on either sidc of a typical strest
planc, to pull apart. Contrsst with c?lnprgsduesrress.
Tcrr"don - Thcforceorloedthatproduuelongrtion.
Touthncr
Trrnrlranular
creclrlng - Cracking or frrcnrring thst ocrur though or acmeea c$rrtal or grain..
L-ontrart with intergron ula r cmc king
ara
- Ability of a maal to abeorb mcrgr and deform plaetically befort frrturin&
ThcRustEBterr
{,
28
8l6l20LO
Gloccary of termg
TrrladtciFnar|t
- I | ) Ao artritnnly ,lelincd tcnpcrensc $at lics wthin lh. lcrq.?rturt rangom whri
rrrtal Frturc chsactcnsticr lar usrully rbtcrmined b lcalr of rr)lchcd rpccrnrcnr)chrngc rapidly, srcb {s frurn
lxtrnanlylibnxr {!hcr) lo Fmlnly orystrllim (cLwagc) frrturc. t2} Sorrlimcr uredto dcrntc an arbrtrarily
dclincd tctryqarura wrthin a rangc in whrch thc ductrlity changcrmprdly wrth tcrnpcraturr.
I ltlirL
lixlur,
runfd
rtrfittl
- I'hc marimurn sfe|. ltcnrilc. coaqrssiw" (r rhar) | metcrid can susreiowitlnu
rcr of thc spccrm. Abo cd|cd
ddlnnirEd by dividing rnrimum lood by thc rigind crercctrmd
rfagb I mari''un sfaF].
lrnlfrra corruior - { | ) A typ. of cmrim anek (d.tctimtion) mrformly dirtributcd ovcr maal strfacc.
(ltCmoom thet pu.crJr a al4roximrrcly thc sarnc6le ovcf a mael surt'rc" Also callcd gancrolcrmosrtxr.
Whit cart iril . ir uncd aftcr rts white surfrc whca frrrurcd dw to itr carbrdcimpuntics whrch allow
crrlu to pe$ strerghtthrouth. G].t crra |ru ir nusl atlcr iu Itc] frs:t|rrcd urfrcc, which occurr bcccur
tha graphnE fiilcc dcflccl e pescingcr*t and inlrnc cormtlccsnc} cf8ls ar thc msl.f,id brc.h
'TheRut 8urtc6
a
p

ctoccary
lSrmr
o
tVmr'lt
wslcd.
urlim,
Yidd
Ybld poirt
- l-hc firn grcsr il a nntcrial, rronlly lers thaa tlp mximum aneimblc strrs, a wluch m
witbrxl u rmearc in nrerr. Only certrin tlErdr - tlnc thd crhibit e laaliz4
rmrcerc io grain sur
- o|v$re r yrald F)id. lf tlFrt
bofi cfuitic deJomuott lo plo.ttr th/onoriil
hctaroFnaou! typo of trmritlm
rn rtrerg aftcr vrcldrng a dirtmction rny bc nadc bctwcclr upper ald lwcr yrcld prir*r. Thc load
is a &crcar
* whrch a uldcn drop in thc florr crrvc Gun! ir callcd thc uppct'yield pornt. Thc c(x[tari load shown on th
florr cunc rs thc lwcr yicld point.
Ylcld rFcrftl
strdn.
YLfd rtr6a nE IrcJs lvcl rn e alsrcnel rt (x abow ttc.vre ld stnngth btt bclo,tt llrc uhiwxc
strcss in rlrc y'xtic rangc.
tEatc4 coH
- l-iquit mltrl porned itrlo r big sleb mold Sleb ir hca bor vrrtcd lrolling mill), h
lhat ic nr)trRcsull is a urulirm mt6l struchnc. Itir ir opp<red lo Crst thd rcrulB ro r|ctd stnrtre
has big-grainr, groaity, and possibly <lhc problcru
- Evidmo.
of plasuc delomonm
in strwhral
metcnrlr. Also cdlod de.gtro flow or crccp.
- Th. $tre3s st which e mrlcrisl cxhibitr a sfccrficd &viation
from proputronality
of srre$ and
ilrungth, i.c., t
Th Rut Bwt?a
i.lhq,
.:jiP
29
TheRustBusters- API 57L
Module 2
RefinervMaterialsof Construction
ClassQuestionsfor Part I
OpenBook
L
Name two elementsfound in every type of steel:
2.
How much carbon can steelcontain?
3.
Most steelcontainshow much iron?
4.
What alloying elementin cast iron makesit difficult to weld?
5.
As the carboncontentin steel increases.doesthe steelbecomemore brittle or more ductile?
6.
Name two elementsthat are usedto kill steel.
7.
Is "outgassing"requiredprior to all weldingprocedures?Explain.
8.
In general,if a metal has a largegrain size,has it had a rapid or slow cool down?
9.
How many gradesof stainlesssteelare there? Name at least4 chemicalcomponentsthat make them
different than eachother.
10. Is therea reasonto specifypartiallykilled still?

I l. A killed steelmadeffom what deoxidizingagentwill providea largergrain size?
12. Why do we want to use "killed" steel?
I 3. Does steelwith more or lesscarbonhave a greaterability to bulge or tear ratherthan to burst or break?
14. ls carbonalways dissolvedin the iron?
15. Specifically,what makesStainlessSteellessweldablethan carbonsteel?
16. Give an exampleof type of alloy that was once engineered& usedas a preventativematerial for hightemperaturehydrogen attack.
17. What will have more impact on weldability, a small increasein molybdenumor carbon?
18. What is the chemicalcompositiondifferencebetween304 & 304L SS? What doesthe "L" standfor?
Copyright@2008TheRustBusters
Page3
TheRustBusters- API 571
Module2
Refinery Materialsof Construction
ClassQuestionsfor PartI
OpenBook
l.
Name two elementsfound in every type of steel:
2.
How much carboncan steelcontain?
3.
Most steelcontainshow much iron?
4,
What alloying elementin cast iron makesit difficult to weld?
5.
As the carboncontent in steel increases,doesthe steelbecomemore brittle or more ductile?
6,
Name two elementsthatare usedto kill steel.
7.
Is "outgassing"requiredprior to all weldingprocedures?Explain.
8.
In general,if a metal has a largegrain size,has it had a rapid or slow cool down?
9.
How many gradesof stainlesssteelare there? Name at least4 chemicalcomponentsthat make them
different than eachother.
10. Is therea reasonto specifypartiallykilled still?

11. A killed steelmade from what deoxidizingagentwill provide alarger grain size?
12. Why do we want to use"killed" steel?
13. Does steelwith more or lesscarbonhave a greaterability to bulge or tear ratherthan to burst or break?
14. Is carbonalways dissolvedin the iron?
15. Specifically,what makesStainlessSteellessweldablethan carbonsteel?
16. Give an exampleof type of alloy that was once engineered& usedas a preventativematerialfor hightemperaturehydrogen attack.
17. What will have more impact on weldability, a small increasein molybdenumor carbon?
18. What is the chemicalcompositiondifferencebetween304 & 304L SS? What doesthe "L" standfor?
Page1
Module2
RefineryMaterialsof Construction
ClassQuestionsfor PartII
OpenBook
1. Explain where in the refinery you would find the "Crude Desalter". What two things
doesit removethat make it a corrosionwork-horse?
2. What is the product of a Hydrotreater, and what is the bi-product?
3. What is the differencein productsin a Sulfuric Acid Alky and a HF Alky?
4. How high can the BH go in the HAZ?
5. What type of stresswill causea pressurevesselto pull apart?
6. Alloys that are usedin a refinery typically containwhat alloying elements?
7. In general,will an increasein velocity help or hurt your corrosionrate? Why?
8. Will corrosionincreaseor decreasewith a higher temperature?(
9. If you put a liner on your tank bottom and then put a small scratchin it, what will be the
corrosionresult?
10. Will corrosionoccur in pure water? Why??
CopyrightO 2008TheRustBusters
Page4
Module2 -
Revised
August2009
ClosedBook
Quiz#1
1.
Revised- Whichof thefollowingis a metallurgical

thatworkedwell to preventcracking:
treatment
a) Useof low alloymaterial.
b) PWHT
c) WFMPT
d) Useof low carbonmaterial.
2. Whatis a commondeoxidizingagentusedin Killed Steel?

a) Cr-Mo
b) Mo
c) Cr
d) Silicone
3. Revised- Thecarb6nequivalent
formulais comprised
of 7 elements.Whatsingleelementhasthegreatest
contributionto the resultsof the overallformula?
a)
Cr
b)c
c)
Mo
d)
Ni
What alloying elementin Cast Iron makesit difficult to weld?

a)
Lack of silicone
b)
Abundanceof silicone
c)
Carboncontent
d)
Iron (Fe) content
5. How manytypesof Cr-Mo steelsarecommonlyusedin therefiningindustry?

a)
One
Two
b)
c)
Three
d)
Four
e)
Fiveor more??
CopyrightO 2008 TheRustBusters
Page1

6.
For most corrosionmechanisms,the corrosionrate of baremetal decreaseswith time.

This is because:
l.
The corrosiveacid getsweaker as it travelsalong the pipe.
2.
The passivelayer protectsthe metal from further corrosion.
3.
The anodegets larger in respectto the cathode.
4.
Oxygen interfereswith the speedof the corrosion,and slows down the rate
7.
The addition of Cr to steelalloy's is known to stabilizethe carbon. What doesstabilizins

mean?
a)
There is no needto pWHT
b)
The carbon in the alloy is less likely to migrate.
c)
There is no inspectionmethodto determinedestabirization
d)
All of the aboveare true.
8.
Is Fenitic SS magnetic?
a)
Yes
b)
No
c)
Dependson the grade.
d)
Dependson the temperature
9.
Which of the following is an Austeniticgradeof SS?

a)
2205
b)
304L
c)
304M
d)
All of the above
10. Whichof thefollowingis a Duplexgradeof SS?

a)
4909
b)
220s
c)
304L
d)
316
Fyl, thesequestionsarerightout of the book.

Rememberthat onlv about 25?6of the APItest questionswill be "right
outof the book,,.
CopyrightO Z00BTheRustBusters
Page2
8/6/20LO
Module z.S Amine Treating
ThrRut E(!td

Acid Gas - Has HzS
Purpose of Amine Treating

_ Remove
HZS from
-he
.lbrrybd
sorrr gas
Pu.ig
P.gffi16
' ltn
I-ean Amine - Very little hzS

Rich Aminc - Has HrS
ThcRutButn
r .h
8/6lzOLo

i.'rd ert
F-{
p,fig
F.gff*d
Thc Rurt Aud6r
Module 2.S Arnine Treating

Acid Gag - Has HzS
Purpose
of Amine
- Remove HzS from

sourgls
Treating
lrlc
t'ryb"
I-ean Amine - Very little HzS

Rich Aminc - Has HzS
Ttlc Rult Burtcrt
i&
8/6/20rO
Module 2.S Amine Treatit g

Corroeion mechanicma:
l. Wet Hz.g demage
z. Arnrnonium Bisulfrde
g. Erocion/Eroeion
Corrosion
+ AmineCracking
5. Amine Corrosion
6. fitanium
Hydriding
7. Coollngwater corroclon
f*'
r:o.ntmr{
tH.Srlorl
P1r!+
Rcflu
P.96(ild
r:trrjanllr
Thc Rurt But?fr
Modul e z.SAmine Treating

AmincSCC
Aftccttd Mrlcrirb
CS and low alloy stctls
5.1.2.2 (pg$Jl)
o!--
-l
q
('rltlcd Fector
. lb cxpenencc Aminc SCC, a combrnation of things must occur:
o Aminc gpc. Cracking rs mote likely to occur in lean MEA and DEA.
. Tempcrature- Craching can occur li'orn ombicnt tcrnp to highcr tcmp, but it rnorGlikcly al highr tcmp.
. Stres! - Rcsrdual, Xclr/,&td firrr;,a - Examplcr are hnding or nalding. Odrcrs ore urrcrcn hciling or
cooling
Appornrcc ol Morpbolo,gy ol thm4c
. Crackrngis INTERGRANULAI.-",Ttuabdel
. Crackrng tlTically developc parallcl to the wsld. In the weld metal, the uracks arc either trancverseOR
knginxlinil wrrh-frc rrcld.
(Xlcr
. TrucAminccrackingisonlyaslociatedwrthf,.E/^/aminc.CrackingassciaterlwithRichamineis
another corrosion mcchanism
Th Rutt Bustert
I -.: :1''
!;'
8/6/2OrO
{'"m
Modul e z.SAmine Treating

Aminc SCC
s ' 1 .2 .2 ( pg$Jl )
l:ll1
lrrl
I
Ir
i
.
'a-.U
Ii
I ; '
i
|
!
i
|
--;
.
--'-r
iaJ
:-..!r-.
L_.i'
L
Cracking along the grain boundaries is called Interaronular

eroclctng. Ttese cracls arc
ustully associated with welds and are typically in the base metal at the weld'g Heat Afrected
Tnne(HAZ).
r<
(h.1
Th Rutt Butlc.t
(r'h
Modul e z.EAmine Treating

,\n icCo r r o cio l
5 .l.l.l
(Pc.tr)
Oi-----
What is Amine Corrosion?

. 'therr src npo typee of amirn, 'rich' and 'leaq' and ac a rsuh tu,o
typce of amine c:orrwion. Rich arnine is amim that hr6 absorbcd thc
acid gaseenrch ar H,S and CO", and lean amim ruferr to amine that
has h:en stripped of the acid garce. lmirr:s arc uscd in refincriee and
chemical plants to rcmolc HrS, CO" and mercaptaru from proc.esr
streamr origination in many unite. Thct irrr:ludc ttrtamr from tlrc
cnrdc unit, rnkcr, otelytic cncking hydro6en plentr,
hydmprurasiry and sulfr[ rc(wer tail gnr unib.
I
I
+1
Purc amincg arc not rlnooiw. It is th ecid Brc (HrS an<Vor CO") in the rich amine that
rnalet it corrmiw. Ccrrcralb nch aminc corrtrsion rsura when thc aminc absorbc too
mu:h acid gnser, is hcated at t@ high 6 temperatur, rnd/or {lowr m too high a wlaity"
Amingldonotcodo.
It't the oonbrc conJatnittgolttttho,t
TheRun Burt6
f'.3
cottodt
8/61zOtO
-*t
Module 2.S Amine Treating
: --.
t
.lm ic ( lo r r m io r
5 .l.l.l
-,r!-r
: le{
( Pg. l l )
i rl l l
trl
{'l
i .l -r,
I
I
+1
ti t
i-_.iJ
ll
,ts
,: _,f |a,
li
i
L=,ll:-(
'r
,",.-
What is Amine Corroeion?

. So what makes the lean amine conosive? tt is the impurities that nrakea th lean amine
cormsive. These impuritiea are often products of amine degradation. Generally, lcan
aminc corrnsion ocour only when it txxnme hot (>zoo F), such as the lowet section of
the amine reg,enerators,reboileru, the honer lean/rich exchangers and associated piping.
.
Tterr are other types of corraion which may be found in amine units, e.g., hret CO,
comxion, ammonium bisulfid corrosion , wc{ HaS cracking, and amine strest cormeion
CfaCbng.
TtE N &t-d.L\.lF.od
dI d h. dbrd
lF.
Thc Rut Eugtn
Ie,
Thc md (Dmmon u:id gascr fornd in the rrfirtcry and pefmclrcmical planE are tt .9 (Hydogfr
SrrlfrdG) and CU, (Carbon Dbndd. Theae are callcd acid gssr bq:eus! they becumc ocidic wtrcn
disrohcd in water. Acid g!6 arc hrth tnrrociw and an errvimnmentrl hazard, thcrtfrrr muet be
remor,cd from produt strcemr. Aquooru aolutionr of amince ere urcd.to rtmorlt tlrcrt undesircd
gascc.Amince in our umine units are attually forndly talled 'allqnohmines,' Thcy arc Egk11ttl4fo
lmss tlr* rzn read with th asid qnce A ferv mmplee of tlrcrc arniner are MEA, D&1, MDp\ UU
tndDIPA.
ln amine units, an arnine moleculc (o bos,like ammonrlo) and an rid rag molcc{h (on u'd)arc
attracted to cach othcr formiq a! aminc aalt. That ir horv thc aminc 'tftat!'thc
a:id gasct up to a
certain looddng or ecid gas conr-ntration. Horryswr, hertinS thc sminc salt can breaft it bacl to thc
acid gar molrnrlc and the aminc.tnlc (rllmohnim;
= rllullm
rlkrlhc = crurtic
' -' f l
8/6/2070
(\
Module 2.5 Amine Treating

,lmic (lorrmiol
( ritlcd
5.l.l,l
(PS.$t)
F.cioE
.\nir.
tlp. in ordcr of aggressivencss

ti'om mo:lt to lcast ts: MEA, DCA, DIPA, DEA, und MDEA.
{mirc cccrrlrrth
- thc corrocirE r|lturc of thc conccnlratiott is rlcpcn&nt oo thc ry*peof aminc.
(:oitalllrrlt
lacl - lr'an uminc aolullonr arc generalty nol corrooive- Hourcvcr, it's the sscumulrtton
ol l lclt StsblcAminc Salts( HSAS) atrovcabout2clothat can srgnilicantlyincrcascccrosidr raut.
Vclodty lini|r - General rndustry rtandrds src to limll vclocity to I { lpa tor rrch amrnc, ard 20 lpc I'or
lcanamrnc.
-Icmpcraturesobovc 220 F can result in acid crr llarhing and scvere localizql oorrorion
TcmFratrnrt thc presrurcdrop is high enough.
o
.
.
.
MEA
DGA
DIPA
DEA
MDEA
AlTcclrd l-hltr or fqrlpocrt

.[lrc
.
hottest arls of thcAmirc unrtc lrc arTcctcd:
. Thc Amirrc regercrator rcboilcr.
.
l'1rcrich aminc srdcof the lean/richcxchangcrs.

ThcRut Burtd
Module 2.S Amine Treating

,{roic Corrorior
5.l.l.l
(Pt.5-l)
Apgcenrctof Morplolo6r of Dur3c

'l-hrnnrngwill bc uniform whcre the proccssslrcEn vclocity is low, whilc it wrll bc locahzal lir hrgh
rr
I
velocltlcsassociatqlwith turbulerxr.
'
I
|
II
Prtviltio! / Vlthrtbr
. ('onrrol acrd gastCO! & HrS) loadingr.
. Monrtor/controlHSAS.
o
Monitor vclociticr - ururlly tha rcrult of'proccsl
I
._l
crccp'.
i: {
-4-1
|-_'
"* ^
''"!
tl l
i +'L
lii
r
lil
r
lir
i.:Ea
tl "-T
;r;
'---
i
:
!,,*
.. ,:.1,'*-
r'l _ .L l
I
fcmpcrrturcr- rnothcrvictim of 'procesrcrccp".
.1?
o loo Scrics SS can be used in areaswhcre llashtng orcrcun.
e Solidsshuld bc removcxilirm thc systcm. FYI, tiltration is morc ellbctive on tlrc rich amine sidc, but
who wanB to opn up a rich smi.rc tlne/fn
+r J
|rrpcctlor
o UT.
.
Corrosion coupons / prohs can be usal.
ftenut
( r?,0
md Morltorl.!
Suac
''

Module2.5
OpenBook
l.
What causesrich amine corrosion?(chooseall that apply)

a) Water
b) Freshamine
c) Too much H2S and CO2 in the amine
d) High velocity (greater than 6 ff/s)
e) Amine at ambienttemperature.
2.
What causeslean amine corrosion? (chooseall that apply)

a) Water
b) Too much H2Sand CO2 in the amine
c) Freshpure amine
d) Impurities (or contaminants)in the amine solution
3.
What are the sourcesof impurities (or contaminants)(chooseall that apply)?

a)
ReactionbetweenH2S/ CO2and amine
b)
Feedgas/ liquid
c)
Degradationof amine
d)
Degradationof water
e)
Freshmake-upamine
4.
How doestemperature(above 190 F) affect amine corrosion(chooseall that apply)??

a)
Increasescorrosion
b)
Destabilizationof the iron sulfide film
c)
Decreasecorrosion
d)
Increasethe pH of the amine
5.
Amine crackling is most often associatedwith what type of amine?
6.
What has a higher pH, leanamine, or rich amine?
7.
Can austeniticsteelbe used in amine service?
8.
What is more likely to causeamine corrosion,highly loadedor lightly loaded? Oh, and loadedwith what?
9.
Which vesselis more likely to be PWHT'd, the Amine Absorberor the Amine Regenerator?
10. Normal 150# steamis about 350 F. Can it be safelyusedto steamout amine equipment?
Page 1
8l6lzOtO
ff
Moduleg
Frlifre
Fatigue/ SSC / Hydrogen
(Prn I ofJ)
I'hermal Fatiguc
o Mechanical Fafig,uc
1-21
.r-51
1-59
1-135
Vibntion lnduccd Fatiguc

o (inrxion Fatig,uc
Strcr (lorrodor
.
Cncllrg
(Prn 2 ott)
Chloridc SC'C
o eaustic SCC (Caustic Embritllcmcnt)

o Ammonia Strcss Corrcxion Crucking
.
l-iquid Metal Embrinlcmcnl (LME)
Polythionic Acid SCC
Aminc SCC
clartxnalc lxlc
4-ll0
1-l]9
4-144
4-t48
5-3l
5-17
5-52
('onflnucd
Copynght,qf 2q)9 TheRutButcn
(h
Module g Fatigue / SSC / Hydrogen
HydrogcnCracking (Part3 of3)

. I'lydrogen
Embrittlement
. High-[empHrlHtSCorrosion (its in thc hydrogenfamily)
. WetH2SCracking
o HydrogenInducedCracking(HIC)
o StressOrientatedHlc (soHIC)
o SulfideSCC(SCC)
. HydrogenStressCracking- IIF
. HTHA
Copyrightrd zoog TheRutButeB
r,
\j-
4- 152
5-13
5-41
5-50
5-56
8/61zArc
Module 3
Fatigue / SSC / Hydrogen

Frdguc
Ferigrc
o llrsmrl Fatigw (4-27)
. McchmicalFatiguc(4-51)
e Vibration F*iguc (4-59)
. C()rrosion
F'atigtr (4-135)
-3
- In Gcnerel
o''---
(.'ausedby varntion tn temperatwe

,Veclanicol ltding (surfxe strcts)
Dynank
ldtngrhte
to vibrotion
u'ater lnmmer or unstablelud
flov
Env ironrre nt .1 ssisled L' rac hing
Husband
Fatigue
Copyrltht (O 2oo9 TheRutBurtcrr
,rfu.
Module 3
Tlrcrmal Fadgu.e +2.9
(Ef l-eZ)
(lrltlcrl Frclon
. Key t'lclorc arc the magnitudcof thc temperaturcswing ud thc licqucnoy (numbcr of cyclcs).
.
Sltrtup and shutdownof cquipmcnt incrcascthc susccptibilityto thcrmd fariguc. Ttcrc ir m sci
limit on tcmpcratures_!Lngr,but as a practicalrulc crrking mry bc suspcctcdif thc tcmpcruurc
swingcxcccrlsoboul200 F
Nolchc! andothcf str68 conccnmion3 mN scrvc N3initiarioo sitca.
,lffcctcd I ritr or [quipmcnl

o Mix Points
.
Coke Drums
tueroa\faugue
Copyritht g 2oo9 TheRurButeE
r,h.
/i.dhf
Module 3 Fatigue/ SSC / Hydrogen

Tlrcrmd Fatlguc 4.2.9
(n
4-4,
.\ffcctcd Units or Equipmcnt

. Mix Points
. Coke Drums
fl -
Appcarance of Morphology of Demrge
t-
Cracks usually initiate on the surfaceof the component. They are

generallywide and oxide filled (due to thc high temp).
Thermal fatigue cracks propagatcTRANSVERSE to the stressand arc

usually daggcr-strapcd. However, cracking may be axial or
circumferential of both.
G) 2on9'IlERunBurcf|
Module 3 Fatigue / SSC / Hydrogen
Degradation that occun when expoeed

to cyclic rtrtsres
(korrtry, sntsr leral, numbcr of

cyclerand material pmpertica
Tbennrl Clcling - Colte Drumr,
&luipment in intetmittent srvice
(boibc). Qrrnch nozzl:r
Mechalical loeding - Rotating pump
shafts, small borr piping. bigb
pncseurt drop control vahec
fufui8!-Minimiu
strcst
concentrationof componentr
A form of MectranicalFatiguewhere
degra&tion ir producedar a rerult of
tlynamic loadiry due to vibratioo, water
hamnnt or ungtable0uid fror.
. .tmplitu&and frrqucncy ar urellar

fatiguc rtrirtance.
. Synchrooousload
Atrythi[
that vibrater. Small bone
pipiry PRyq Heat eachanger tubes, etc
De*ign,and thc ure of mpportr and

ribration dampening
C4pyritht ,g a0o9 TheRutEutr|
('-\
8/6l20rO
Module 3
Thermd

Frdgue 4.2.9
(4. +nl
,lllectcd Units or Equipmcnt

r Mix Points
. CokeDrums
Appearance of Morphology of Drmage

. Cracks usually initiate on the surfaceof the component. They are
generally widc and oxide filled (due to thc high remp).
. Thermal fatiguc cracks propagatcTRANSVERSE to thc strcasand arc
usually dagger-shapcd. However, cracking may be axial or
circumferential of both.
(e)2oo9 ltnurtBrrtd

I Mechrntcd
T\rDG
D6criptioo
Degradation that occurr when exposd

to cyclic strcsss
Aft:rled
Motenalg
Critical Facton
Fetlrrra
(homctry, strcJslcrd, oumbcr of

cycJee
and mrterial pmpcrtica
| lnir.
Mechanicalloading- Rotatingpump
shaftr,smallborc piping,high
pn:rsun: dmp control vaheg
Prerrention
/Mitigation
fudr:rig!
- Minimizestrcsr
cotrceDtratbnof compoDentr
C{rpyritht '9 2(X)9 heRurtBl[tsr
i- h
f,'rtlcrra
A form of Mcbanical Fatiguewherc

degradatbn ir producedcr a rerult of
tlynamic loading due to vibratioo, water
hamner or unstablefuid f,orv.
All engineering materialr
AII engineering alloyt
Ttermrl Clcliry - CoheDnrnrq

Eguiprnentin iDtemittent seryice
(boilers). Qrench nozzlee
Affda,|
I Vlbrrtlon
Amplitu& and @ucncy aer,nellar

fatiguc rtrirtance.
Synehmnousload
Arythiot thst vibratec. Small borr

pipiry
PR.Vs, Heat exchanger tuber, etc
Duign, and the ure ofsupporB and

ribration dampening
816/aot0
Module 3
e
Mechenicrl
di.l
Whu ls
'|{cchanlcalFalguc?
hf
-o
F atiguc
4.2.t6 (Pce- lt)
Mechanicaltarigucis a damagemechanismthst doesnot necdmuchcxplanation.

Fatigueis a crackingmechanism
thatcrccurs
whena componcnt
is cxpxrscd
to cyclic
srcssestbr an cxtendedperiod,otlcn rcsultingin sudden,uncxpcctc{fhilure.Fntiguc
crackingis analogousto "overusc"of a part,which thcnbreaks.
A part that I'ails by mechanical larigue t'ails hecause

of cyclic mcchanicalstrcssing like too much
vibration or rcpeatedbending. lt is relatedto but
typically consrdcredseparatcfrom the failure
mechanismsthermal Jittigue rnd corrosion Jbtigue .
copyrightrOaoog'n nuisurtn
Module I
Mechrnicrl Fetlguc 4.2.16 (Pg.+53)
Dcrcrlptior
. 'Ihis is a mechanical form of dcgradation that
occurswhen a componsntis exposedto cyclical
stresscslbr an extended period.
The arrow points to the failure of this bleeder

assmbly off o[ a pump. Note the
unsupportd weight of the assembly.
c{rrd
Cbpyntht
O 2@9 TheRutBEtd
.. -:E
t- ,fl
'::T
816/20ro
Module 3
SSC / Hydrogen
(Pg.4-53)
Mcthrnlcrt
c!r_a
D.!.rlpttor
.
I-hrgrs a mochanicalform ofrlegradatioothatoccuruwhena componentis expocdto cyclical stresscr

lor rn cxtcndal pcnod.
Attcct d Mrlcrbb
o All allo's,butthcstresslcvclsandnumbcrofcyclcsrequircdtocau.sctbrlutvarybym.tcrirl.
Crltlc|l l'rctir|
. Gcrxncfry str6S levCl, numbCt of rfclcs and matcrirl propcrticr {strfigdl hardness& miLTontruciurE)
. ('S and Titanium cxhibit an endurancclimit below which htiguc crackingwill not rrcur rcgardlessof thc
numbcrol'cyclco
. lo0 / tl{)OScriesSS,alumrnun\ and mosl othcr non-tbnousalloyr:
r' llavc a latigue characteristic thm docs ntl exhibh an endurancclimh (larigue f'racrurecan bc achievcd
undcrcyclical loodingevcntually,regardlcssofstrcss ampliludc).
. Marimum rycli|j.| str6r amplirurh ic drcfinirEd by rchtin8 thc rtr6s nq:ca!.ry to (:au* li.*tufc of thc
rlcsrrednumbcrof caclcr nocr:ssrryin r crmFnent'r litctinE. Thir rs tlprcalty l06to lot cyclcr.
cdrd
Coryritht O 2e9ThcRun8ut6
Module g
MochrnlcelFrtlguc 4.2.16 (PB.+53)
(lSrd
Trndu
Hevc n cf,drurnca limit bclow whicb fangrr cracking wrll not occrr. regrrdlerr of thc nurnbcr of cyclcr.
ltc nunrbcr of cyclcs to faligrr
A!|ttiialc
.
strlrh$
tiachnc dccrcarcr with strGls ilnplitu&
stccb rad dr[l|ri
Do il). hrw m Erxlrrm:
do nci hrvc m crxruretr
limit.
uf cyclcr a . grto 3trcsa
Carbonsteel
')::
magnitudeof
cyclicstress
csrtd
m cndrraocc limrt ls mhcd.
lim4 will h:rc a langrr limn dcfincd by tlE nmbcr
sFatiguclimitfor X
numbrof dcsign
cydcr
stll
Enduranca
limit
Aluminum
alloy
N
Numberof Cyclesto Failure
CopyriBht 'c) 2oo9 ThRurtBwtN
8/612O7A
Module s
'3
Fatigue/SSC/Hydrogen
Vlbndor - lduccd Ctrrmlor l.Ll7

d-a
(P& T59)
O-
Dcrtrip6or
A l'ormof mochanicalfatigucin which cracksarc produccdrr thc resuhof dvnamicloadingduc to
vrbration, water hammct, rr unslahlc lluid llow.
Aflcttcd Melcrirh
o All
:
.
('rltlcrll'rctorr
. Amplitudcand frcqucncyof vibratirn u wcll asthc tatigtr rcsisrmccof thc cornptncng.
. I lig,htikclihrxd of craukingwhcn thc input load is synchnmnxruswith thc naturd frqucrrcy of
the componcnt.
Aftcrtcd Uil6 or Equlp|rcrl
L Smallborc piping that ir not sutffcicnt$gweclcd
:. PRV'sthst arc subjcctto chlnct
l. l"ligi prtrlturc drop contrrrlvalvcc.
cd{
Copyrisht O 2oq, ThcRutButd
th
Module S
Vibntlor - ledrccd C'mmdor f.2.17
(P:. +5t)
Apparrmc of Morpbologr of Dur;c

. (lrack3initirtinS Et l point of high strcastr discrntinuitysuchrs a threador wcldjoint.
r Failcd refrrctory.
Prcvcntior / Mltljrdor
. Bcatprwentcdby gooddcsignfiar hclpcminimizcvihralion.
Inrpcctloa rnd Moaitorlng
. Lrxrhl'orvisiblc signsof vibralion.pipc movancnt.
e Sond I
tlrpyritht
l- \D' t ll\\
{c) 2oo9 TheRutBNtu
/.
' ':l
8/6/}OLO
(*
Module3
Fatigue/ SSC/ Hydrogen
Corrocion Fadgue
re
ll'hd b Comnion
4.5.2 (Pt 4-$5)
o---
Foigtrcl
Corrosiontatigucis crNckingof r matcrid tharrcsult! from thecornbinuionof a conosivc

environmentandr.yolicloading.'l'heeffectof lhc corrosivecnvimnmentis to causethc matcrial
to lail t'astcrthu it normallywould in a non-corrosive
cnvrronmcnl.l'hc mechanism'corrosirn
t'aliguc"has two scpantcpart3,thc combinationof wfiich rcsultsin l'astcrmatcrirl dcgradation
thrn by cithcrof thc two mcchanisms
scparatcly:
t.
Firsl - conosion ofany kind causing metal l<xs, for instancc galvsnic cnnorion. chloride
pitting, or tbc likc, thd scrv6 to rcducc mad thickncss and incrcasc ft str63 in thc maal.
Sccond - I'atigueca[sing thc cquipment to ful in a brittle mode. Ihis fariguc t'ailure is liom
vibrating or cyclic opcration, actinS on thc corrodcd or thinned area. However, unlikc purc
mcchanical fatigue, the strcfs lsvcl rssumcd saft trx in{initc life is lowrrcd or climinatcd.
l'hc cornxion inhgent in comxirn fatiguc sc'nes to promotc failurc at a lowa strcss and/tr
lower number of cyclcr than would oomally bc expcclcdin thc abscncc of sonosioo..
copyrilht (O aoog TheRutSutF

t
Corroeion Fatigue.r-d
4.5.2 (PS e-rgS)
Artrr ofConcctrr
'fhc term 'cprnnion farigrF" hrt bcqn ured to den'bc
feih s in th. folloh'int typcc of equipment:
Rolating c{nrilllncnt: Cornxion of thc impcller and pump shafi mry eaure pittinS thrt can act
as a stresa conL:cntratorand crack initiatioo sita. Cahanic L:ouplcebetwen impcllcrs and shaftr
with dissimilrr materials have produccd lo<alizcd cprroaion that led to corrosion fatigue.
Irc0,erato'. eracking, Deaemtors are port of stBm generation equipment and urtd to prepor,e
Itoilcr Ferd Water ka thc air out) b mcchanir:rl ogitation. Residual nq/Ecn in thc watcr i!
oftm aeffittal
with wrtcr of
thoufaht to provide ttr tpnwion componqrt. Fluctuatiry strffi
steam hammer in the system prwidc thc cyclic atrccser that ran dianrpt the normally protectivc
onde laver and causc local stress concntration and cxpose frcsh metal to cormeion.
Qc&'ng boitar.' A qrcllng boiler is susccptiblc to corroeion fatiguc bccausc it can se sd\tral
hundred cold startr in its lifaimc. Due to differrential erpanrion, teee mld stlrt8 can true thc
cracking of the pratectirc magntite cvrrtsion scale allowing corrosion to rcsume. Damagc
ususlly stsrt! with r pinholc leek on thc cold side of a wrtervJsll tub .t a bscktey attschmcm.
(LJrcling boilur opretion is nct typical in a refrcry or chemkal phrn, unlcss steam Benerstion
unitr arc unreliabh).
copyrifht'a)2oog lheRustButn
i"\
8/6/2010
Module 3
z
:'h
r
--o
Corrocion Fadguc
C.S.e (PSC-I3S)
Conrparisonwith Ordinary Fatigue
Module 3
o
Now with r general concept of Fatigue, lets look at the book
l'rtiguc
o fhcrmal Fotiguc
. McchanicalFatigu
o VibrationlnduccdFatiguc
r CorrosionFatiguc
+27
4-53
4-59
4-r35
;ri
-/ffi
10
,.*r,
|..i
t:,
8/6/20LO
i:3
Module B Fatigue / SSC / Hydrogen
Module g
Strtrs (lorrosion (lrrcldng

o Chloridc SCC
e CausticSCC (Caustic Embrittlcmcnt)
o Ammonia Strcss Conosion Cracking
. Liquid Mctal Embrittlcmcnt (LME)
o PolythionicAcid SCC
o Amrnc SCC
.
C8rbonoteSCC
4-ll0
4-ll8
4-t44
+1 4 8
5-3I
5-l 7
5-52
Copydtht rg 2oo9 TheRutBu!t6
{"-ru
11
8/6/2OrO
Module3
Intrrrduction
- StrercCorrosionCrecking
SCC is thc crauhng ol'alloys rs s brinle-typc lbrlurc ofo normally rlucrrlcallo' by rhc srmultsncousprescnoc
uf tcnsrlcsrtxs and o spesllic sorrosivemtrlium. Given spqcrliccorditions, alrnostsny alloy cm bc mde to
larl try a stresscorrosroncracking mechanism.
f;rnecu-ks pnelralerleeply into the menl while thc surt'accexhibitsonly l"aintsigns of cornrsrooand oller\
a bnttlc t'rarlurc ray occur rn llfial would nornully be a duailc mucrial. 'thc lblkrwrng t)pcs of rrndrt
strcascaIn a mctal may bc rnvolvcxlin SSC:
RcslduolS:''cssc'- Examplcsare bendingor nelding. ()thcn arc uncvenhcrtlng or cooling.
4ppllcd Slrf'sd' - Workrngstresstiom intemal pressureof structual
In nrost instances,rcsrdual slresssare thc majof

lactorin SSC.
Ihe specrlic corroolvc spccier thal carser cracking
neql not bc prescntertfierin largequantniesor in high
eoncantratr(xls. (ieleral cortrrsronas rneasuredbv
Inelal loss rs otlen ncgligible.
!t
'a
(:)zqryThcRutBui6
Ci)pyriSht
Ti
Module 3
ChlorideSCC
.dbaa
Dcscrlptbr
4.5.r
o-
(Pg+-rso)
Surl'sccrnltiatdcru*kr causedby environmcntalcrackinSof 100 Sfiics SS undcrthc combineda,ctionof

lcnsrlcstr6s. tempcratureand a water/chlondeenvironmenl. Particularlyharml'ulare acidrc,os wcll as
0xygenated,chlofl de solulrons.
Aflcclcd Mrtcrirb
o All J(X)scnesSS is highty susccptiblc
. Duplex SS arc morc resistant
. Nickel bascdalloys qqr be highr)*rcsistant.
('ritkrl
Frton
o .l(X)SenesSS is su.gceptrble
to Cl SCC rt dDsl rly colccrtrrtlDl of Cl rt tcmpcrrhrt! rbovc
I l0 F. lncrclsing tcmpraturelncreascstb susccptlbllrtyto cracking. Incrcasingconcentratron
rncrcaseslikelrhoodtool l'lowever,cascsof chlorr& crackingarc daumentcd tb'r lolrr lempcrnturcs,
s{)thd l{l F rule is not abs{rlutc.
. Ni qlnlcnt of the alloy hasa major alfec'lon resislance.Th greatstsusceptrbrlityis al a nickel
eontentof 8 - | 2 %.Alloys wrth Ni contentabove15 % arc highly rcsislant.
. t-ow Ni alloys suchas Duplex arc m<rr resrstanlto Cl SCC, but are ilt rmmune.
cont d
Cnpynght rO 2oo9 Tt.'RutButerr
'_l
tz
8/6/?OLO
i.\
ModuIeS
CNoridcSCC
4.5.r
(Pg +-rSo)
('ritlcrl
Frcton
. l'he prcscnccot ()2 wrll incrca$ th litelihuxl tor cracking but thcrc rJ no rdcntrliedthrcshold.
. ('ISCC usually occursal pH valucsobovc 2.
. CISCC rendencydocrcascsrn thc alklline pH rcgion.
Jurt sey'NO'
Copyntht rO 1q)9 TheRudButs
Module 3
ChlorideSCC
4.5.t
(Pt4-rgo)
Alfcclcd Lldtr or Eqrlpi.rl

. All .1(nSSequrpmcnt.
. llcllowr and rnstrumenttubing porticularlythoocoss{xiotcdwith llydrogcn n:L)clc slteam!.
. llxtcmal Cl SCC har ulio beenexpcricncal fnm unling tower rlritl and marineenvironmenE.
Appcrnrcc of Morplology of Drnr;c
. Branchingir'IRANSGRANUI-AR- ln scnsitrzcdlO0 Scncs SS,thc crackingcan be intcrgranular.
. Characcristic strcnscorrosron cracks have many bnnctr,s lCrac{rrts)'
Pracotbr
. When hydrotesting utc lo$, chloride water,and llush adequately.
. ttsc resistantmalcnalsol'construclton.
. Appry coalrngl
I Np.ctio! .!d Molltorir3
. Cru*king ts surtbcc connoutcrland MAY bc VT'
. ItT is the pretbrred mcthtxl.
. Lxuemely tine craeksmay be difiicult to tind with Ft
Copyright,O
2009ThcRwtSultert
/'*\
ta
13
8/6/2OrO

3 Cauctic Streco Conocion Creddng (Cnrrdc Embrittlemcnt) 4.5.S (pA4cautTtc
.6r|-.
ll<xra
ceivtcl
cxait
2W
?@
.9Pr|o|s
or .krd
ro r
c6a6r-
2ao
'd
.kF
thn d-
tm
rto
2'&
r@
200
rp
f, tat
zo?.
""i
mS
l ,-
I
!r e
rm
20
.E'.H 'E.q
to
co ffi Fffi N g .tb ti d e h

tud,.
Copyntht'q
C@rj.aSu,,q
MCE.
lgag
2(x)9 ThrnurtButctr
.'"\
t,
Module 3 Fatigue / SSC/ Hydrogen
tensile stresses in a metal mav be involved in SSC:
Raidual Strrrsas - Examples are bending or welding. Others are

unevenheatingor cooling
,4pplied S'tresscs structuralloading.
Working stress from intemal pressure of
,'.
1+
8/6l20LO
("'*

Causdc Stresc C-orrocion Crackinf
----j:=---
(Caucdc Embrittlement)
4.5.3 (pg 4-r3E)
n ---
Dcscriptlor - Caustrs"canbrlnlcrrnt" 13ilctually a rrH-.

n plcal causlrcEmbnnlernc'ntdosnot occut
as a srnglclE:*ture, but as 6 nctwork ot linc crackr. No truc cmb'rlttlcryrcm
ot'thc mctll is puluccd.
('rltlc.l
Frcto?t - Scc !'lgrrt

Susccptiblcmaterralr
. Caustrcatreng,lh
o 'lempcraturcand
{-t3.
o Stresslcvcl.
Causttccrackrngrn carbonand low alloy steelcoocurr bccawc clustic snack! thc grarn boundurcsof thc
nretal. Crackrngalong the grarn boundancsis calld tucrgroulo crxhag. 'fircrc crackr arc usually
rrs$)eratdlwrthweldsandaretyprcallyrntheboscmetllatthcwcld'sllcatAtfectcdZonctt{AZ).
Stainless
stcclhos marnly highly branchcdtransgranularlthrou8rFgtain)sracksthlt lo* lilc chlqidc strcssco.rosion
crackrng.
t**
^,
ffib
ttM
G)pyritbt a) 2dx) fheRutBrstd
Module 3 Fatigue / SSC/ Hydrogen

C.aucdc Strccc Corrocion
Crackin;
(Caucdc Embrittlemcnt)
4.S.3 (pC l-rlE)
t1*lensile Slftis: ('austic crar^kingonly occurs rf tenl#stresscs are prcsqrt. lEnsrlc stressca"pull- thc
matcrial. As thc caustic corr<fcs thc grain hrundarics, th teflsilc stress pulls thc grairu apfft
allowing the caustic io reach nerl grain boundaries,causing further corr<xiorVcracking. lncrcasing
tcnsilc strcsse3increasesthc cracking growth ralc.
.
Tensilc strcascsarc always prescnt in our pressurccquipmcnt. Tcnsilc sEcsscaarc thc rcsult of:
o Residual stresvsJrom welding
o Resuluol sttzssesJromJorning
o ()peratingprcssure
o
of materials, e.g. rolling,forgtng,
extruding, etc.
Thermol grou'thishrinkage
A
4
f*$n
f*gm
hh
t,d.tA
CopyrightO zuNr'fheRutgut$
i\
15
816/7OrO
Module S Fatigue / SSC / HYdrogen

ArnmoniaS@
4.5.4
(ps 4-144)
What'sAnhydrousAmmonia StressCorrosionCracking?
(DAS)
. Dry ammonia cracks steeL
. ll'el amnunia crachs copper. (wAq
o Anhvdroust rln ) ammonrocancauscslrc$ conosioncrackinS(SCC)of carbonstccl andlowalloi stccls. Stresscon$ion crrukingis r crackingprucessthdrcqutrcslhc slmgllsldNs aclrcn
t.'rackiijtypicallytrcc,uis.inarcas.ofhighrcsidual
.i'i'"riiJintino.*iiinc,tr"nsilcsfftss.
lcnsilcstrcss,suchassl wcldr andin cold-tbrmcdcirmioncnir. Crackshavcbccnfoundin
(vap()fsp8cc)thu st'oreor hrndlc anhydrousamntofli4but
ificres nnOurtra prcssurc.vessels
havevsldomoccurrcdIn ptplngsystcms.
llow AnhydrousAmmtnia
o Purcanhydrors ammoniawill not causecracking.
with aslittlc as I PPT^9f g*ygcn, will crack
. llowcvcr,anhydrousarnmoniqwhcncontaminatcd
hiehstrenrrh;lcck(tlSS).MatcriahsusccptiblctoanhydrousamrnoniaSCCincludc
c-rtbonslccfl vql smallarnounts
*c.is, nickcl stccls,aridto a lcsscr'cxtcnt,
;;dfiillvbd;uln
ul,rxvscn iir ammoniewrll rxrrorJcthc stccls,lirrmrngan oxidc tilm. lcnstlc tpullrn8ap&t) strcas
."n Uiiof this film, frccing thc mctal sutfaccto bc coirulcd agatn.
copyritht (g 2u4 Thcnutlutten
3
Module 3
4 ArnmonhS0C
,Ycl anuttorrl4 claclr conc?.
Fatigue / SSC / HYdrogen

4-54
(vt+'tu,
llould Wrtcr
SCC is an electmchemrcal proeessthat rcquirg an aqueous(ty?ically liquid watcrl
Iffi*.ttronia
rn.uno.t *rth t|1cmcral. Very lirtlc warcr ts requtrod. A.vety lhln watt lalct oo
,-fiug ro * ot"dr
wncn mC
itrc nraal su;i'!cC can
-,1causc alucour ammonia SCC. Aqucous anmonra SCU wlll lx,l occLlt
uarcr'is onlv orescntin rhe fblm-o?-avapor (dry sleam); a solid t ice).Ammonium saltslcftl to bc
riom rtrc sunioundirigcnvrronment)Nndc8n prqlu{c s walcr-r ttcd condition
rr"frrji,iii'ir'"6ii"6-*aicr
wtrin in c'ontacrwith tlrc aurt'ile oI the rnctal
.
Oryrcr - kySqr is ralurrctt l'c rnitiationol-alucous ammoniaSCC. Tt '.t)l: :f_rpgXljs lo tercl

wtth coppcrBod rn" oqu**alnnronii rJpmau." ttc coppcl-irmlxxliacomplex ron (CtdNHr).'l)
nussarv to rnrtratcscc.
llor lo Stoo Crrclirr

.
Rerlu,cingtensilestrcsslevel (stressreficving; will reducethc tendeneyto crack, but aqueousammrxrle

SCC can-occurat low strcsslevels.
Theorescnccolhvrlroccnsullidd(H,S)tbuftlinrelinetysreamsappcarsloinhibrtcrackingofcopper
the dismlverl oxlgen conrent'
alloyi. Ilus has betn irtnbuted to HrS redu,r:ing
Copyritht (9 2oo9'ItleRugtEuter!
1'T?,
1r
8/6l2OrO
{..-*
Module 3
f.-{.5 (pt {-l{E}
5 l,iqrid Mctrl Enbriltlcncrt
Whar'st-iquidMetalCracking?
l-iqurd N|etalCracking rs I b-pc of crackingthal rrccurswhcn cerlain mollcn mctals come into
c()ntactwtth spccitic susccpliblcsolid mctals. l his crackingcm lced lo I csloslrophichtitllc
lailurc of a mrrmally ductilc mctal whcn sullicicnt tcnsile stressis prcscnt. Cracking can uccur
evcr whcr a smdl amount of thc moltcn mctEl contacts a susccptiblc matcrial ond thcsc cracks can
rmmcdiatcly bcgin to grow oncc thc susccptrblc matcrial is "wencd" by thc nnltcn mcral.
Forfunatety.this is n{t r c(}mmur problem since nv;ltcn mctrls arc fi)l uo|nmon in pctrochetnicrl
f'acifities (except duringwelding) aul,donlyspccific combinations of molten and solid mctals causc
cracking Also, thc solid componcnthas to bc at an clevated tsntDrltute lbr thc liquid melal
cracking to o,ccur.
Volt.r Ma{d
Smcpdblc Alby
100 Stri6
Q UI ZTI M E
Fh- l' a*.tl.al:
f.ir
SS
(,'uAlbyt
Mnry
Alby .xx)
Mtruy
{hminm
Mtrcury
albvs
copyritht /i) 2009 TtcRulEwt.[
('h^

7 PotythionlcAcid
SCIC(PASCC)
5.r...r
(pg S-gt)
Dcrcripllor
.lhistyFrofsCCrsmorearrcurately&scrrbedarstress-rDcclerale{rinte4rrnularcorrosionofsensitizcd
starnless
sleclJ.
Allcct d Mrtcrlrb
o SonrelO0 Seri6 SS tlul hrve bocn semrlizd
('rttlcrl Fr.torr
. '[o rpr'icflie PolythionicAcid SCC, a combinationof things mun <xcur:
. Sull'ur must bc prercnt li.r:m tlrc p|iocess. Sult'ur scalc rcarctsw|th air (oxygcn) anrl rxrsturc to lirrm
sulturacids(Pollthronrcarid).
. Materialmusl he in a suscepttbleor "sensttired"condition.
. Stress
- Residualor applied.
o .)04/I)4H & I | 6/3 I 6H are particularlysusceptiblclo sensittzrng
. Ilw carbongradcr "L" (0.01oloc)arc lcsssuscepatblc.
. Chemicallystabrlizcdgrades321 &. 347have improvedresistanceto PASCC. Chemicallystabilizcd
gradeshavesmall amountsof'Ii and Nb addql.
,tppcrnrcc ol Morplologt ol llemrgc
. Crockingrs lN-IIRCRANUI-AR.
2009ftiRutButd
Copyright'O
i'h
\
T7
8/6/2OtO
'
tE H S rIrZA tl OX
\
-(
t.t
Sencitizrtion
(^F - ta/x "n ciroE
At hith tempcnnr
mimtructE.
Dephtc ruuir o{ Cr
bpyntht
rg 2q!)'fhef,.ut
qrbldaa
pGipitrt
Lutiomudya.loo8
irlin
bounl&16
in mtsl
BtEt6
i!j'
F

7 Po\rthlonicAcidSIOC(PASCC)
S.r.r.r
(pSS-tr)
Polythionic acids are formed when imn sulfide FeSon the ID surface
of an austenitic stainless steel in sour service is exposed to moisture
and orygen.
oFeS+Or+H"O
HS*Oy+ FeOH
The polythionic acid attacks the sensitizedgrain boundaries of the

austenitic stainlesssteel in the presenceof residual tensile stresses
which causesan intergranular stresscorrosion crack to form.
LirpFighl
ie) 2oo9 ThcRultButd
,:'\
1u
t
tr
81612070
,':b
Module 3
8 AmincSCC
5.t.2.2 tpe*t^l4rl
tlfcctcd Mrtcrlrb
. CS and low alltry str'cls
('ritlcrl Frcton
. lo cxpericrccAmrncSCC,o combinationol'things
mustccur:
. Amrnc Opc. Crackrngrs morc hkcty to occur in lcan MEA and DEA.
. fcmpcratutc- Cracking can occur ti'om ambienttemp lo higherlemp, but is more likely at hrghcrtemp.
. Stress- Resrdual.Residtpl Smsses- f:xamplcsarc bcndingor wclding. Otheasare unevenheatingor
crxrling.
.l ppcrnacc of Morpbolqy ol Drnr3c
. (:mckrngrs INTERGR.ANUIAR.
. Crackrngt)'prcally.levelopsporallclto the weld. In the weld rnetal,the cracksare either transversOR
l0ngrtudinal
wrth thc *eld.
()lhcr
. l"ne Amine cracking is only rusocrateiwrth f,f,,ii{amrne. Crackingassocrated
with Rich umrnc rs
an(xhf cofro3lon mochanrgm
Cogryri3ht '9 zoog ThcRutBwtd
(:h

lt
(lrrboartc !JC'C5.t.2.5
(pG$52)
What is Cartonate StnessCorrngion Crackint (alkaline SCt)?

. Carbonate Stress Corrosion Cracking (Carbonate SCC) is a form of alkaline stress
corrosion cracking that can occur in water solutions containing carbonates. The
crachng affectscarbon stcelsor low-alloy (t - gX chrcmium) stoelsthat have not
ten strs6relieved.
Wh.at arc C-anbonrtec?
A carbonate ig a cnmpound that r:ontains tlt carbonate ion (COro). The carbonate ion
r:annd erdst by itself, and in solids is often found in <xrmbination with sodiunr (Na),
potassium (K) or elcium (Ca). What we are concerned about in cracking potential are
dissr.rlved
carb<lnates,where the carbonateion is in a water phase.
. Sodaash (Na"COJ,
. Sodium Bicarbonate (NaHCO/ is also tulled bahng sod8.
. Calcium carbonate(CaCO), or limestone.
All thes carbonates are to some extent soluble in water, and will form carbonate ions if
the solids are dissohred in water.
CopynSht /O 2009 TheRwtBustero
i ::q
19
8/6l70tO
Module 3
tl
(}rbonrrr SicC3.1.2.5 (pB$,52)
Howdo Carbonattx form?

Cartxrnatecracking requirrs the presenceof the clrbonate ion (CO, 1), a water pha.se,
and pH above 7.6 (more on this later).
'lte most common way for carbonatesto form is that CO, presnt in vapor absorbs
into water and forms the carbonateion (CO"o) and the bicarbonateion (HCO.')
[OnV the cartonate ion is thc bad aetor].
CaEb&icsra!:kinsuiF
There is sig,nificant CO, prr:duced by the catalytic cracking pro{Jcss,and water is present
in the condensingsystems.. 'Ihe areassusceptiblearc the main fractionator overhead
piping and condensing qstem, reflux ryrtem, downstream rvet gas c'omprcssor system,
and the sour waters emanating from these areas.
Thrxe waters are qlled'alkalirrc sour waterr' hr:use thcy ontain ammonia, sulfidcc
and other contaminantr in addition to carbonatec, and arc ma& allaline by the precencc
of the ammonia.
Cot y''ight d) 2oo9 ThcRulBrrtca
'9t'.
Module g
ll
"f

crrboDrrcsc'c5.1.45 (p|39,32)
Q,
Allcctcd Mrtcridr
. CS and low alloy stcels
(lriticrl
Frdon
o Stre$ levcl and n,alcr chcmistry rrc thc critical factors.
. CrackinB susceptibillty incrcasegwith incrcasing pH and carlnatc
curcentration. It cm occur
undcr thc tbllowing conditions:

.
.
.
.
Nfi str6s rclicvcd carbon stccl

pH > 9.0 and Carbonatc lcvelg > l(D ppm
E < pH < 9.0 and garbonatc lcvels > 400 ppm
'l'he
prcsence of -50wppln H2S tr more increascssusceptibility
o Cyanides incrcasc suscrcptibility

Appcrnncc of Morphology of lhmgc
o Cracking is INTERCRANUfiI.
. Cracking typically develops parallel to thc weld
Copyrithlo 2m9 ThcRuBuAw'
r ::'\
20
8/6lZO10
Module 3
Now, what does the book say about thesc ??
Str?r. Corrorion Cncldlg

. Chltridc SCC
o Caustic SCC (Caustic Embrinlcmcn0
r Amm<rnia Strcss Corfo3ion Cracking
.
l.iquid Metd F.mbrittlemcnt (tJ\,E)
PoUthionic Acid SCC

o Aminc SC'C
o ('arbonatc SC'C
.t-130
4-l3t
1-144
4-l4t
5-3I
5-t7
5-52
copyritht (9 2uJ9 ThcnutBwten
Cogyright O 2009 -fheRustlutn
f"'':i.h
2t
8/6/2010
Module 3
HydrogenCracking (Part3 of j)
. HydrogenEmbrittlement
. High Temp Hz/HzS Corrosion
. WetH2SCracking
o flydrogenInducedCracking(HIC)
o StressOricntatedHIC (SOHIC)
o SulfideSCC(SCC)
. HydrogenStrcssCracking- HF
. HTFIA
4-152
S-13
5_41
5-50
5-56
L'oplrrEbt ig 2009 Tbcnrut8rftdr
"t!:r,
Module 3 - General Corrosion fips
a
a
H. ic not the same thing ar H* or (H")

lI, is the "normal state for Hydrogen to be in.
I lydrogen (H) is the smallesr amm.
Hydrogcngas which is comrnonin thc rcfincry is a molccuremadcup of two

hydrogenatoms1l!. -the hydrogenatomhssa strongneedto bonditsclf with another
alom, so it normally docsnol cxist as atomic hydrogen. But at high temperaturcs,some
hydrogcnmolecules1II) breakapart creatingatomichydrogen o. Hg .
6f'
'
H" is what is used in the Hydroprocescingunits (atn qttd
a desu{urinr)
. H' or ( Ho) is a product of the corrosion reaction.
bpyrBht
(9 2n)9 TheRut8urm
r' l'
s
22
8/6/20LO
(:=
Module 3 - General Corrosion fips
t**-r* ;;;;*
,"**Q;;;
;;;
***
A very interestinS aspectof the hydmgenEom ((H* or l l0) is ite ability to actually
travel through steel! It is so small that it can work itself through the molecular
structu of steel.
^;
'Ihe hydm8en molecule (HJ is tm large to ualel thmugh steel. ,{s well as Hydrngen
Embrittlement, other damagemechanisrnssuch as FITTIAand hydmgen blistering are
caused by this ability of the hydrogen atom to migrate through steel.
rl,.C*
F'
lt.ra.
...
*ctt
ltc
b
dlo-qt
FlrFr---
whr'l'r'dbt'ba
dmffedtdry.
t|*tad
f rod'f
dffiffiil
haton
d |!d.!0-
Uafr.
O)p_vril,ht {c) 2oo9 TteRutBwteF
Module 3 - General Corrosion Tlp"
Tlv HyfuenMysteryIt
llydroganin stccl is a bld retff in scscralwfryl. Ardnic hydrogan(61'cr H9 is alwsysthc

culprit Hcrc'sa simplifrcd oomparison:
. llvdro8el f,nbrlttlcncrl - At high tcmpcraturc,a smrll amountof mohculu hydroScn(H?)
will split into elomichydnrycn1H+). Atomic H' difftsc in stccl,but stsysasrtomic H'. When
thc stcclcmls, thercsuhis a lossof ductility. Controllcdrtrrt-up andshutdownof hcrt up / u:ol
down andtcmpraturc for pressurizalionto prcventtircturc.
.
llTllA - At high tcmpcrsture,

a smallamountof molccularhydmgcn(H") will split into aromac
hydrogcn(H'). Atomic H' dilftsc in stccl,rerts with carbooto lorm mcthane(CHr) and
resultl in cracking.Operuinglimits oftcmperaturcandhydrogenpartialprcssurcprcvent
IITHA.
phcnunanawithH,S andwatcr.
Hvdroger Blhtcriag, HIC i SOHIC- low tcmperaru'G
Atomic H diffirscs in stccl, asa rcsult of a carosron rcetion that libcrarcr dornic hy&ogan.
Monitu environmeltalconditiom(pH, HrS sontcntof wltcr, dissolvedcyrnidcs)to pcvcnt
akmic Hr scneration.
Copynght tO a(x)S TheRut8uter!
'''h
23
8/612010
,.\
"' . f r
Module 3 - General Corrosion Tips
The Hyd;,rtgen
Mysteryll
I lydrogcnin stcclis a brd acttnin scvcralwrys. Alomic hydrogcn(H) is alwaysthc culprit.

llcrc's a simplilicdcompffrson:
Whaa r+@6t
C'ondit{oar
ltlrcowngc
Blf,ttering /Cttcking?
Hydn4en is a by-pnxluct of many types of c'orroeion, A hydn2gen atom is formed on the

sur{ace of the stecl and usual}y inrtantlyjoins with anothcr hydrogen atom to firrm a
hydmgen molecule. Sinrx the hydrogen molecule is tm large to move into steel, the
hydrogen bubbles off into the proq:ss stram causing no damage.
Howwer, HzS in water can slow the formation of molecular hydrogen. Thee are called
rcmmbination poisons since they signrficantlyslow down the rate that hydmgen atoms
reurmbine with themselves to form molecuhr hydmgen. Since this recombination ta-kes
morr time, the atomic hydnrgen hao more opportunityto mrrye into the metal.
Anothcr ruconrDinationpolson is CYANIDE. Cyuridc is colrunnly found in FCCU units.
C"ogyritht i8 2q)9 nrcRutBrBld
Sr
'.i':
Module 3
6 llydrogcaEnbrittlcmcnt (tlD) 4.5.6 (pS+152)

rfl
o
i.
t).!crfilbr
li) drogen Embrrttlernent ( l-lydrosen Strcar Crackrnt) is duc to lhe FrerEtratim of arodic lrydmgcn ( H+,
not llr). Hldrotfl in thc atomrcstatcran dilf,rc thmugh thc strue'tureof nrcrslsto highly suesgqj sitet
(notchca,inclusionorcracks,andcantherebyproduccembrittlemcntofthcmetal.
Ihecrilical
concenratronsofrlissolvcd llydrogcn dcpcndron the rtress(applicd & rcsrdual),thc exrstingdefects,
and th inhcrentioleranccol'thc mlul towffd hydmgen.
Allccltd Mrttrleb
o Mosl commo.rtyussl malcriElr incluting carbonstecl, Iow alloy stccls& 40OSeri6 SS,
(friticd Frcton
o Ingcncral,verylowconccntralion(inthcpartspcrmillionrangc)ofhydro3cncanbeharmful.
. Hydro8enmust be presentat criticrl concentration.
. Steel/alkrymust bc suscep,trblc
. Strcssabovc thc thresholdtbr HE musr bc prcsenl.
o CXcun tiom smbicnt to 100 F ElIcictsd"cr?arr wtth incrcasingtcmpcnrurE,ond HE is not likcly,.to
(xcur abovc l6'0 F.
. As strenglhincreaser'susccptibrlityto HE increarcs.
. 'Ihc prescnceof cyanides, arsenic anl FeS can rct as hydrogen recombinuiur poisonr.
.{ffcctcd trnlt'
. Scrviccsin wct l{rs or sour water(due to the contaminantofcyanidc).
Copyright,O:@9 TheRuctButdr
/ryl
'v
24
816120rO
(r=
Module3
6 llydrogcl f,mbrittlcncnl
t-5.6 (p6 +152)
.tppcenrctof M.rpLL3r of Drrq:

C'raclingir IN'ITRGRAMILAR
Prwention
.
Hvdmgrn Ernbrittlernent cracks often pmpafstes qute rapidly and tan lead to catastrcghic
failurct, P.\'enfrequcnt impectionr Lrnnot bc expected to dctect sites of impending failt[es.
tte?usc of thc suscrptibility o{ high strcngth materials thc maximum hardncl of critical
refinery materialr urrd in thc moc cummon form o{ lrydnXm F.mbrittlem{t (sutfid. strrxs
eomxirxr cracking), ir rrften hekl to:oo HB.
.
tligh strngth ASTM A r.r3 Crads 87, ar high strength bolE thst dhould not be used"
RcLrld Mchrbrr
Su.ltklcsfca! cr.ckiry (5.1.2.1)andt{y&ogd Str6s CffioerooCmking in tlF (5 | 2.4)ar cbscly rclatcd
lurmr of hydmgcnctnbnnlarncnt.
CopyriBht rc) 2oo9 TtcRNtButer!
Module
_" - r
3 - General Damagc Mechanisms
- Refinery
Industry
tllgi Tcop H2lHaSCorrcioa t.l.l.5 (P8.$lJ)
--..\D..crlptlor
.l-hc
prcscncc of hydrogcn in HrS stscamr rrrcrcascrthc scventy of high tcmpcralurc rulfidc c'orrosion at
tempcrsturs above50OF. Ihis tbrm ol' Sultidationusuallyresullsin uniform loss in thickness.
Qi
Atfctcd Mra.?i.l
o In <rdcr of incr{sing,rerbtarcc, CS, tow alloy, dOOSetics SS, and 30OSri6 SS.
('ritlcrl Frcton
. l l:S concentntbo - Tempcrarurc- Prcscmc of lb'drogcrt ( H:).
. Higher corrostonratcaarr lbund in gar orl desulllrizers and hydrmrackersthan naphthadesulfurizen by
a tactor of almosl "2".
. IncrcasingCr contentin th slloy, increasesconosion resistance.llowever, there is little improvement
wrth rncreasingCr contentuntil about 7- 9 Cr.
Affcctr{ Ullts or EqrlP|rctt
. Noticeablcincrcoresin conosion occur downstreamof hydrogeninjectionpoinE.
. '[his cormsron u:,uun wfrere high tempcraturEHy' HrS str.rns are tixnd. This nreansHydrotreaten and
l{ydrocrackerrll!!l!
Orpynght.cl
zoogTheRutBrsterr
25
8/61z0to
Module
3 - General Damage Mechanisms - Refrnery Industry

lligh Tenp ll2l112sC'orrosiol 5.l.lJ (Pg.Sl3) cont'd
.\ppcenrcr of Morplolo6r ol Drne;c

o Conosrcn wrll be unrtbrm bss in thlcln6! and aocompanralb'y the formationof an imn sulfide scalc
. Scalersatxul 5 tlmcathc volumcof mctallossand may bc in multrplclayerr.
o 'l'he trBhtly shrnygray scaleona{hcdto the surt'acemoy be mrstalen ttlr unatle:ted metal.
Prwcotbt / Mlt|irrbtr
. tlsc alloys that arc morc rcsistant.
.
l{)0 SeriesSS suuhas J04L, J I 6L, l2 I and 147 are hrghly rusistant.
*l'$
lnrpcctloo rnd Monitoring

. l-l'f / RT suspoctcdareas.
. Monrlo'rt'ccdstrcarnsto conlirm thEtHrS levclr havc not srgnrlicantb'lncrcased
N$fue^
\'u
.\
t
g - General Damrge Mechanisms - Refinery Industy
Module
ll|3h Tcnp H2llLllSCorrosior 5.1.1.5(Pg.t13) coot'd
C'oupcr-(ionnr. ctrvcr - Flgurc 93
n
1"'
t
*---
--f k d Fd b *
. --F, . . s d -
l do'F .ft*
tl 6J r * dt* @ l * t
o@ dr .
bs i
lo.d4.
-rd d Fd * 4
hY-
Cotryfl8lht 'c-) 2rr09 The RstBustcB
i,?
19
z\
8/6120L0
.."'q*q\
t
Module 3 - Gencral Damage Mechanisms - Refinery Industry

lligl fcmp H2lll2S Corrrxior 5.t.tJ (p:. ltJ) coet'd
The McConomy Cun'es

We wrll get to it later, but thtxe
cunr'esaneused when there s no
llydnr;cn prsscnt.
_ -,r*:Tb",
/. .r$v
^. C.rnL.r5'r
.alv
*:--T$"t$bP
I
i
r)02;- ---;--a,":'l -----i -J--:*
r50
,nil
nlo
^\5!F
r
r
I
600
"a)0
f'r r p !:r Jl L r c,
ModllLd
Mccdomy
i
,
i:
I
,
;,o
tstn
_l
r30
r \ilff,
\\
rta-'.N
'tr
Cutv.a
Cbpyrifht q) 2ur9 TheRut8urtan
$)
J \ l''
. r[\
rt'\
Module S Fatigue / SSC / Hydrogen
9 Wct HIS Drnrgc (Bllrlcriry / lttC/ S()HIC / SSC)5.t.2J (pB 5-{t)
('hcmicrl liryinccring l0l

. Panial Presgurc
rm rorrrrarr
PartiolPrcssure - rxroccntrationof matcrirl X opcr.ating

A H28
S)trtem hecanrc
PtlI
Puftd Frcrrurc PSf
25
loo
5o
too
loo
5o
loo
loo
t HrS
Sptem
Prerrure
25
PSI
Prrtid
Pres.urc
lo
I,OOO
20
I,OO O
2()()
3o
I,OO O
300
PtlI
too
f"\
27
8/6120L0
Module 3
Y1]Y
Drorsc(Bllilcriu / lllc/ soHlc / lisc) 5.tJJ {6 s-0t)
Aflcctcd Mrtcrieb
o ('artnn Sterl and low alloy stccls.
('rlilcrl FrctoE
o'[o expcrienccWet llrs .Jamagc,
a combrnstionof thinggmustuccur:
o l:nvimnrnenlalc{rndilioff(p}l HrS levcl, contarninmt* & tcmpl:rilurc).
. | l)'drotetr permeatiql incrcrscs wrth irrreasing HrS porriol pttssutc.
Partrd Pressutt * HrS concertratrcn X opcrating presrurc
'l'cmprstutc
- lr must bc WET (rltl trtc?), so thc susceprrblitytcmpsraturcis bctuecn ambicnt and
l{n l' SSC gencralty rxcun bclow about I t0 F.
l lnrdncsr- fhis rr pnmarily an rs:tucwrth SSC. Wcld hardncsrshould bc cootrollqJ to bo < 20OllB
(Rrincll lhrdn6r).
Brirull llardncss = t sl / Surtbrx arca.
Cofryritht O 2oo9 l'hcfi,irabutcc
Module g
"igr\
-" '".:.i9
9 Wcr HrS Drmgc (Bllt|:rllg/
.2
HICYSOHIC / SSC)5.1.2J (pg 3-lt)
,. :"X1.
2b
8/6/20L0
Module g
9 Wci HrS Drn4c 1Bltuicriry / HIC/ SOHIC / StiC) 5.12J (6 ${l)
:_____-_nv
'lypcsof craclingtbund:
lllC - llydrogcr loduccd (lrrcliing

. (i)nsrstsol Blistcring& lissuring
. (.llcanlincss
of stccl ig kcy t'ar.ltr
SOlllC - Srrc* Oricnht.d lfydrogcr hdrccd Orrgtile
o Strckin8, of fissurcs
. Stecl Clcanlincgs md rcsidud / applicd strcss
r.-.---.*
\-_f--\_
ISC - Srlfidc Strco CrrcHlj

. t lard Wcld Cracking
. Wcld Chcrnistry & Wbld Proccdurc Rclatcd
.--....'--_t
LIIJ$
Sullldc Strco Corrorioo Crrcbns ISSIC)-Hrrd Wcld Crrcliln6

CopynAht {g,oo9
(*
ttcl'ut8ut
tr
Module g
9 W"t HrS Drurgc (B{rtcrlry / lllc/ SOHIC / SiC) 5.1.2J (6 Sal)
A cban rtocl rurlacr normally cotalyzar tha cofnblnatbn ol etqnb hydrooon

lorm.d bV corrotlon to moLqrlar hldrogon, hrt It X28 lt th. conod!il
fha
coimDrndbn rt tha mid etrts
it grofly r.tafd.d rnd rtomlc hyrtrogon dtffurt
Inlo tha rl..l.
Hcl
Ho
H0
. Ho
H2(11o
Fe+ 2HCf - Fc C l , =Z X o
Fo + H'S
FeS + 2ll'
2t{ Hl
2W -tH2
The bulldup ol an iron tulfbe laycr d tha mdsl ],|rfg
lbrt tha rda d conoabn,
and eycn il tho sl.ol hla an lila.nrl <lolrct, blltiarlng mq/ nol occur. Hoi,auar, it
cyenidcr ara prt'ant elong wlth tha HrS, tha tonour stfiO lrta. mly ba dlrcolva4
and hydrogan cllffution conllnu||, cr.stlng hlgh inlomll pralturca !| tho draacir
and aa lh. Caol oyonturlly ybldr, producing bllrtan
Urpynlht (c) 2u4 T}IcRrd8ut.fl
i'h
29
8/6/2OrO
."\
Module 3
s
It
9 Wct HrS Drmrgc (Bllrt ri4 / HtC/ SOHIC / ti*t) 5.1.2J(pC9al)
HPC}W
,M
-'
wlth ctnl'.
dltrolu-:
ll'**
Wlth FaO|ryar, nrstlo|r rlofa

rnd t ltl.rlng nat nol occu,.
F+!Ctl-*
IrI.|(
F.t Hb
r.(Cil0f,8'
snd conoabn ontln

wllt
fonndbn ol htd.ogaa-,Uuarr
Grpyritht (O 2009 TheRutDlltEr
Module 3
/ Hlc/,{ltltc / !isc)s.l.2J(6 s4l)

Wa"lllLDrnuc (Bllrrcrlns
o)
Prsycntion/ Miti gation:rd i. rl&)

Stecl making
r lllistcring and HIC arc stmngly atl*:ted by thc prcscnceof inclusion and larninations
provide sites tbr difhrsing hydrogan to accumulete. Usc clean resistant (Killed) steal.
. tjse IllC resistantstccl (what's that)?
CopyriSht (O 2o0g TheRwtButtd
tl-.h
't
30
8/6/20L0
("\
ModuleS
9
Fatigue / SSC/ Hydrogen
Wei HrS Drmrgc {Bllsl.rint
/}{
s()HlC / sS() 5.1.2JtPe5-{l)
d..bt
Prcvention/ Mitigati<n:
.
.
.
o
llwllT
Ctmtrolwcld hardncssto lcssthan200 tlB & localizcdzoncsabove237tlB. (NACE RKX27)
tlse t)7M h)lr. lhey arcsollcr andbwcr strvrgththan87 hrlts
(cE) lcssthan0.43.
lrsc carbonstcclswirh carbon t'iquivalents
\f-
hal_
cEls<refineda^s:
CE = YoC+ %Mn/6+ %(Cr + Mo + V)lS + %(Cu + Ni)/r5
Steel
]Yo
Cast lr0n
2V"
i'/c
loA
5oh
% carbon
O)pyrbhr,O 2oo9 ThcRurButd
Module 3
ro
6o/t
tr
HydrogcnStrcao
Cnchnglll
S.r.r4
(pCS-So)
___Qr
Alfcclt{ Mrterlrh
o CS andlow alloy stccls
(lriticd Frclorr
o Steclhardncss,strcngthandshcssarc thc critical faltors
,\ppcrrrrcc of Morphologyof Drnr3c
o Crackingis IN'I'IjRGRANULAR.
. Crackingrypicaltydevclopsparallclto thc wcld. In thc wcld metal,thc cril;ls arccithcr
tmnsvcrs
OR longiludinalwith thc wcld.
CopyriBht
'O
2oo9 ThtRustBwtn
(\
31
8/6/2OrO
F a t ig u e / S S C/ H
Modul eg
ro
llydrogen
Sbetc Craclilnt
HF
5.r.2.4
]
(pC S-So)
I{F is the SAMEmechanism

for SSCCin wet HzS,exceptthat HF is
that is responsible
generatingits own atomicH+.
Blistering,
HIC
and SOHIC
damage is similar to that found in wet HzS.
".\
Module g
HydrogcnSbctc
hwcntion / Mitigatirn:
.
.
.
o
'fl
Crac&in;HF
-o
S.r.z.4 (pg5-So)
PWHT
to lcssthan200 llB & localizedzncs abovc237 tlB, (NACE RP0427)
Controlwcld hardness
t.JscttTM bolts. l'hsy arc softerandlowcr stnnglh than87 boltg
[Jsccrrbrn stcclcwith CarbonEquivalcnB(CE) lcssthan0.43.
CE is defined as:
CE = %C + %oMnl6+ %(Cr + Mo + V)I S + %(Cu+ Ni)/t5
% carbon
-IhcRutSut6
Copyright O 2009
i.
n?
5-
816129ro
Module B Fatigue / SSC / Hydrogen

High Tempcrature
llte ll fl lA Story. ('hapter I
llydrtrgen
Attrcl
5-56
'l'hestorv beginswith ....(.)nceupon u time,

a prxess stneamcontaiNt some hydrogen gas.
I.
.lt high temperatures,some molecular hydrogen 1H) brcoksapan rc forn atomic

h.vdrogen(ll+1.
2.
Some of the alomic ltydrogen (H+) ditluses inta the steel (that r could be bad).
J.
At elmated temperaturcsand prcssurcstlrc atomic lrydrogen (H+) rcacts vith

unstable iron carbidcs orfize corbon in thc steel toJ'orm metharv gas (tltat'is bad).
The Rcactlon:
+ Fc, (iron)
4H + FerC (ircn-carbide)
- CHr(methane)
Continued on the next pege
Copyrighi rc) 2ooq fhRurt8urier|

Iligb Tempcraturc
The HTHA Story. Chapter2
llydrogcn
Att d. 5-56
t(
.\\
Thc Reeulon:
4H + FcrC (iron-carbide) = CHt fuethane) + Fe, (iron)
Eventually, the hydrogen migrates deeper into the steel. Methane (CH)
below the surfoce is too large to dffise through steel. It becomestrapped and
uillects in voids. Thesevoids are normally a the grain bounduies.
.4s additional methane collects, the pressure in these methanepackets gets
extremely hig,h, exceeding the strength of the steel, and creotinglissurcs.
If uttack continues, the/issures become more numerous, and occur deeper in
muterial leading to crach growth.
Copyritht rO 2009 TheRurtBElct!
(.%
33
81612O1O
Module 3
t f igh Tenprattue
Hydrqcn
Altet*
5-56
llTHAdamage is permanent and irre!'erslble.
4II*
+ Fe"C(iron-cvrbide)
= CHr(methane)+
Fer(iron)
,/--i /
| 4Z'
) \/.-' L-'-',
IIigh Temperature Hydrogen Attack

( II'fHil causesfissures (micro-cracks)
and wentually crackswhich significantly
reducethe strength and toughnessofsteel
nraterials. Thic damagecan ocsur in both
the basematerial and welds
..) +-\r\
rl F
'.\,
CopyriBht (9)2(x)g fhcRu.it.8utcil
Module 3
'?',,
i, l
Illgh Tempcrature
Hydrotco
Altadt
S;-S6
Itc HTIIA Story. t-'haptcr3
(/
t\,
'the wil villain HTHA is prwentable thanks to Mr. Nelsen
who invented the Nelsencrrnrcs (se pageS-S8)l!
Mr. Nelscn's nrleg to keep HTHA away are:

r.
Usealluy steels with Chnrmium (Cr) and rxrVbdenum (Mo) to increase

carbide stability and therrby minimize methan formation.
z.
Usc a 25 to So F safety fastor when uing his curvest
(})p}{idtl,r,) 2oo9'IteRurtBr$6r
fl
3c
;/
8/6/2OLO
{-^h
Module 3
Fatigue / SSC I Hydrogen
f)*
Co!ryri8ht O 2o9'fhdlult8wl.rt
llitl
fbnpcntrr.
HydrolcrAttrcf
(Fftl^)
s.lJ.l
tFt. 356)
oI-HTHA damage is permanent and irrevereible. When operating just above a material limit
cunre shtnvn in ltigure 4 Opmting Limiain Hydrqen Servicr, it may take years for the
damage to oi'en start to occur. But when operating significantly abore the curve, the damage
may start to (x)cur within a fer,vhourg.
HTHAdonogc
.Flisururil
'.-\
Thr Rut 8r!16
(R
35
8/6/20L0
3
lligb limpcrrturc
llydrogcl,lltrcl
{ll"l'llA)
o*
Whet ic Prrtlrl Prcsrurc?
(Pt. 5-56)
5.lJ.l
Vapormolcculesin any containerbouncearound,reboundingoffthe walls. Every

time a moleculestrikesthe wall, it pushesthe wall. Any onemolcculedoesnot creote
a lot of push,but whenzillionsof molcculesstrikethe wall, a significantpushis
created. Whal do we call the push on eqch
t;
F")Il
Itd4
ZE
tnNt
Waa',..ai--
'fhc Rlrt
6upd?
ilttalalb
buters
'...\!
,,,
lligl'fcnpcnturc
llydrogcr Attrck (llTHA) 5.t J.l
What is PartialPrcssurc?
(PI. }'56)
r:_
J-r4.
{t4-
Hyttttt
re Go
Hlalrtil
t;s
e,dvd5Hr*r-tpra
llfbotq
lit
Suppocc thcrc arc two contEincfi of cqual sizc fillcd with diffcrcrrt gascr andmaintaincd ar thc
sarnc tempcrdunc. lhc tirst containcr is fillcd with a hydrocarhn g,asand has a prcssurc of 300
psig. Ihc sccond c<rntaincris tillcd with hydmgcn and has a prcssurc of 6O0 psig. (Notice tlvft
une mone molecvles in tlc vcotd contoirer lncrcasing tlte nunber oJ molectles im'rcases ile
prcssure.)
lf thc contcnts of bolh conlainers are put togcthcr in a conlaincr of thc samc sizc. what is thc
prcssure? lt will bc XX) psig the hydru:arb<n e,.c contrlbutes J00 psig and thc hydrogen gas
contributcs 600 psig. Even though the containcr is 9O0 psig thc partial pr$sur of th lrydmgen
gas is only 600 psig. Partial prcssuc is just lhc amount of prcssurc thc spccific g'3 contribulB to
thc total prcssurc.
hcssurc gaugcs display total pressurc, nu partial prq$urc. Partial prcssurc is usually calculated
by pmcess firglncers.
t,*:
3b
8l6l2OrO
/'T"!h
llfuh Tcnpcrrhrt
HydrogerAttrcl (H'I'HA) S.lJ.l
(Pt, 5-55)
Opcrrtbr l!$rcr
Normolly,cquipmemand prping ir rlcsignodto opcrat al l6t 25-50oF below thc API 941 limiu. Frr
ralulpmenl opcrating clncct to thc apphclbh curve, tlre tempcrehlc rrd hy&ogcfl ponial pre3surEshould be
rnonitorFd For hydrogcr crlurprncnl and piping that opcralcs ovef
'lO0 "F, thc tbllowing operatroo changcs
should always be approverl usinga lvtougcn*nt ofC'lrngr vrork puxsr,
l.
Incrcosing ttn operdiAgrenpraun
:.
Incnasinttlr
open ingryssun
3.
lncr"asint ilt percentagt of Mrog.a tn ilp prwess sman (hit ,tsy ircease Mrcgcnl ponial
pt.rs'|n!,)
t.
Btw$inga ltd erclunger uscd to cal a lrydmgen proc.$ slrcam flr &tnttnm
piptng<tttd
e.luip,rrt l my nol lwvc been desigrtdlo trE higlvr tearyrdue.
5.
Rennving tlz hy&oge; qucrchfroa hfrogen contoinint proccts st E@r ,trultint in higlvr
t?mFrcnnt tn funsrQai
eqilprsrt 6d pipin&
o Any of thc abovc itctns could incrcass thc risk of HTttA. Thc irBpc;tion group should always bc
nolitid whcfl an up6A cruidr equrprncntto opcralc at lcmpcraturc3 o( pr6sur- hrghcr than dcsigr
conortK)rrl|.
. You ruy-- notic. thrt lomc equipmcr! thrt h|3 bcen idcntificd 83 bcing nlccptiblc to IITHA will hsv
hvdrDgen probcs rnsulled on thc outsidc. Thcrc probcs mcarure lrw much atomic hldrogcn is dittrsing
through thc steel,wtich rclatesio how much arornichydrogenmsy be gettingtrappcdinsido.
'fhc n un Burtd
(}
Module 4 High Temperature Corrosion (4oo+ F)

lligh Tcnpcnrrrc HydrogcrAttrck tlfIHA)
fimeto
s.lJ.l
(FS.S56)
Ponder
A carton steelexchangprshelloperate! at a ma.ximumbydrogeapartial prr:csurcof tooo peig.

At what tcmprrture &n HTHA'occru?
Which of the following materialr is most susep,tible to HTHA?
o r.25Cr - o.5 Mo sttd
o 2.SCr - r.o Xo stecl
o Corbon6td
o Stainlcrrned
Hot atomic hldrogen diftrsing
1[iemth 1f,g steel reacb with carbides to form:
o llydmgensulfi&.
o Methona.
c llydrcgcnorbi&.
o Mobtder lrydmgen.
Advanced stag6 of HTHA c.ould causc a(n):
o lnmase in tle material's towhncsa.
o lncrearc in the msterid's strength.
o laally thinnsl area.
o Erittle haiw.
ThcR6tBut6
f%
37
8/6/2ALO
Module 3
Copyrisht (g 2oo9 TheREtDurteil
tB'!,
',ri
Module g
o
Formaffing and supporting information
for this Module were attained from
API RecommendedPractice 571First

Edition, December2003
Copyri8ht r0 aoog TheRut8ultcE
38
'r.i^
":]:7
$'
Module 3
Fatigue part1or3)
OpenBook
1. What shapedo Ther.rralfatigue crackstypically have?
2. Is corrosiona surfacefeaturethat can leadto Mechanicalfailure?
3. Explainwhat an endurancelimit is.
4. Which of the follou'ing is an exampleof equiprnentthat is not susceptibleto
Vibration Fatigue?
a)
Safetyreliel'valves.
b)
High Pressuredrop controlvalves.
c)
Fractionatortrays.
d)
Heat excharrgertubeswith vortex sheddine.
5. How do yoll preventcorrosionfatigue?

6' As an inspector,where would you anticipateyour interventionto preventMechanical
fatigue?
7'
Will the use of Killed steelincreasethe likelihood of MechanicalFatigue? Explain?
8. What fatigue failur-chasa "clam shell,'appearance?
Page1
Module 3
CorrosionCracking(Part2 of 3)
Stress;
OpenBook
l.
Explain u'lrrrtthe sirnilaritiesare betweencarbonateSCC and CausticSCC.
2. What nratcrialis lcastsusceptible

to CISCCbelow 140F?
3. Austenitic:;tcclcan suddenlycrackwhen contactedwith what commonlyfound metal?
4. Amine clrr,liitrg,carbonatecrackingand causticcrackingcan all be calledwhat type of
cracl<ing'.'
5. What docsrrrrlrydrous
mean?
6. Are the vrlrot spocesof ammoniatanksof any particularcorrosionconcem?
7. What is th.' eIrcrnicalsvmbolfbr arnmonia?
8. What is lni,tlicl uamefor graphite?
9. Mercur'; ern clr.lscwhat four (4) ductilealloysto crack?
10. 300 Sctics SS is susceptibleto PTASCC. What grade of 300 series SS is lease
susceplilrlrurrclwhy?
11. Lean arrirr, clacliingwilloccur abovewhattemperature
and concentration
combination?
12. What is ,,\St'(' anclgive three(3) exarnplesof it.
13. Zinc will crruscwhat materialtocrackwhen they come in contactwith eachother?
14. What is rrrri,llrcl
namefor StressRelievins?
for what corrosionmechanismare:
15. The tlucc cr itical lzrctors
.
.
r
Hydrogcrrirrrrstbe presentat a criticalconcentration

within the steel/alloy.
The strcrrslirlcvel aud microsttuctursofthe steel/alloymust be susceptible
to embrittlement.
A stress 11iri)\/c
tlre threshold fo(Hq must be present from residual stressesand/or applies
\-/
stresses.
CopyrightO 2008'l'hell rr;tIJUstr:rs
Page4

Module 3
SSC @art 2 of 3)
()ui:: 7'ime-ChallengeQuestions
maybe containedin thefollowing!
l.
ChlorideSCC- Is C'albonSteelsusceptible?
a) Yes,all gradcs
b) No, carbonstccl\vill not crackdueto SCC,butit will pit
c) Yes,but only il thetemperature
is abovea certainpoint.
d) It strictlydcpcnrlsorrtheconcentration
ofchlorides.
e) Depends
on lhc rrx)'gen
content.
2. CanWFMPTbe userllo detectCt SCC?

a)
b)
c)
d)
Yes,but onh' on CS
No
Depends
if thc ( l S(lChtrspropagated
intothebasemetal.
Depends
on il thccrackingis Transor Intergranular.
is tlrccriticaltcmperature
for Cl SCC?
Whattemperature
a) 130F
b) 140F
c) 160F
d) 180F
4.
Will Cl SCCshowttlrrr:rtlcak
a) Yes
b) No
on llrt gladeol'CSused.
c) It depends
if otlr,'r'conttrminants
d) Depends
suchascyanidearepresent.
5.
Strrirr
lessSteclequipment,
whatis themaximumchloridecontent(ppm- partspermillion)the
Whenhydrotesting
watercancontain?
a) l0
b) 50
c) 200
d) 500
6.
SCCslror',Lrlrls a lcak?
Will Caustic
a) Yes
b) No
c) Depends
otttltc:-r:rrlc.
on tlic tcrttpet'iLturc
d) Depends
7.
Whencausticisabove-temperature,is
CausticSCC-PWll'li::knowntoreducetheincidenceofCausticSCC.
1or( Sl
PWHTsuggested
a)
120F
b)
140F
c)
160F
d)
180F
@2008TheI{ustlJusters
Copyright
Page5

requiredfor SCCto occursothatthermal
8.
L .,rcepteclthatstresses
approaching
- It is genel'ir
Revised
_are
caustic
SCC.
reliefiseffectrr.in prcvcnting
stress
a) MAWP
b) Yield
c) Creep
d) Critical
9.
shouldnotexceeda BHN of
RevisedWith amnroniaSCC'-*clcl hardness
a)
237
b)
22s
c)
235
d)
2 r7
10. Ammonia SCC - SorneCu allol s are susceptible?

a)
b)
c)
d)
lt
Only in the virpor spacc.

Only in the liquid spacc
Only at high temperaturos.
Only when exposedto oxt'gctt.
what rnatelials?
Revised
-Liquid Mctal Emblitt Icnrc nt (LME) af'f'ects
a)
CS
b)
300 SeriesSS
c)
Low alloy sleels
d)
HSLA steels
12. Can LME cracksbe repailed b1 lrrinding?

a)
b)
c)
d)
Yes
No
Dependson llre basemctal irlloy
Dependson the hardnessol'the HAZ
13. LME
occursdr-reto combinatioirsof metalsin contactwith low melting point metalssuch as zinc, mercury,cadmium,
lead,copperand tin. What is a sourceof Zinc?
a) Entersthe lcfinery with thc crude.
b) It's presentin the atmosplrcre.
c) It's usually part of the chcrnicaltreatmentprogram.
d)
It's found in somemetals.
fbr CS?(Pg5-52)
is reqtrired
14. StressRelievingabovewhattenrperature
a) 1150
b) t2so
c)
d)
1450
1050
Copyright@2008ThcRustBustcrs
Page6
The RustBusters- API 571
Module 3
HydrogenCracking(Part3 of 3)
OpenBook
l.
What tl,ree critical Factorsmust exist for hydrogenstresscrackingto occur?
is being referencedwhen it is said that higher corrosionrates

2. What corrosion rr-rcchanism
are found in gas oil Hydrotreatersthan naphthaHydrotreaters?
3. Will killed steelrcclucethe likelihoodof SOHIC and SCC occuring? Why
4. Blisteling,HIC, arrdSOHIC damagecausedby this damagemechanismis similarto that
found in wet H..S.
5. When hydrogencr-ackssteelat high temperature,how can the darnagebe repaired?
6. What is the partial pressureof H2 when in a reactorat 50 vol Yoandoperatingat 500 lbs?
7 . The chargedrurn o I naphthaHydrotreateris madeof carbon steel and is operatingat 500
F. It has 0.5 % srrlfurin it. What will be the corrosionrate? Will the corrosionrate be
higher or lower dorvnstreamas it entersthe reactorat 650 F? Why?
Page 7
TireRustBusters- API 571

Hydrogen Cracking (SCC) Part3or3
l.
HydrogenEmbrittlement. Arc all welding proceduressubjectto inducinghydrogen in the weld?

a) Yes, all SMAW techniqLrcs.
b) No, hydlogen cannot bc irrducedduring welding.
c) Welding with wet electrorlescan causethe problem.
d) Welding during a rain carrcauseproblerns.
e)
Only affects SS.
2.
Hydrogen Embrittlement. Thc

and the presenceofirnperfection in the steel.
a) Intergranularcracking
b) Quantity
c) Damage
d) Temperature
3.
HydrogenEmbrittlement.As rnrrlcrialstrengthincrcases,
susceptibility
to HE
a) Increase
b) Decreascs
c) Changeswith the opclrrtingpressure.
d)
of trappedhydrogendependson the environment,surfacereactions
Doesn'tchangeat irll
4.
Re vised- Hy dr ogenEm br it t lenr ent

Ser.v ic e s w h e r e F I E i s a c o n c e r n i n c l u d e c a r b o n s t e e l p i p i n g a n d p r e s s u re ve sse l si n
wet H2S service. However, carbrrnsteelis usedfor vesselsand piping in most refining applications.Therefore,where
is HE most likely to be found'/
a)
In equipnrentthat is in ILrwplessurehydrogenservice.
b)
In lorv plessurehydlog.enequipmentthat has not been"baked out".
c)
in heavv rvalledvessolsthat are in higli pressurehigh temperaturehydrogenservice
d)
In the basemetalil-suitrrble
PWFIT is not performed.
5.
HydrogenEmbrittlement.Will tirepresenceol'Cyanidehelp or hinderhydrogenEmbrittlement??

a) Cyanidcis a catalystllrrrtwill causerrofe Embrittlement.
b) Cyanidcspeedsup lhc lrydrogengasreaction.
c)
d)
6.
PolythionicAcid SCC.
a)
b)
c)
d)
7.
Cyanidc has no efli:ct

Cyaniclc- is only plcs, nt in the units that don't utilize hydlogen,so there is no effect.
This crackingonly occrrlsduringa S/D.

Only non sensitizerlnrrrterialis affected.
Only aI'l'ectsCS.
All ofthe abovealc corfect.
Polythionic Acid SCC. What is the descendingorder of materialsthat are affectedby PTA.?
a)
b)
304H, 304L, 321

321, 304L, 304H
c)
321, 304H, 304L,( : S
d) cs,321.304L,304H
CopyrightO 2008TheRustBuster',s
Page8

8.
Sensitizationoccursin what tempefaturerange.

a) Ambient conditions.
b) 200 - 400 F.
c) 400 - 750 F.
d) 750 - 1500F
9.
Polythionic Acid SCC - Improved resistanceto PASCC can be achievedwith modified versionsof alloys containing
small amountsol'_.
a) Chrorne.
b) Carbon.
c) Titar.riunr
&/or Niobium
d ) Cr & C
10. WFMPT
a)
b)
c)
d)
can be usedto find PolythionicAcid SCC

Yes, in all cases.
No
Yes, but only aftersubstantial
polishing.
Yes, but only with specialcolored flakes.
11. Amine SCC. Docs heattreatrnentPWIIT haveany effecton Amine SCC?

a) Yes
b) No
c) Depcudson the gradeol'CS or low alloy steel
d) Dependson if the rnetalrva-sannealedor normalized
12. Amine SCC. Docs pure aminecaLrse

crackirrg?
a) Yes
b) No
c) Dependsstrictlyon the rrmineconcerrtration.
d) Dependcnton the aminc concentration& temperature
13. Amine SCC. Docs leanor rich anrinecausearninecracking?

a) Lean
b) Rich
c) Both
d) Neitherwill causecracking,but both will causeaminecorrosion.
14. Amine SCC. An umine towcl is going to be stearnedout to get it gas free. What specialprecautionsshould be usedto
preventAmine SCC?
c)
Don't stcamit out Lrndelany circumstances.

Monitor the tempefaturc.and make surethe metal temperaturedoesn't get above 140 F for more than I hour.
Wash tlic tower until thc amine concentrationis 2-5% or less.
d)
Neutralizethe towcr with causticfirst.
a)
b)
copyright@2008ThcRustBusters
Page9

15. WFMPT
a)
b)
c)
d)
can be usedto find Amirrc SCC

Yes. if the crack has beerrfound by X-Ray.
No
Yes, but only after surfacepreparation.
Yes, but only with speciulcoloredflakes.
16. Which of
a)
b)
c)
d)
e)
the follorving statenlentaboutAmir.reSCC is true?

Amir.reSCC will not propagatethru wall.
Amine SCC is not cffectedby PWHT.
Amine SCC only occulsin SS
Amine SCC is more likcly to occurin MEA than in MDEA.
dLrringS/D wlien exposedto air.
Amine SCC only happerrs
17. Wet H2S Cracking.- Cracking can occur in what cornbination.

a) Liquid lrydrocarbonand H2Scan be preseut.
b) Water vrrporand I I'S can be preseut.
vapof.walor vaporand H2Scan be plesent.
c) Hydrocrrrbon
d) Hydrocrrlbonvapof,watorand H2Scan bc present.
18. Wet H2S Crackinlr- At whar H2Sconccntrationis olten usedas the defining concentrationwhere wet H2S damage
a) An albitlary 50 wp1tm.
ol'100 wppm.
b) An absoluteconcentrati'rrt
c) Any anrountofFI2S
ol'200 wppm.
d) An arbilritrycol'lccrttrali()r'l
19. Wet H2SCrackinr- Hardnessis l ltrimaryissuewith SSC. Weld hardnessshouldbe controlledat what levelto
addressthis issuc'.'
a) < l90lll]
b) < l95llll
c ) < 200 llll
d) < 2lollll
20. Wet H2S Crackinlr- What is the nrostpotentiallydamagingfbrm of Wet FI2SCracking?

a) Sulfidc StressColrrtsiorrCracking
InduccdCracking
b) Stress( )rientedHlclro-ecrt
c)
Hydlog, n InducedCracliing
d)
Hydrog,'nblistering
21. WFMPT can bc rrscdto find Wet I l2Scracking

a) Yes, in lll cases.
b)
No
c)
Yes. btrt only aftel surfaccprcparation.

Yes. btrtonly with specrllcololedflakes.
d)
milE
Copyright@2008'f hCltustBuster.s
Page10
22. HydrogenStressCracking HF - Irr general,Timeto-failure

a) Decreascs
b) Increases
c) Remails about the same
d) Is a function oftinre, tenlpel'atureand strength?
as the hardnessincreases.
typically propagates
23, CarbonateStressClorrosiotlCracltrng- Carbonatecracking
a) In the I IAZ onlY
b) In the r,r'clddePositonll'
c)
d)
to the weld.
Parallel
horizonliLI
24. Does a heat treatnrcnthave ar.rye1'lccton PASCC?

a) Yes, in lll cases.
b) No
c) Dependsor.rthe gradeoI CS or low alloy steel
or normalized
d) Dependson if the tnetal rvaszrnnealed
CopyrightO 2008ThcRustBusters
Page11
8/6/20rO
, 'qF r
{.
Module 4 High Temperature Corrosion (4ooiD
Sulli&rim
I
l
lligh fcmp H.H.S (inurm

('artmaaron
l}cubunlatkm
t- 109
{- t3
c(xcrcd)
{- il.1
-"&
Mctal Du3lrng
O\rdattm
liucl Ash ('onosrm
t
u
NrtndinB
(iraliutizlron
to
Srrllcnrng(Sphcrurdi2ation)
II
l"dnpcr ltmbnnlcmenl
12.
StBn Agrng
l]
8t5 F Embnnlmcd
ta
SrFra lthala Embnttlcmcot
rl
17
Bnnh Fat|'l
('rec? r StBr Rlptr'r
Slx)n Tcfm ()rcrtEadn!
lt
liluiu
to
tprsviruly
1- l t6
4- i l E
'il
,\.
',
1- t05
r-|]l
4-t26
.*t\
&
--}
.t- |
.1-5
14
{-r2
1- t4
{- 16
4- 19
+21
1.12
, Srrcar RuptE
Hyrhding
5-6t
Thc Rut Bustc[

Sulltdatlon
..t
4.4.a
WhatlesulfidlcCorrrrlon?
'
(pt4-ro9)
Sulfidic Corr<rsionis corrosion of carbon steel ond other alloys rcsulting fmm their
rcaction with sulfur cnmpoundsin high temperature envlronments,gnnter than about
5oo oF. The presnceof hydmgen aq:elerates corrosion.
How drrce Sulfldlc
Corroclon
Appcar?
Cornxion is most often in the form of uniform thinning, in which thinning is spread over
a relatively larye area. That is the reason sF UT techniques (spot ultrasonics) are often
used to detect this ty'pe of corroeion. However, sulfidic corruion can also occur ag
lrxnlized cormsion or high velocity erosion-corroeion damage, particularty in
liquid/lapor streams containing H.S. Sulfidation corroeion is often combinedwith
naphthenic acid cornxion with high naphthenic acid crudes.
t:
'l/
fhe Rut ButeF
I
t
''4
816/zOtO
1+

.9ulfidedon
(-i-a
Vullflcd Mc(lonony ('urvcr - Ihcac

cuNcs arc lo bc uscd tbr cornxton
prerlrcttonwhcn thcre rs N0 Hvdn rcr
prcjcnL
4.+2 (m4-roc)
1'r l
-t-
| ,'1,
,,.
;ti
,-L-1
-e--4
-i
- ,-
i,,,'4
cl
-t
--)
:-z
|
9'
I ' ' -"'
L
)l --4
'i't t l
*1
--1--
l- -:ii,!
ll'thcrc is hydrogcn in the proccss{ such

as a lfdrotreater), the corrosron
envrronmcnt bM$lbtl{tf9!!gl,
and
anothcrsct of curvcsmust bc uscrl.
ln Yoor hcrd !'

Plcturc tblr ltrrpb
i 0n
---*-1
l i j ,8
0 02 r- --.---1-|
1,1,r
c5o
]50 ,{n
--+ -* [_,
60t
t-
r,5o
|
rco
|
|
7.a
,:
-1 "
|
J
atI)
r r J 'r r p r : r J l L r rl , ' t
Modatl,.d
Mccmmy
Cir.v..
TIF fug| Burtcd
lq.
Module 4 High Temperahrre Corrosion (4oo+ F)

Sulfidadon
Prwention/
4.4.2
(pgl-roS)
Mldgrdon
Sulfidic r:orroeion is addressed first by proper materials selwtion.

Incrcased resistane to sulfidation ia generally achieved by upgrading to a
hig,herchnrmium alloy.
One the materials of construction are in plar:e,it is imfrrtant to keep in
mind the limits of sulfur mntent and temperature for which the materialg
were choeen, and not let increased sulfirr or increased tempratur caus
accelerated cormsion rates.
.g{ n
Ttc nrut gut6
\,\i'.
't
816/20LO

lllgb'fcnp HZH2S Corrocion!.t.1-l (PB.$ll)
Dcrcrlptlcl
.t}lc
pressr.c ot-hrdrogan in HrS stseamsrncrsascsthc scvcrity ofhigh tcmpcratura sultirlc corrolion nl
lcmpcroturcraboveiOOF. fhis l'orm of Sullidationusually resultsrn unif'rrm loss rn thicknesr.
.{flcctld Mrtcrhb
o ln onler of incrcasing rcsistrncc, CS, low allay, 400 Scrics SS, anrl lm Seri$ SS.
('rltkd
.
c
.
Frctorr
llrS orrncenlratinn- Tempcraturc- Presen<rof llydr,oggfl ( Hr).
und hydmcrrkcrs than mphtha dcrulfrnzcn by
lligltcr corrosron rat6 E c lburd in gls orl &rulftnzn
n tbctot ol'almoct "2".
Incrersrng Cr cr'ntcnt in thc lllry, increascccofiosioo recistsrrcc. l{oncvcr, thcrr is llnlc improvcmcnt
wth increasing Cr conlcnt untrl about 7- 9 Cr.
Allcctrd Urllr oc Eqrlpncrr

o Noticcablc increascr in corrosion orrur dornilrcam of lrydrogm injoction poinu.
o This corru3ron or:cur wtrcre higlt tcrnpcrritrt Hy' l{rs slrearnssrc lbund Thr mcrnr tty.dnrrcetcrr and
("*

Carturizrtion
'd't
4+3
(pgl-rr3)
n,
\J.-_-Dcrcrfpdoa
o C'arburiation ir thc abcorption of carbon by a rntal liom it! envrronnrcnl
. AlTcctcd Mrterial3
o lror boscrl materials inclurling carbon stcl and low allq stcclc.
o l0 O&4 { DScr ica SS
Cridcrl F...!or!
. Thrcc conditions must bc nra,i:
t.
[xposurE 0ocarburrzrng anvironnrcd or carborsanrs matcrial
:.
Tcmpcraturchigh cnoughto lllow diltrsion ofcarbm into tho mctal (typically abovc I l0O F)
I
Swcptrblcmaterirl.
Carbunation inclwlcs high gas phasccarbon activiU (hydrocarbons,cokc, glsscs rich in CO, CO2,
rnerhsrc 8nd cthlrr1 and low oxygen.
Prcvcotbr
o Thc problem of carburizatior cannd bc complcrly avoided in many instanccsbccauc sorbonocoots
environmcnts at high temperatlucacannot bc avoidcd. Propcr'furnacc control wtll lourcr tempraturs
and minimia carburzatrrn.
TheRurt Butrr
']'h
8/6l20tO

Carburiration
4-4-3
(Pgl'ug)
What'r Carburlzation?
Carburizotiotr
-Addt colrDon to thc metal at high tcmpcroturc
. Carburization is the abarrption of carbon into o metsl at high temperature. The earbon is
quickly atxorbcd into the maal surfar:c. The rate of erburizatjon further into the metal
slows with depth. 'Ihe depth and carton cnntrntration into the metal incras.x with
temprature and with the exposure time. The most common place for carburizationto
rnrrr ig in firtd he'ater tuhx. It is found in cat rcfnrmers and rnker units where
*earn/air derxrl.ing,occun.
Carburization (dark areas)of an

HP-mo<tifiedtube from an
ethylene furnaur after 3 years at
r9oo"F. (From APl RP-Sn)
Thc Rurt Burt6
'%
':4

Cerburizadon
44.3
(ptl-rrl)
Environmntr that promote carburization include hydmcarboru (i.e. methane, ethane),

coke (rarbon), and carton monoxide. Coke deposig are a source of carbon that may
pr.omotecarburization. Decoking cyclec have temperatunx that exceed thc normal
operating temperaturcs, aerrlerating the erburization. Mditions of o4gen, steam, or
hydrygen sulfide can reduce carburization.
is an important factor, Cartnrization begins in moet casesaround
and aerrleratesas tcmperatur incrcases.
N
(
Eft:tc on Auctcnldc (3oo ccrlce) Stainl.cc Steclc

Carburization mmmonly oc'r.:ursin austenitic stainlese stels and other
aurtenitic alloys. Effects include the carburized metal slightly expanding and
hrrrming magnetic. Austenitic stainhqr stel is not normally magnetic and
more brittle.
Effe&t on Catton rnd low Alloy Steale
In carilrn und low alloy steels, the carburized surface is hard and brittle. Ttris
t'an causecracking and/or spalling upon cooling.
,"W
816l20to
r'ru
L

Carburizadoa
4.4.3
(pt4-rrl)
Carburizati<rn:A Dr. Jekyll and Mr. Ilyde Uselul hoperties

e Plain carbon steelsand krw-alloy steelsare often carburizedto pruluce a
very hard, rvear-rssistantsurface(e.8., for gear teeth, cutting turls, sliding
surfaces,etc.). In this case,carburization is deliberatelyperformed during
the manufacturing pror:ese.
. Detrimental ProogltiaTlte carburized layer can bc brittle as a rr:sult of
forming hard metal carbid* and the coarsening of carbides. The
carburized metat wi[ have loss of ambient temprature mechanical
properties(sper:ificaltytoughness/duetility), cormsion resistantr, and be
more su.sceptibleto cracking during and after welding.
TtP Rut Eutd

DeCarburlzation
4.4.4
(pg4-rr6)
Dcrcriptior
o Cartxn it rcmovedtiTrn a marcnalal elcvllql tempenture while in contactwith a low carbonaceous
matcnal(suchar hydrogen).
.{ttcctd Mrtcrbb
o lron basedmalcrralsincludingcarbonstccl and low alloy steclr.
Crillcel Frcton
. Ttrcc conditronsmugtbc mcl:
t 'fime of exposurq tsmpcralurc& carbonactivir)*(or lack ol).
Aflcd.d Unitt
. llydnrtreatcrs& Catalytic Rcformcfsthcaten, piping & equipmert) in hot hydrqen scrvrcc.
Thr Rr.lstBuste$
(,.th
8/6/2OrO
,':"1b
.C.44 (ple-rrO)
DeCarburlzadon
ThcRstBut6
Module 4 High Temperature Conosion (4oo+ F)
a?!tr.
j'i i.i
*o
Metal Duattng +l.S (pt 4-rrt)
Whrfr
Uatrl
lludql
Mctal durtin! ie m aggrtriw
Metd duung snwnr tlrc rurfrc of a sEtd to looc omsion

whicb on euily bc ulml
at hith gar llm rata fllt sufre
fom of cartuiado
(6rboa ir abmrbql into | rutaiall.

prodult lmirUnt
of erbcr ard 6m mcrd parddcr,
of thc mlrl appam hwily pitted or gou8cd rr drom
Th. tcmlEatw
Mcta.ldwrinlm
lo4H dainlllf
for Etal dutiDt mtrt6 6om about !r@
Metal dutin8 ds not ftcu al low

csc{ion mle ir to rlw,
Mtal (lutint ako &E not tru

at hiSbd temDcnttm
becau the ruction mte in the Ba m high muth to allfl
rarbon dqEilion (fon colc depditt Eths tlEs DitFG into
mctal).
lemlHtlE
tEw
efuo'
|hc
rtd pipi!r!. Frm A?I RP-Stn
Tte Run BrEteF
rl''B
v
8/6l2OLA
i "\
Mpdule 4 High Temperature Corrosion (4oo+ F)
PraYantloD
fcmFnaE @drol . wh.ffi
wls.di
dlaio3 my eil
tssblc, tlE b.l lp|fMh
u to rvod .'palirn
io thc tcrnparc
roryc ot'mo b l65fF
Pmcs ctulc:
Mulili thc anvironmal to clhancr tl|c t'ffmatior of potcttivc m& ()( snlfxlc rcalcr by takmg m r ryrc o{'
thc follwing atirru:
. tncre
ol o sable urdc rcule.
lLa ilaat coaccrtrdioa
tn the 1pr lo enhuce ,rndtm
, lnc'cw tlt emd
ol nltsr n the cnrtffimcnt 1c.9. H ,\ n u gtt $treum). fh. omlryn! ol H ,\ reqrtrcd to
und mdul .omgtstltm, uill myst hc dctermrned for
lruveil milat .luiltng dependt upn the ttmptmtun
Lxh t1*trlic u1ryli.'otum. hut il tt generolly qule IN.
. .lwH rte &r
qrrla fl<'h us ft'E vhencvcr psuble.
of (ilo?tdq
Il tllerr ure u reqilrct cntrcl the
nf.ttn
mle to pevcnt .rvenlof,ing.
Maellurgy chngr - Sclar alloyr rcristmt to a:frl dusting In garml
lha sulccpnbillty lo mrld &Btint ot
iron-barcd alloyr is ralrrcd whcn tbc chnxrium cutctrt i! >2J%. Augmitrc lraidcr! stcds rrd nrckcl{nrcd
alloyr vary in ficir rcaiducr !o nrrrl dusting.
'fte
R!6t Butd

Metaf Du*ing 4.4.5 (pt4-rra)
The damage taket the form of sever lq:alized metal loecwith no surfart depositr.
Sulfurin thc carburizingatmosphflcformsa protcciivesulfidcthatminimizcscarburizdionBnd
mctaldusting
,eoq
Atfcctcd trtritr or Equipmcnt
t\imarily fired hcalcr tubcs,
thermowells and
f'umacccomponents opcrating in carburizing environments.
T?reRul Buters
(,"h
7
8/6l2oro
:_-o
Oridation ++r (pt 4-ro5)
Whatis Oxrdation?
. Oxidationis the rcactionof oxygenwith the irun in steelsat hig,btemperarurer'
scale(carbonsteclhaswer 98%iron). Oxidationcanbe
convertingthe metalto r-rxide
nr.sting.
thoughtof ascata.strophic
Usually air is the rnain sourte of oxygen, but tlue garea fmm furnacrx a.lsocontain
sufficient oryB,ento causeoxidation.
.6\
, ,..
l
d o _+4.r (pt 4-ros)
Hdadon
What is Oxidation?
.
Oxidation is the reaction of oxygenwith the iron in stels at high temperarures,

converting the metal to oxide scale (carbon ste'elhas over 98% iron). Oxidation can be
thoug,ht of as catastn:phic ntsting.
Usually air ig the main soufce of oxy8en, but flue gaseefrom furnacea also contain
sufficient oxygento (:us oxidarion.
nE Rust BuncF
,r'' 7."""
I.
:l
8l6lzorc

Oxidrdon
* Q) 4.4.r
(pS 4-ro5)
t'
!"
{D
rqD
CD
r{D
r2lD
rtrD
rd,
1!q)
t7u,
@
Tr6frdan
-+-CE
*>xD88
l-rao
+iOSA/}{
lt('
ffiy
ttID
IED Z ID ?J @ nN 7An
+EnGi
-- lEf,l*
-D.ul4|'-
-ftc Rr[t Buncn

ffdadon
4.+1(pt 4-ro5)
hwendon/
Mitigrttort
o Chmme ir the primary alloying element that affecte rcsistancc to oxidation.
lnspecdon
r Monitor
o Monitor
. Monitor
(ft
and Monltortng
process conditinns - watch for "prucess creep'
tubeskin termocouplee and/or ure infrared thermography
loss in thicknesE bv external UT
8l6l2OrO

Fucl Ach Corrocion
44.6 (pg l-tn)
Dc!.ripdc.
in thc frrl tsulftr, sod|!r, pofstium anllrr
llrdr tmpcraturc w&slrgc whd mlr''linfft!
dcF)srtr arxl nrh on thc rnad surfaccs of thc fitad hcalert, hnlcn arxl grs turbmcr.
Alltcttd Mrlcrlrb
.
All mtiml
Critkd
o
alloys rrscd fr
prm
larc
end boikr crmtnrtim
veildlnt
lim
ue su*cDtrble.
Frcrorr
tlrrtc cuxlitionr mug bc ma: I ) t'urcGntratioo of moltcrt s.lt l'rming

ldr0 F) & 3)Alloy c<rmtrxition.
c{nlminants,
2 ) 'Icmpcranrc
| 700 -
of Mcrpto|oaf
of llrrrgc
Appcrnxc
e Corrorion rarcr of l(D - 1000 npy cu bc cxpenmccd.
o
Asb dcposits will bc in at leg

"alligrtor hxb" agpcaramc.
2 dirtinctrvc laycrr. Whcn tlrc glassy sceh is rctptt4
tltc srrrfrG wrll haw an
Prwcrrler
o
Blcrtding to conttolhblc
bvch.
Ths Run Bufilr

Nlddl{
Datdptier
o
4.,1.7(pt +126)
A herd brittlc surhcc laycr &vclopr rir to cxposurc 0o tigh ternpcraaur cmtrmint
suh a.l mmnia
tr cymi&s - pa'tcululy
urdcr reduing cuxlitionr.
cqnFxrdr
fugh lctek of nlrogca
Alt cad Mrcrl.b

.
lrm bilcd nutcnds
('ridc.l
ircluding crhn
st l ltd lN
.lby
ncck.
Frcton
Ilrcc
Tcmpcmtuc (strn! i6ovc 6fi) F lt bccurE!
Alloy compogition
Timc
Partial prcsre
cuditioilt
muC bc mct
wr
above 9fi) F)
ofnitrogen
Tha Rurt EuteE
L i{''*l'
10
8/6l2OrO
r:q
-*-c----
Orephitizrtlon {.2.1 (m +l)
ttcacriptlor
. Aproces3whererroncarbrdesdecompostntotietron(lbrmtclardcarbon(gr8phttc).
Aflccicd Mrtcrhb
. 9rmegtadccof CSand0 5 Mo. llint.tha.!,lirionof about0.TToCreliminatesgraphitization.
('rlticrl l'rclon
. Ihrcc condtltonsmuct bGrEt:
I lempctalure( EOO- | lm F). Ilckry tfi) F. thc ratc is exfemcly slow. but guerowhat happensas the
lcmp g(r3 up?
: Alloy comp$ition (CS ofll C-0.5Mo).
I Timc of cxposurc.
r Sress.
fh. nrrt S*rt a
Module 4 HighTemperature
Corrosion (+oo+ F)
Rrldor - grapfiitenodulcsarc distrrbutcdranrJomlvthruuthout thc steel. Whilc it may lower the roornlempcnture tensile strength, it docs not loncr the creep resistanrr.
e Tbc morc dtmr:hStypci

rrt:
t. @Mosl frequcnrlvtound in rhc FI,AZcorresgrndingro rhc
low ttflp edgc ot' the HAZ Uraphrte nodule3can lirrm al thcae flAz's r6ultin3 in a bqrd of weal
thc
acnnr
sccrion.
Drrc
to
its oppearanr, this graphil formarioo is r:llcd cycbrot
BraPlile-extending
graphtltrtlol,.
t. :ip+*cll Gqolltll4tFr
- lhis is a fbrm of l<ralizsl graphitiztion ttnt sometimsoccursalong
planesof localizcdy iclding rn stcel.
Thecxlcnlanddcgrecofgraphitizationisusuallyrcprrralinaqualitativcl'ashiur(none,slight
moderarc,
sevef).
Notc-Sphcroidization(4.,1.2)andgraphrtrationarccompetingmechanisrns.
Spherordizrtionterdstoocur
pretbrentrallyabove 1025F wfiile gmphrtrzatronpterlominatt-sbelow this tcmperature.
'fteRutBNt6
i3
11
8/6l2OrO
'ro
-
l:*
dl

Gnphitizrtior
4.2.1 (pg{-l) ..*r
O HAZ
. Eyebrow
graphitization
Insper.tion
. f)amagecan be midwall, s<r
field replicasmay be
inadequate.
Evidenrx is mmt effecively
evaluatedthrcugh rcmwal
of full thickness samples
using metallographic
techniques,
TtreRuri Buterr
---h
Module 4 HtghTemperature
Corrosion (4oo+ F)
(ps4-l)
j
J
i
t.
T
t
I
r Bandof graphite
nodulesin Co.SMosteeljust
outsideHAZ.
i
a
f
i
i
"'}D,
1.. tl
d
L2
8/6/20rO
t"rh

:ioftrnanB (Spbcroidlzrtioo)
f.2.2 (Pf +S)
Dcr(rlpdo.
l"ltcdtspcrsal carbrrJes
aggl<lnrcratc
to lirrm sphetoidalprriclcs whrch incrcascin srzr wrth contrnue.d
cxpo3ure.
.tlfocttd Mrtcrirb
. lrun basedmatcnalsrncludingurbon stceland low alloy ste=ls.
('rttlci Frclon
o (londilionr muil be mt:
I lemperarure The rotc of Sphctoidiation dcpcndr on thc tcmpaaturc. Sphcroidizarion can oocur rn a
Itw houn sl I l0O F, but may talc scvera.lycarsat 850 F
2 Alloy composition(CS and low alloy steels)
r limeofexpmure
I MisrostnrcturE
r'
Anrcdcd stealt arc morc rcsrstml than nomrhzcd stcels.
/
Coursc.gratnal stcrls arc morc rcsistant than linc-grun al.
o Grabt slu lns a pmlond efcct on lh. $rcngth lprdtps
bnftleu$
orrd ducfilitv of ,reral!
Th. Rurt Butd
(B
lroftcnlng (Sphcnrldlzrtioo)
.0.2.2lPg GS) corr
Procar
M?thod
Grrin Sizc
Rerirtrncc to
Frrclurc
Anncrling
A cr-rntrollcdcurling pnrccss thal

involvn hcating a mctal and
thcn slowly rcducing thc axrling
tcmpcraturEto attain a high
dcgrcc of rcftncss.
lârgcGrain
Sizc
ElJy lo tcar,
brcrl or
fracturc
Normrlizing
this involvcsa morcrapid

c<xrlingprocessthanannealing
SmallCrrain
Sizc
I lighrr
rcsistrnccto
liacturc
Grcin sizc lrr.so profovnd efrecton the strmgth, lardness brittlettcssand thtchlity of metal!
Th Rut BurtcB
ih
13
8/6lzArc
"&
f
Module 4 High Temperature Conosion (4oo+ F)

lioftcnin3lSphcroidlzrtion)
f.2.2 (Pg+5)
Looklng ior tphroldtrrtlon

'lhc only rcliablcmcthodl'ordctcrmrning,
if a steclhascxpcriotccdsphcruidiiattonis
Suchcxaminationscanbc pcrtirrmedcithcr in thc
by examinationof its microstructure.
licld with portablcmetalk4raphiccquipmcnt,or in thc lahnatoryon samplcsta&an
lirxn thc equrpmcntin thc tield.
Do [. tvrn 6ro?
tJftcn,the angwcris generalhno. ln gcneral,cquipmcnlis scldomrencwcdrr
rcparredbecauscol' sphcroidtzation.
Hov*ct. wc shouldbc awarcof thc grtcntial lossof strcngthliom prokngcd
cxp.rxurcof carbonsteclandlow alloy stcds to high tempcraturc.Ir canalTcctus if thc
gilcntial is nol rcurgrizcd. Timcsto carcarEwhcnrpcratingprcssures
ond
tcmpcralurca,
or prcssures
aloncarc incrcascdaner bng-tcrm fip(xure abovc850"F
(tr shon-tcrmat around1300"F).
'ItE Rusl Butcn
.t
&
Ft'
crrbo.r rta.l
Prrtlrlly
rphoroldbrd
Tho platah
certldor
rlrontn
mlcrortruclutr.
hrn ch.t[ad
to urry fina c.6ld.
elorr
(bLct
dott) whlch rr. mro or lrrt
'rplrarort
dlrtdhrt
d.
.anly
'fhe RuJt BtrstcE
t4
8/6/zOLO
i'*

Softcning (Sphcrokllzrlioo)
.
,1.2.2(Pg {-5) coot
_1i
'r .1-
Itrlly rghrrcldlrrd
c.rtorr
rt..l
mlcro.tnrctlr..
Tho rphorlcel
hfla gro[rr.nd
crrtld.r
tt.r
rccnnrilrtri
at Or grah borrrdadaa
(arrowrf.
k thc
witi ltr-wic
rphmi.li-d
r cwm
d$ipm6t? (li!i sll thrt apply)
'Yc* and th. cquiDocnt ncGdr to bc cphcd
.No, u rphcro4dlntim rtrmc urully d6 no( had to fsilrra
@frlitima rsh er pffi
wlll be char4ed
and temtfrstw
'Yr., if sicc
'nu Rul But6t
6.*

r.2J (P8+t)
Tcnpcr f,nbrittlcncrl
.d
Ilcriptic.
o
Thil rr m uprud rluff of Ihc low imFTrarc

duptilc/britth trsrsitioo tct|ry.f,d|rc.
It is &r lo dF lmg tcrm
cxpxrrc in thc tanpclerurt raryc of ahxl 650 - I l0O F Althougb thc losr ot toughrrs is n x crdcil r
(prn0ng tmFTanm,
quipt|cnt
d|c iJ tcopcr mbrinlcd nrry bc surccgrblc to bnttL lirenrc dring 3ral-r{)
an l slnil&ryn.
.tftcclcd MrGrirL
. ftimly
2.2J C-'r
. ()ldcr gsrahon
2.2J Cr-l Mo rnenufrtud
('riticrl
.
bcfrn
1972 ntr'y be panicululy
sucpriblc.
Frcle.r
fhrEc qrxfitruor
muJt bc nEt:
Tdnpcraturc (650 - I 100 F).
2.
Alby crnry.ntion
'fir of crfxurc
ICS arrl lw
alloy stcclsl
Sutplrbrlity
Mangancsc and Srlicm.
tramp clcnrentr Phnspluxur, Tin, Aoumooy md arscnic.
is largsly &tlrmind
by thc prcscncc of tbc alloying clcncnu
'the Rst Bust6
f?*
15
8l6l2Aro
'3

{.2J (ft{-t)
Tcopcr f,mbrittlcncnl
c..ha
OL
Prcttion
.
it lo limrl thc lcvclr of mmgarr:c
t'mhrnlcrncd
lllc bed w.y lo mimmiz? thc lilelihxrd and carcril of tcnF
rMn), siliconc tSi), drospll(rla tP), tin t$), nruimory {Sb), sd a'!cn|c {A!} iD tlE truc rnctd anl wcklng
crmrurnablcr.
*J- Fda
.
fr br* nEid Jd thc'I'fdttr
A cmmoo way to minimizc tqmFr Embrinlcmcm ir to limit thc
tirr wcld orad bercd rn mnsial q)opocitioo er lirllowr:
J - (Si r Mnl X tP + Snl X l0r BascMad

X = { lOP| 5Sb r.lSn + A!/100
Wcld Mad
-fi'picd J and X lsr"tors used for 2.25 Cr arc I 0O lt | 5 respcctively

lest Blaks - A s(xnmon way of monitoring is to insoll blocksof original
allny stel matcrial insllc thc reactu and pcrrtxfically rernovc lb,r rmpar,r
le3lrng.
MPT's (Minimum PressurizationTernpcraturrs)war 150 F in old metslr
and rs now I 50 F.
Thc Rud Butd
,ry

'fcnpcr
Embrlttlctcnt
Drrilig
(lupy Tmitiuono
fa flil
f.2J (Pca-t)
sd E adlld
Sbd
rffifd6
r'trEfn
.rfl
+>:
Ns*
Td (OpaditT,)
Tqrpanm
Thc R.ut Btrrte$
/.'h
{
16
8/6/2070
t'*h
\,
Module 4 High Temperature Comosion (4oo+ F)

a.2J (Pg.Lt)
fcmpcr fimbrittl.mcot
Tlm.
to Pond.f
uf equrpnEnt is m[t secplrblc to (dnts qtnnlcmcol?

rwtff rwlc of vilid sreinlm srl ard ogtrarirg ar t{XPF atd l0o0 pci!.
a a hydropruring,
consrnstd of 2- | /4 Cr I Mo rnalmd and opersnnB et j00pF anl -100 pua.
b. a hrthorerrr
c a thm wdl lral cxchanger chanrcl
d crytxn stccl pipc
c a hyrtrpnrc*rng
rcdrt
construdd of 2-ll4 Ct - | Mo stccl ard oprrlrng al 8O0"F and lOm plt
Whrch piu
It rs posiblc to prwa lriulc limtm rcsulting frm

prolrr iurt cmtrolhd olrcralron. t l'nr u Fals).
I lnr
?. Fahe
lkn kng r IoF ir it lypicnlly thurgil

temps mbrinlc{?
r. r slrrt tgm tqnperature qctrsion
b. I day
c. I wEt
d. tlxrsdr
of km
[cmpcr Fsbritllcm"ot
ol'a suscptrblo natcnal by rrsrs
of
bc crposcd to lcrnpcrDturlr of 1I)O "F to bccunc
dut e 2.2J Cr - I Mo ael

is sffcicn
Thc Rut Brste6
Module 4 High Temperatrrre Corrosion (4oo+ F)

SrainAglng
(Pg4-rzl
4.t.4
-tuiFsStcd rhr lwlt

in iEqrcd
rrd ryinj u u ntamcdiu
Alk
with | rcdnin
ln dnility^dtdrE[
lt mrhr
ciloct rf ddimir
u r coabind
r.d Mitc||l
Ocqn
Crffki
'
/ nrq$i
hrdldr
tcrpcrrm.
n d&
CS lpa
l9lo'rl
liti
r h.Ba Bnh
ti!
ud C4 J Mo
fri6
(r ('pci lEni
pr@
@drin
(8oF) Fffi.
fully killod lnd will d b. $rtgnbb
Srch |tidtLuc{
by rh. Bffi
rtwrlicud
by rhc Bsic Orygd
Srcdr mado nth
BOF c
srnir urtt
ctltTil rc obsrcd
wittr[
{@
rdidir[,
slnin |!ir3 it I mid
cwm
ro inamaliuo
ropaltul''
Prw@aL.
.
fh. bcrr u'
\ppbin!
tutaing
lo.IKth.
higls
ld"lr
ot oitic.l
inrp.r.ity dcrilt
th!
tffi
n.dt
Furo
il rorsidr
tl|t
hsE b.ri
lc aluipmn
th.t cortdrE
lha ,m of dalirnr.d ruod
ro mitrioiE rhc likclihood 6 to fl.
cold worid
ino Ficc
crulr
lf arlrrblc
mtaidr
my bem
h.td6r.d .[d ls
thc Flwidio
nMlfT to sld icprn ot *mc16b

d6idr
Bddirg
rlsld
lo nirihi4
b. codiddld
.rd dald
wi0 climinc
qSrc
ilrc cdirt
at iflFtrr.di.tc
rc y'uiol}y
6.Eirb.
tmpqrnG
dclirurd
urd ogrod
impquul
o4'r.io
rgrf,
WhdE PwHT it d
polt$lq
a MilltEbt
InqEtio
Bh! Bri(krE$
ud trMiruing
tr e(hq
w
t-m
n* urcd to codrol
of Slnr
*nin
aging,
AlirE-
'fhe Rust Buten
,.'-\
(" ,,;r
L7
8/6/2010

EEf F f,mbritrlcmcrt
{.2.5
O'
Dcrfilrr.
b Embdtlbmcd
ttith chfll@m
trrritic rtElr ur Mrptlblt
ph.s.
of r chrr'niumncn
rr rd8q, lo dE p.Eiprtlio
,{lTcr.d
rtld
prd6gd
D th. 6{D - l00O F ntlga
apou!
Thi, plEu|EM
Mrr6hl
4truScricr 55(4OJ, 1119,{10, {10S, 11Ol 4.16)
Duplq
33 ui
Wnrthi
rd
C.tk.l
u Alloyr 220J, 21fl .td 2J07

cd
:lx) Sds
SS coddning
tiniq
wcldr rnd wcld ovahy.
Ff,i@Lrt
trrt-l
\tlq
lmruint
DuuS!
Tlp cllLo m ktughrd

i. nd ptrnural
p|!n rlutdmr
rtuupr &d uprclr
pnicululy
wnposira
ol ltrrir
m!!r
"hr(mium
p,l.- irru,G|
c(frd,
mM
ol firirc
sr4pobilify
to d.drgo
I thc opantiog
tongmuq
ph.4,
an, otmlitq
tm9.tilw.
hl
ir ri6nifrca
I lorw
tr $rnrlrtiw.
,lppaffiof
.
t {)
M-DlFLOf
rdnpcrturo
cxFicnod
&rr{
cf Du{t
EtJ EtrtbrittlctrF a u r rmdhrqicd

i uil inst
rcdir{,.
clryUE thd L drr .adily
rpguer
whh ffidlofrryary,
ht ry
bc qnfrnod
ttru3h
bod r
?scth
tl5 F Finb.inlccd
qF..d
lo th. m
it rlwiltlc
qrditiool
bt hal lffitrd
it *ill Gobfitlc
(q-ti.Jly
/er
lh.r
I I m f ) to dilolvc
n did itritirlly
Fcipnr6
- tilt|(sql
by rqrd urlir4.
lftm,
if
fhc Rut B[nn

8t5 F Embrlttlcmcnt ,f.2-5 (Pg,l - ll)
TlmtoPowld
Whc
Which
o
o
o
o
o
Ai
N rtcb which my be sbje't to 88S'P obrittkrlottypie0y

. rcs(1or efilEnt prpint
. Rmtmfurutube
. Tnyrof a fr-actionationcolum
. all thc aboc
Whai msterhl i! mdt pmm to 885'F mbdnlemnt

r.
b.
c.
rI
fourd?
if oeoced to the prcp6 tcmpcntw?
Carbonrted
TyF 3oa Skin csr Stcl
TlDc4o5.9tainlcoSta{
Tcllon lincd pipc
facton led a mttcrid to bc rure prce to 88t,P embrittlmat?
Thicksmll
A ffiitic rtainls ltEl with roi chrcoim
A ferltic stainl6 ncl with r3.SX chmim
A! aurtmitic stainls rtql with 161 chmiuo
Expocw to 80'F cm|EEd to 60o'F
(clxru
all thrt appty)
ttr. n* i*,"*
t -'
18
:':;'
816/2010
(\

Sigmr Phrr
Embrinl.mcnt
1.2.5
__::'
l).icrlptlD.
Sigms phascrr a har4 bnttle, intermelalliceompound,Fd'r, which cm lbrm in ccrtainhigh chromium and
ehromrum-nrckel
SS'sfbllowrngerposurEin thc temperature
rangeof l(nO - t 750F
.{tt .t.d Mrtcrlrb
o Wroughl and castl(lo ScriesSS containlngllrrite, portrcularlywcldr. Alloy-swith high ( | 0 - l4% fcnitc
areespocrally
suscepnrble.
. ltX) ScriesSS and other lerritic/rnartcmiticSS wtth | 7qloCr or morc (.{3Oand ,l,l0)
o DuplcxSS suchar Alkrys 2205.2lO4arxl25O7
.
M a le ttr lswlth lT ' /o Cr o r m o r e u e lhcmosl susceptabl (thi smean3l mtcrrc3S S -mosl ofthcl l rne)
'fhc Ruat Bwtqt
{h
Module 4 High Ternperature Corrosion (4oo+ F)

Signr Pbrr
f,mbrittlcncat
{.2.6
(PS a - t6)
Signa phaec formatlon ir rlcpcndent on a ltriety of fectorr, in:luding:

o fime and tempanture of e4n9dr",
o ulloy atnyxition, and
degree of akl work presmt (cold wnrk promotes its lonnatton).
Normally, long perinls of time are requiral to form sigma. But
formation can octrrr in hours or minutea. Sigrna has been formed
during prst weld h.:ot tre{tment (F}VHT) of stainless stels, which
Dnly takes a priod of hotrrs to prrform- It can also formed in hot wall
stainlr:ssstel n a('tors that operate at high temperatunsHigh nickel dllqs with no eold wort are relatively immun to siglna
formation, wherear, high chromium alloyr are more suscrprdblc.
Whet ic Pha.ae Formadon?

All metalsarccrlstals.AmctalcanhavcscveralcrysoltbrmsdepndingonwhcrerhcatomsarE
lrtaterl wrthin thc crystal. Whenotherelemcnb Breadds!- which fbrms an atloy - rhesealditlonrt
clementsalfect the shapeof thc crystals. 'fhe diffbrentcrystalitructurcs havedifferent perccntages
of
eachalloylng element. lltes dilTerentcrystalstruc:lures
0re callal "phases". They are glven narn6
Irkc "austenirc", 'femtc", or "sigma" for examplc.
TheRut Bu$en
i'?
19
816/2010

Signe Phrrc llmbrltflcmcnt
4.2.6
e\,
i '- . t
J
t6)
(lrltlcrl !'rcton
. Alkry comp($rlion(Fftrculrr! chnrmrumcontentlbnttcpharc),tlmemdopcrstrngtcmperatuc(l(X
- l 7 5 0F ) .
. Increaitngamountsof lbrrite phaseincreascssusceptibilityto damage
. SigmaEmbrmlementincreascswith increosingamountsof Cr and Mo.
.
A lloys wrth sigme can normalty wrthstand normal opcnling ltrstrca, but upoo cailing to tempcrslurct
hkrw 5fi) F may show a complac lock of ftacturc loughncat.
nl mclallurgicalchangcrs aclually thc precipitationof a hard,brittlc intcrnrtallic compoundthat c8n
also rcndcr thc mstcnd more susctprrblcto intcryranularcorrosion.
Prwcrtlor
. Sigmars rcvenrbleby solulionannealingat 1950F, but thrsusuallyisn't praciicsl.
Thc Rurt Buttcn

SignrPb$cEmbrittlcmcnt
Tkn.
,q h "
''.9
4.2.6 (Pg4-16)
to Pfll6
Stsinls sted quip@ail op6!tc! rt l36o'F and truy halt

wlc
o' Ihccquipm antr uymdin
myaad
durtgcml don
o Th.quipnat
o Theequipmtmymdduin6,rhutdom
up.
o Theequiprotroytrutdurinlm
trupoctN c|n tdl if siggre formarim hu ilruned
oTr e
o Paba
whs
o
o
o
o
o
Rat
indic?te thrt sitE
ir thc lart
by vtrud tntFction.
equiprcDt ir sup(ted to haw forFl sipu hom opsndond i6tpmtw,

Mclunlol
rlnkint
rt olENtlond tmpratw
Watswhintduingsrhutdm
Thmal shakint at ltarl-up
lncpea'tint tha equipmqt
Applyiot load! suh u rafrolding duiry thutdow
of wfiich eLml
tlitb qwtiti6
o Niclcl
o Nitrogs
o Carbon
o Chmmiu
]}lc
Which of tht followin8 natmtr
fomtid
whlt should ba N{rid6d? (c-hck all that appty
i! [tdy at hisb tmptrNhr?
BurteF
i *1
2C
8/6120ro
fe
Module 4 High Temperahrre Corrosion (4oo+ F)

Brlttlc Fncturc
{.2.7 (Pg+19)
Dc*riptior
Brittlc ftacturc is the surJdanrepid fr.ctur undcr suocs(reridual a applied) wherc thc marerial cxhibiE littlc
tr no cvidcnccof ductility ot'plastrcdformdion.
,'\ficctcd MrlcrLL
. Carbon and low illoy rteclr - psrticulady oldcr srcclr.
o {mScns SS
('ritlcd Frctorr
. Tcrnpcrsturc & Matarialg of conctn"L:tio,n
Aflcctrd Ul|tr or Eqrtpilcrl
. F4uipnsu manuhcrurEd prior to lhc Docmbcr l9t7 ASME Sarim Vlll, Div. I corb arc surccptiblc
. Mosl proccas6 run at elcvclcd lrmpemturg so ttrc mrin conoem for Britllc Fractufr ir during sortup,
shuldown and hydrdGnint.
. Thicl wallcd vessclr should bc co$idcrcd.
. Brislc li,arturc can abo occur during autorcfrigcration.
Appcrnncc of Morpbol4y ol lhrrgc
. Cra:kr arc tlpio:olty strright ad noo-branching.
Thc Ruli Buttar
(M
Module 4 High Temperatrrre Corrosion (4oo+ F)
BrltdcFrrctrrc
4.2.7 (Pt1-19)
ftc nur nuten
#e
2L
8/5/70rc

Brittlc Frrcrurc
1.2.7 (PB+19)
Thc Rut Bl8tert
.aB,
Tubc bulgc and longitudal crauks. 800 H

convcction tubc
flre nut nrrtero
2-
.,.:r.v.
1,...,,
*
8/6/2010
(*

(lrccp / Strdr Rrptrrc
1.2,
(PS+23)
Dcrcrlptlor
. Al hidr lcmperaturc$,merrl slowty arxl continuoustydetbrm undcr load
.{ftccr.d Mrtcrlrb
. All meta.lsmd albys.
Crltlcrl tr'rclon
.'fhc rat! rl which a matenalwill crccpis rlcpcndcntuponrt'r:
o Stren3rh
. Stre$ impmcd, and
. ltre opcratint tcmperstur!.
Th. Ruc Butat
( Th
(lrcep/ Strcrr nrptlrr
4.2t
(PS+af)
containing/z"h or morc molybdenum(Mo). Thcreforc,is shouldnot bc surprising

thnt l- % Cr- | /2Mo and2 t/t Cr- | Mo steelsare usedin refineriesfor rcactorvesscls
thatoperateat high temp and pressure!!
.lttcctcd Urltr or f,qrlpncrt

. lhe rateofcreep delbrmationis a functionof matcrial,loa<!and tempcrature.
..{ ,a ir cr tla o fr b o r t2 5 F o r u lr r r r co fl S ou6orctr6acrcrttl cari ai .i 4l i fthbdl cr
morc- dcDcrdhj or ttc dloy.
. 'fhc life of mad componcnB bccomc nearly infinit al rcmpsrrurcs brlow thc threshold limit.
.\ppcrnucc ol Morpbolo6r of Drorgc
. lnrtisl stag6 ol creepcan only bc idenrifiedby scannrngeleclronmrcmsc'ope
ISEM).
. At temperaturesabove threshol4 noticeable dl'omrlior may bc observed.
f':h
23
8/6l70rO

'fltmirr
cfl
Hydridlng 5.1J.2 (P8.5{l)

A.
\J-Dercriptioo
. Hydmgro diffir.sccinto the titanium and rscts to form an embrittling hydridephare.
Critical Facton
. Temperature,solution chemirtryand alloy.
. Oc'crrnr
in specificenviruomrotsat tempabovet6S F and a pH bclow3 or above8 (or a neutral
pH witb bi8h H2S contcnL
Aft:ded Unitr
. Primarib io Sour water nrippcrr and amine uoitr in thc overhqld coodenren opereting abovr
r65F.
Appearancr
. Embrittlement ihrt can only be confirmcd with tbe harnnrer,s3 1furorrghrnctdlurgicsl teft
^1.-
at'

'fileriuu Hydridlng 5.1J.2 (Pg.541)
Prcrantion / mitigation
. Doo't ure titanium in known newicts for bydriding.
lnepeetion/ Mooitoring
. A specializedEddy currcnt was noted ar beiog succtssfirl
. Uctdlo$apby
Ilre Rut But6
TH\
'g
25
The RustBusters- API 57L
Module 4
High Temperature
Corrosion
OpenBook
1. Are nickelbasedalloysresistantto sulfidation?Explain.
2.
Doessulfidationinvolvethe formationof sulfuricacid?
3.
In a dieselHydrotreater.ls the likelihoodfor corrosionmoreor less aroundthe hydrogeninjectionpoint?

E x pla i n .
4.
ls therean uppertemperaturelimitto metaldusting?
5.
Whichelementcan be addedto reducemetaldustingtendencies?
6.
Pipingand equipmentin hot hydrogenservicein hydrocessingunits or catalyticreformingunits as well as

fired heatertubes operatein a hydrogenrich atmosphere.What type of damage can this lead to??
7.
Heatertubes,thermowellsand furnacecomponentsoperatingin carburizingenvironmentscan have what

type of damage?
8.
9.
These Monitoringtechniquescan be used to detectwhat corrosionmechanism?

o
Monitorprocesstemperatures(watchfor processcreep)
Monitortemperatureswith infrared
UT materialduringS/D
What type of steel is the most susceptibleto Sigma embrittlement?
10. What is the chemicalsymbolfor Tin?

11. Crackingis typicallystraight,non-branching
and largelydevoidof any associatedplasticdeformation(thisis
an easy one for you).
Copyright@2008 TheRustBusters
Page4

Module 4
High TemperatureCorrosion
Revised
Aug,2009
Caution - This quiz may contain more than one "Challenge" question.
l.
Whatis thehighest
temperature
thatis considered
acceptable
for useof carbon
steelin liquidoil no matterwhatthe
sulfurcontentis?
a.
b.
c.
d.
200"F
450"F
600"F
1000"F
ql}5'
This corrosionmechanismresultsin the lossof weldability, and can be confirmed by substantialincreasesin

hardnessand loss ofductility. It diffusesINTO the componentat a high rate,and then tapersoffas the dept
increases.
a. Creep.
b. Thermal Fatigue
c. Metal Dusting.
d. Decarburization.
e. Carburization.
Thiscorrosionmechanism
is Mostfrequentlyfoundin IheHAZcoresponding
to thelow tempedgeof theHAZ.
Graphitenodulescanform at theseHAZ's resultingin a bandof weakgraphiteextending
acrossthesection.Dueto
its appearance,
thisgraphiteformationis called.
a. Creep.
b. ThermalFatigue
c. MetalDusting.
d. Decarburization.
e. Eyebrowgraphitization.
In creeplife,an increase
ofabout25 F or an increase
of_
half or more- depending
on thealloy..
a.
b.
c.
d.
e.
on stresscancuttheremaininglife ofthe materialin
2o/o.
l0 o/o
15 o/o
20 o/o.
25 o/o
Page1

5
Are annealedstealsor normalizedsteelsmoreresistantto carbideagglomeration

in iron basedmaterialsoperatingat
1300F?
a. Dependson the time of exposure.
b. Annealedsteals
c. Normalizedsteels
d. All steals
e. All theabove.
After longtermexposure
in the650- I 100F range,thisspecificmetallurgyis subjectto an upwardshiftin the
ductile/brittletransitiontemDerature.
a. CastIron.
b. Annealedsteal
c. Normalizedsteel
d. 2.25Qr
e. Noneofthe above.
The Bessemer
openhearthprocessandtheBasicOxygenPurnacearebothprocesses
that havebeenusedto make
producefully killedsteel?
steels.Whichof thetwo processes
a. Neither.
b. Bessemer
openhearth
c. BasicOxygenFurnace
d. It doesn'tmakeany difference
e. Noneofthe above.
In FuelAsh corrosion,
theseverityofdamagedepends
on:theconcentrations
ofcontaminants
in thefuel,sulfur
content, and
? Pg4-l2l
a)
Temperatureofoperation.
b)
Metal temperature
c)
Alloy content
d)
CarbonEquivalent
9
a)
b)
c)
d)
FuelAsh corrosionin someinstances,

the characteristics
andmeltingpointsofthe slagscanbe changedby:
Operatingvelocity
Firing with low excessoxygen
Mixing of thefuel oil
Fueloil viscosity
10 Revised
- Whichelementcanbe addedto steelto reducemetaldustinetendencies?
I ilil;'"'
c.
d.
"t^.,\rnY
Molybdenum I r r*'.
Sulfur
\J
copyright@2008TheRustBusters
PageZ

11
Sulfidic corrosionPrevention/ Mitigation. Once the materialsof constructionare in place, it is importantto keep in
mind the limits of sulfur contentand temperaturesor whick the materialswere chosen,and not let increasedsulfur or
temperature cause acceleratedcorrosion rates. What is the name of the industry acceptedcurve for materials
selection in sulfidic corrosion for liquid only streams?
a.
Cooper-Gorman
b.
McConomy
Nelson
c.
d.
Cooper
12
Which of the following statementsis not true concerningCarburization?

The most common place for carburizationto occur is in fired heatertubes. It is found in FCCU reformers
a.
and Delayed coker units.
b.
Carburizationdoesnot causemetal loss,unlike other high temperaturecorrosionmechanisms.
c.
Surfacescaleofcorrosion productsrarely form.
d.
The main requirementis that carbondiffusesinto the metal, and the formation of metal carbidesis not
required..
NN
IJ
Is carburizationever useful?
a.
Yes, it providescorrosionresistance.
b.
Yes, it provideswear resistance.
c.
No, it always hardensthe surface.
d,
No, it makesthe materialsusceptibleto crackingafter welding.
14
Which of the following corrosionmechanismshave a Dr. Jekyll and Mr. Hyde effect?
a.
Sulfidation.
b.
Carburization.
c.
Metal Dusting,
d.
Graphitization.
I5
Revised
- Which piece of equipmentis most susceptibleto temperembrittlement?
a.
A HydroprocessingSS reactoroperatingat 900 F and 1,0000psia.
b.
42.25 Cr Hydrotreaterreactorthat operatesat 800 F and 500 psi.
c.
A thick wall Carbon steelheat exchangerchannelheadoperatingat 500 F.
d.
Carbon steelpipe operatingat 450 F.
Page3
w/
.&
8/6lZOLO
Module
5 - General DamageMechanis-* ffi
o
a
a
o
a
a
a
Steam Blanketing
Dissimilar Metal Weld Cracking
Thermal Sh<xk
Enxion / Ennion - Comrsion
Cavitation
Refractory Dqgradati on
ReheatCracking,
.1-35
.{-38
4-42
4-44
4-49
4.69
4-63
The Rust 8urle6
.'4
Module
5 - General Damage Mechanisma

Storm Blenkcting 4.2.11
- All Industries
(PgrL25)
Ilrc tlow of heatcncrgy through thc wall of r stcm gerrrating tubc results in thc fomotion of discrstc stcmr
bubbld ( nuclclr. txriling) oo thc lD. 'l"hc tluid llow s*cepc thc bubblcr away. Wh.tr ahchcrl llow balanccis
disturtc4 indivdual bubbhs jorn to form r srcemblenlet r conditron kmm rc llcp.rturr fror Nnhrtc Boililg
(DNB). {h* a stcrn bhntct forms, tubc ruFurc csn q:cur roprdly !s r rcaull of short tcrm overheeting(usrnlty
within c fcw minulr!).
Allcctcd Mrtcrbb
r lron barcrl mdcrials irelrding carfurn sEcl rrd low alloy sr.ch.
('ritlcrl
.
.
Frron
Hcat llur li llurd tlw.
Flamc impingcmcnl can pnni& mrc hcat llux than th. stcrm gcncratingtubc crn accommodatc.
Apparrmc of Morplololpr ef Durgc

. Failurcs arc alwayr an o[rn btusl with nerr knrfe-cdgc fncturc cdgcs.
. Mictostructur is scvcreclongation ofthc grun stnrtuc duc to thc plartic dctirrmationPrtrcltinr
. Propcr burncr mrna8emcni
. hopcr tloilcr FeedU'hter (Bf'W) tratmntcan hclp pwent rertricted tluid flow Poq opcretion (Boilcr Fecd
Wstcr trcatcnt can lead to Steamtslanteting
Thc Rur BtBt6
-+\
...1
8/6/?ALO
r'+l\L
,i
t
Module
5 - General Damage Mechanisms - All Industries

Dissimilrr Mctrl Wcld Cncking
{.2.12 (Pg. +Jt)
flccriptbr
('racking of dissrmtlarmetal welds uccun in the l'erritrc(CS &, low alloy steel)sidc of a weld bctwEcn
[ustenrtrcSS and r tbrntic mstcnsl opcrtrtlngat hrgh temp.
.,\ftccfcd Mrlcrirb
. llc mon common materialsare t'cnilrc (CS & low olloy ) stcclslhat are urcldcdto the austenlticSS.
. An) mrtenal combrmtKrruthal havewrdclv drflbrrngthcrmalexgnnsroncoetficicnts.
('ritlcll
.
.
.
Frclo]|
('rackrngoccursbccousclhccoctlicicntsoflhcrrnalexFnnsronbctwetlt'crrrtrcsteclsandl0OseriesSS
rlttltr by .J0?6tr morc. At high opcmtingrmpcraturcs, tlrc dlfErcre in cxponsronlcad b higfi srrcssat
thc llAL, on thc l'crrrtlcsidc.
Ferrttic/8uslnittc
fatiguc strcasesat
Jointgcan gcneratcsigmficanlthcrmal expansron/thcrmal
lcrlpcnlr'ti
lrt|Lr tbri 5l0 F.
Stresscasctrngrxr thc weldmentarc signifirrn0y highcr whcn an austeniucSS lillcr mctrl is uscrl. A
oiclrcl brrt{ 0llcr mctrl har a cofncicntof thnnsl expansronthat is closcrto CS, resultint ln
lowcr stres!at elvaldlamperrturc.
srgnrlicanrry-
Appcrrrrcr of Morpiologr of Drnrgc

o ('racks lbrm at th t(x of the wcld in thc ll,AZ of thc l'errittcmaterral
'Ihc Rut Bunen
,'',lt'.
Module
5 - General Damage Mechanisms

-l'hcrmd Shocl
- All Industries
4.2.13 (Pg +421
o,
Ocr.riptlor
A lbrm of thcrmal f'aliBucraukrn& this can occur when high and non-unitbrmthermalstrBscs dewlop ovcr
a relatively shorttime rn a preccof aluipmenl duc to dilfcrent cxponsl{rno( cont@-tion. Ihermsl shock
oocun whcn a coldcr liqurd cr:ntacBE warncr mcfal surfbc.
usunlry*
AtLcl.d Mrtcrhlr
o All mctalsand alloyc
('rlt|cd
.
.
F.ctort
Magnrtudcof thc tempraturtdilTcrcntialand thc corllicrent ol'thcnnrl exponsronof thc matcrial.

SShasahrghcrc,rxtficientol'tlErmrlexponsbnthanCSandtherelinersmorelikelytoseehigher
strcsscs.
'Ihe RrBt Buten
f+
8/6/2010
Module 5 - General Damage Mechanisrr

Thcrmrl Shoch
.\tlcctcd L'nl6 or f,q[lpD.rt

'
.
{.2.13
- AII It dtr"t"io
(Pg.{-12)
Any hrgh tcmpcroturcprprngand equipmcnl.

Mrtcnals that hrvc lost ductrlity, suchas Cr-Mo (tcmpcr Embnltlmmt)
AppcrrrEcc of Morphol4Sr of Drmrgc

o Surlir,ccinrtratingcracksmay also appcarar "crazl" cracks.
Prtrantlor / Mll|;rtlor
. Prcvc'ntInfcrruplions in lhc ll.ow of high temperaturc lincc
. l)cslgnlo rnrnrml"lsrvcrcrcstrarnt
.
Inrsll thcrmal slccvesto preventliquid impingement
|lspcctbr md Moritor|ll
. lhrs tlpc of damagcrs highly l<xalizedand riilfrcult to locatc.
o PT & MT can bc usgl ro conlirm crackrng.
'l}le Rut Eutcn
.*ts,
Module 5 - General Damage Mechanisrra - All Industries
Erosion/ Erocion- Corrosion1.2.111?g 4-44'1
o--
DcrcrlpllDr
l]rosirn -. (aka - abrosivewear) crrrosion is a drrnagc that txcurs when cr:mxion c()ntnbutes!o
erosionby removin3prol*livc tilms or scalcr.
lltcctcd Mrlcrhb
All maals, dlcys, and rcfrartoricr.
('ritlcrl Frlo|t
. Metsl loss ralql dcpendon thc vela;ity and conccntralronof impactingmcdrum.
. 'fhc siz.cand hardnessof impsctingparticlesar well as angleof impact.
. For each cnvironment-materialcombimtjon, there is ollen a threshold vclcity above rvhich
rmpactrngobjectsmay prcducc mclal ltxs.
Unl$ or Equlpmcot
'tffcctr{
. All typesof u;uipment moving tluids antVorcatotyst.
. l{ydrupro<r*srng rcactof efllunt pipint may bc sub.lar to erosionrorro3ioo by amm<nium
bisulfidc.
. (lrude units cxposcdto naphthcnicauidr.
IlE Ruct But@
t:)
8/6/2010
Module
5 - General Damage Mechanisrur
- All Industries
Erorioa / Erorion - Corrorion 1.2.14 (Pg. a-+{)
App.rr.!c.
ol Morploloqpr of Drnrgc
. Charrtcnat
by a hxalizcd loos rn thrckncss tn thc tbrm of plq govcr.
rounrJalholcs and vallcys.
.|
-ossesexhrbit drrcctionalpattern.
.Farlurpsare usuallyqurck.
gullbr, wrvcr,
Prwcntlor / Mlt|8rtbr
.lmprove dtsrgn, shapcgcometry,rerJucellow ratc,
.l lsemore corrosionre3istantmct8l.
.t.lsc hanleralloys.
I nspcctlor rod Molitorlag
Visual.UT and RT.
Thc Rut Bt na!
Module
S - General Damage Mechanisms

Crvitrtlor
d
4.2.13
- AII Industries
(P& rt-49)
Dclcrlptbr
'llrir ir a ftrm of erosim oured by thc tirrmuiqr snd instantrnoora collapse of innunerabk tirry vapor
bubblcr. Collapcingbubblcscxen rvcrc localiad imp6!'t tbrccathat can result in mctal losr.
.{lfcclr{ Mrtcrhb
Copper/brass,csst iron, CS, low alloy stecls, lO0 & 40OSerics SS.
Cddc.l Frcton
. PrcssurcDnp, tcrnpcrDtrnclt vapor pretrsurc.
,VotF As an examplg in a pump, tho ilillercnce bctwen thc ar,trul pessurc of hal of thc liquid
avarlnblc and thc vapor pressurc of thst liquid is called the Nt Pmilivc Suctron Hcod (NPSH). fltc
mmlmun heartrequrrul to prevc'ntc{vitrtiar with a gverr liqurd at a given {low ratc is rnllod thc NPSH
required. lnadaluarcNPSH cm rcsult in covitation.
. l"cmpcnturesapgroarching
thc boihng pourt ol'thc liquid arc morc likcly to rcsult in bubblc formatiqr
than lo\ er temp.
udr36
Itc
Run But6
{%
4
8/612010
Module 5 - General Damage Mechanisrrur - All Industries

Crvitrtion
'-3
4.2.15 (Pg.&19)
---.--{ficci.d t itt or rarripocrr

O
. O,ccunl
in pumpsandtn prpingdownstrcam
of trificcsot ctmtrolvalv6.
. Cavttalrrncanbc lbundin somcrgtricted-tlowpassagca.
Appcrnmc of Morplologt of Drm4c
Chsrar.tnzodby shnrpodgal prtting,hn may algohaw a g<rugcd
appearlnccin rucatronal
componcnB.
Domrgconly <rccurc
in localizcdlow-prcssur
zoftlr.
Prwcrllor / Mltfrthr
Bcstpccvoltcdby avoidingcorditimr tha allow thc abcolutcprcJsurrto tirll bclow thc vsporpresrureof
theliquid.
. Dccreascfluid vclociticr
. Strcamlincthc flow pathto rulurr turbulcn
. Ircrearcsuciionprwsurcof pumpr.
lmpcctior rrd Morl0orlry
L Sourdrlike pebblcs
2. Acousticmniroring
3. Visual.LITandRT
'lh. Rud Brste[
T!t"
*t
Module S - General Damage Mechanismr/

Rcfrrctory Dearedrtloa
Dcrig'dor
4.2.1t
Nl Industries
'h!
tt1n{-C\ 1r
Reftrcror damagetiom mcchanical(cracking spalling& erosioo)ar well as comxion duc !o oxidation,

Sullidstion and othcr high tcmp mochrnisns.
Affcct d M.tcrlrb
r All
(lritlcrl Frcton
. Sclcctior\ desip and insollatioo.
. Dry out guhcdulcr, curc times and spplication predur6.
Aflcctd Ull6 or Eqolpmcrt
. Used in FCCU pipingcycloncs
.
Boilcr firc boxcs arxl hcatcr stacks.
Appcrnrcrof
Morphologr of Drmagc
o ln erosive scrvicts, rcliactory rnry be washal away.
o Coke deposits may dcvelop in refrautory promuing cracking.
Prwertlor / UithrtfD.
r Propct dcsigr and rnstallalion- Propcr anchorsand tillcrs.
Inspccdor rad Morltorin3
o Survey tnld-nall equipmorton-stream with IR.
r. MsuelduringS/D,
Rust Brrrtcnt
.'..'\
1,.::T,
816/20L0
(*
Module S - Ceneral Damage Mechanisms - AIl Industries

Rchcrr('rrcHng
qznceIru
t.2.19
(pB.t4l)
As with all cracking mrchanisms, strers ir na:'ded. Thicker scctions and higher strcngh
materials add to the internal metal strrssea. Arran wherc thi.s mechanism i8 typically
found include nozzlewel&, piping to fitting welds and rryeldswith poor fit up. cracking
typicalty ocr:tus in weld HAZ's,
Prarcntion
Reheatcracking can be contmlhd try either metallurgical specifitionE or by welding
prcrcedurrx.
Thc Rurt 8utcil
Module S - General Damage Mechanisnu - All Indusfies
---O)-_Formatting and supportin g information

API Recommended
Practice571First
Edition,December2003
Qe
ew
Module 5
GeneralDamageMechanisms
OpenBook
1. This crackingmechanismoccursprimarily during PWHT, It is most likely to occur in
heavy wall vesselsin areasof high restraint including nozzle welds and heavy wall
piping.
2. Will changingto a hardermaterialimprove cavitationresistance?
3. SteamBlanketinghas similar characteristics
to what other mechanism?
4. "Abrasive wear" is another name for what?
5. What materialsare most susceptibleto DWMC?
6. Can poor operatingtechniquescauseSteamBlanketing?
7. Selection,designand installationare the keys to this mechanism.
Page5
The RustBusters- API 57L

Module 5 GeneralDamageMechanisms
Aug.2009
Revised
Caution - This quiz may contain more than one "Challenge" question.
QuizTime#5
l. Thiscorrosionmechanism
is characterized
by cracksthatareproduced
asa resultofdvnamic loadingdueto water
hammeror unstable
fluid flow. (4-59)
a.
V ibration I nduced'urroiron'
D,
Mechanical
Fatigue
Reheatcracking
d.
All theabove.
This corrosionmechanismis characterizedby a clam shell fingerprint ofconcentric rings.
a.
Vibration Induced Corrosion
b.
MechanicalFatigue
c.
Reheatcracking
d.
All the above.
3.
Thisfailureis characterized
bv nearknife-edee
fractureedses.
a.
D.
d.
Brittle Fracture
DissimilarMetal Weld Crackine
MechanicalFatigue
SteamBlanketing.
What is the critical temperaturewhere fbrritic/austeniticjoints experiencethe most significantthermal expansion?(4-
38)
a,
b.
d.
5.
Above500
A b o v e5 1 0
Above1000F
Noneofthe above.
Thisfailureis goingto showup asa crackin thetoeof theweldin theHAZ of theferriticmaterial.

a.
b.
c.
Reheatcracking
Thermal shock Cracking
Dissimilar Metal Weld Cracking
MechanicalFatigueCracking.
Thiscorrosionmechanism
is characterized
by cracksthatareproduced
asa resultofmechanicalloading(4.2)
a.
Mechanical
Fatigue
b.
VibrationFatigue
Reheatcracking
d.
All theabove.
1. Thisfailureis characterized
by a localizedlossin thickness
in theform of pits,grooves,gulliesandwaves.
Lossesexhibitdirectionalpatterns.
Cavitation
b.
Reheatcracking
Erosion/ Erosion- Corrosion
d.
Vibration- InducedCorrosion.
PageL

8. Revised
Which of the following will causeCavitation?
Lackof NPSH
.a.
b.
Fluidsoperatingat theirboilingpoint.
High suctionpressuredrop.
c.
d.
All the above.
joints to minimizethermalexpansion??
9. Whatfiller metalshouldbe usedto minimizeferritic/austenitic
a.
Sameasthe ferriticjoint.
joint,
b.
Sameasthe austenitic
High in siliconeto "kill" it.
c.
d.
High Nickel content.
pitting,but mayalsohavegougedappearance.
is characterized
by sharp-edged
10. Thiscorrosionmechanism
(4-4e)
a.
Thermalshock
b.
Erosion/ Erosion* Corrosion
c.
Cavitation
d.
All the above.
Page2
8l61ZOLO
(''}i
Module 6 - Uniform
or Localized [.oss of Ttrickness
.rtt
(iolvanrc Corrosron
I
't
AtmosphcrrcCfiroslon
432
Crrnrsrr,rnUndcr lmulation (CUl)
4l ]
CmlingWatcrCorrooion
MicrobrokrgrcallyInducrxlCormsion { MIC)
{14
l)ealloying
(;raphrtK C()frosion
43 i l
4 t.t2
8<lrler Wbter condcnsateCorrogron
{ 3.5
.t
I
6
{l E
e COr Corrocion
to Fluc Gar Dcw PornlCornrsirxr
Il 6
41.7
tt
4l 9
Sorl Corrosron
4l l o
12. CausticCoffosron
Th. Rurt Butf,
{"3a
Module
6 - Uniforrn
or Localized Loss of Thickness
Grlvrnic Corrmion {J.l
fr..rt1l".
(Pg.fis)
Cnlvanrc cofrorron rs thc tcrm gencrally applial o thc aocclaatcd corrrrldr of onc maal whcn rn contct
with arxrthcrin a suitrble clctrohlc.
Aftcclcd Mrtcrhb
All mtab wrth thc exceptionof thc most noblc.
(lrlthrl Frcfort
'lltc tbllowing conditionsmwt be mct:
. An elqctrol)1c- tluid thal can conducta currcnt
. Di ffcrent t) pes of mltcrial3 ( lnodc and cathodc)
. lilectrical connection bcowcn the anode and cathodc.
. The more notrlc marcnal (tho&) is protectal by sacriflcial cormsion of thc morc altivc mrtenal
(andle).
. Thc t"artherthc alloys areapart in thc table,thc higherthc driving forct lbr corrosion.
. Thc reluive rxpcced surfacc areas bctwcn anqlic marerral ard thc orbodic matenal has a signrfrcant
allee't.
. Corrosion rates ol lhc anorlc can bc high, if thcrc is a largc anorle lo cathqb raiioo
. Corrmion ratsr of thc anodc wrll bc lcas afectcd rf thcrc is a largc anorleto catlxxlc ralion.
. Thc sanr alloy fiay d at both an anolc arrl tuthalc dtc to surfbr= lilmg sr:le etc.- Considcr okl pipc
conncctat to ncw prpe.
(
-'aRut But6
Thc
i&
8/6/2OrO
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f
Module 6 - Uniform or Localized Loss of Thickness

(lrtvrnic Corrorion {J.l
(P& 4-65),-.r
(lr|ivArrc
3ER!E3
CDt
NETALS AXO ALLCDV' II|
aE
w tttt|
CorrodedEnd
uartr.r
t-
rht|aa
nlttta
auru
LB
rultttm
caat
frtL
ar-r
utl
3rn
rE
rtt
wtr
Ir
.to (aqtLt
rta (lctrQ
L
^llltttt
ru.nt
atlta
SCTI
trrutroE
-r|l
m.
arll.E
rnD
(taaa[t
tn:.io
rvt: tra (t aarrQ
trl.
mtl
l[]
uttll.ot
nru
'q'
Module 6 - Uniform or l"ocalized Loss of Ttrickness

Grlvrnic Corrorlon 4J.l (Pg.{-65).r'r
cathodeih-
^ri"u, fr
c"tl"a"
The rate of corrosion resulting from galvanicaction

dependson - the relatiue eqrosed olrecraof the
tuto metals in contset!
If there is a large ratio of anode to cathode areq thc cethodc will effectivety be
protected and may not corrode ar all! Howcvsr a smsll rnode area when coupled
with a large crthodc area will corrode rapidly.
,'nwr
The RNt ButeF
-i,F.i.
816l2OtO
{3
Module
6 - Unifonn
or l-ocalized Loss of Ttriclsress
Grlvrnic Corrosioo
{.J.1 (Pg. !l.65)
Allclcd llrl$ o? Eqrlptlcrl

Any whcrc tlrcrc rr s condur'tive lluid anrl allop arc c'ouplcd.
Appcrrrmc of Morplolo6r of Drmrgc
.thc
morc active (more anodict matenal can sutfer gererahzodloss rn thiclncsg or may hlvc a crtvlcc,
gtmvc <r prtrm3 consioq depcnling on thc dnving tbrcc. conduetivrtyand relalive antxJidcathodicarea
rattoo.
Prrvcrttor / Mlrigrtbr
. O<nd tlesiglr
. Cootingr
. Intcr6tingly cnorgh, gllvrnic curosron has sonr vcry b||clicid aspcc'ts. Calhodic prctc(1im with
sacrificral anodcc are examplco of protection ofonc rnctal by lh p(eferenlrElcorrogion of anothcr.
hrFctlor
|!d Morttorlrt
. Visual and UT.
. Damage is oficn hiddcn undcrntarh and can't bc detcctcd.
Thc Rut Burt6
Module 6 - Uniform or Localized Loss of Thiclsress

Atmorptcric (lorrociol 13.2 ln
449t
Dclcriilfor
Comrioo that occun fiom moisture associatedwith atmosphcric conditionr.
At?GcLd M.t rirb
CS, l,ow allq secls snd coppcralloyed aluminum.
(lrltlcrl Frtorr
Plrysrcallocrtim:
. Chlorida, HrS lly arh and orhcr airbome contaminab lirom c@ling towcr drift, fumar:c strks and
othcr aluipmant aucclcntc oorrosion.
. Bird "drnppingr" can also causcaccclsatcd corrosion.
. Marine environmdils and inlustrid environmcnts that contain acids o,r sulfur compoundr tha can
tbrm acidr.
The Run Brsim
816/20tO
Module 6 - Uniform or Localized [.oss of Thichress

..llnocphcrlt ('orroclor {J.2 (Pt. l{9)
Dcr.ripth.
(lomBlofl thatoccursfi'ommorstur{xtnocntqlwrthatmmpherrccondrtroor.
nfinnadcCanodmbb
CrbrrdLqAlryi-
(lrldcrl l-rctorr:
. Phyricallocation
(marinc,rural).
t2
lo
. Designsthal cantrap
mtristurc.
Ett
i.
E
. Prcacncc
of salts,sulfur
& dirt.
Pr
2
o
o
'r(I)
rs
200
2!It
no
rihlf|.rF.-,r
r
N/biB/HngTcr.s0ltAfl
Trrp'dc-**Add/Oy
Thc Ruc Butil
--T'ir,
il
Module 6 - Uniform or lôcalized Loss of Thickrress

,ltnoryhcrlc Corroriol 4J.2 (PS.{-69)
Crltkrl Frcton:
. Madnc cnvironmenB
. Industrnl envirunmGnb
. lnlmd locatioot
20 mpy
5 to l0 mpy
I to I mpy
Allctlcd Uri6 or tqoipDcrt

. Equiprncnt opcratin3 at tempcr:aturerlow enouglr to allort moistrrc to bc ptescnt.
. Paintrr cctin8 rystem in poor condition.
Appcerrncc ol Morpbolo6r of thtnrgc
Atbck wrll bc generalor localized.dcpcndingon whelhcr or no{ thc motsturis trappcd.
Praertbr
/ Mlt|;rtha
.
Surtur preporBtionand proper coating application are critical for long-term protectioo.
.
lnspcr'lronand Monnonng
.
Visual and UT.
i^lT.'-h,
t'
1
816/20t0
r"{?\
Module 6 - Uniform rrr l-ocalized Loss of Thiclsress

('orrorloo tindcr Insulrtioo (CUD 4JJ ( Pg +71)
('-'a
Dtscrlpflor
Corrosrrn that resultstiom wucr rnppcr.lundcr insulotim tr tireprooling conditions
Vc$al
Insuhllo! Rint
n r Ru t&r td
{'*
Module 6 - Unifnrrn or Localized Loss of Thiclsress
-o
(lorroriol UnderInrulrtlo. (CUl) dJJ ( Pg +7t)
DclcrlpttDr
Corrosrofl that rsults from water tlappcd undcr insulation of fircprooling cooditioG.
.{ltccLd Mrtcrlrb
CS, Low alloy steclr, 3OOSeriesSS and duplcx SS..
(:ritlcrl Frctort
. Desrgnot inrulaion systenl imulation r)-pc,tempcmturc,enviroruncflt(humidrty,rainlbll and chhridcs frorn
mannenvrrontncnt).
' Conosron rales incrcaswrth incrcasing metal tempcraturc up to thc poini whcre watlr evaporstcaquickly.
. Cormsron becorncs m(tc sverEEl rnlEl tempcratures bctwecn thc boiling pornt 212 F at}d 250 F wlprc
*atcr rs lcss likely to vaporizcand insulatrcnstayr wct longer.
.,ttlcctrd l]Dltr or f,qdprtrcrt
. CS Eftl low all<rystelsore subjcctto pining and thinning.
. l(U. 400 & Duplex SS Erssub.ic&1
to prning aod locahzcdcorrosron.
. -l00SencsSSissubjcclioClSCCifchlorrdcsarcprcacnt(duplcxislcsssusccptiblc).
. A paint of coaling systcmin p@r c{xdrtion.
Ite Rwl Butte6
i-'&
5
8/6l20rO
Module 6 - Uniform or lôcatized Loss of Ttrichress
-o
('orrorior Undcr Inroletio! {(:tjl) 4JJ ( Pg ,}71)
Appcrnrc
of Morplok45r of lhnrgc
. llx) Scncs SS rs sub;octto Cl SCC rf chloridcsare prcantI duplcx is lcassur(rptlbl).
. In CS and lol,valloys, C[.ll damagcwtll appeatasloosc, llaky xalc.
Prwclilor / Mlthrtbr
. tlsclowchlondcinsulation
. tlsc apprupruL pont/csting
Ingtcsll
ard nurntarn thc insulrfior/scding/vapu
bofr|e'r to prEverrt mobtur!
Inrpcctlol ud Molllorirg
. Visual is dwup th best.
. t.fl fin thrcknesr.
. X-Ray.
TlERurButd
;'\
*;i
Module 6 - Uniform or lncalizr,d l"oss of Thickness

Clurllng Wrtcr Corrodol aJ.a (PB.+75)
D6.rlgtloa
Gencrd or locsfizcd cormsion of cnrbm stcclc ard othcr metals causcd by dissolvod saltr, gasscr, organic
compoundsor microbiologicalrctivity.
.{ltcctcd Mrlcrlrb
CS, all gradcaof SS, Coppcr,aluminum,titsniurn and niclcl bascdalloyr.
(lrltLrl Friorr
. CorroJion ratc! and fouling arc closcly rclatcd.
. Highercmling waacrtcmFrraturs increascorrogionand fouling tendcnLf.
. When thc proess sidc tmporalurc is abovc l4O F, a sr:aling potcntrol cxirls with fi.esh warrr. Ilris tcmp
drop8to I I 5 F lor tlrackish (salt watcr).
. Velocitics should bc high nough lo mrnrmizc deposits ftom dropping out, brn not so high as !o caulc
erosion. J t-psrs thc minimum ratc.
. 30OSS can sulfer pining crcvrce and SCt in dl *atcr rystemr.
. Copper/zinccan sull'rdszincificltim.
. trRW CS tubcsmay sulftr scvercwcld and./orHAZ corrosion.(grmving).
. Titanrumcan sulfcr scverchydriding Embrrnlcrrrcntin tempcraturc above I t0 F.
. Inrrcasing fu'gen c{xrlenl tcn{b to increascCS corro3iofl rdt6.
rh. R*;;..
6,i'-E
8/6/aOtO
,.q
t'
t
Module 6 - Uniforrn or l-ocalized lpss of Ttrickness

('rxrliog Wrtcr (,lorroriol
{J.a
{Pt }7S)
.\llccled Ltnltr or nqulprn.nl

All water-crxrledhcatexchangersand crnling towers.
Appanlcc of Morpbobgy of Drmrgc
. I)amagccan includegencralcorosron, pitting MlC, SCICand tbuling.
. l,ocalizs! corrosronmay resull li-om underdeposilcorrosror\
Prrryeltlor / Mltl:ralD.
. Propcrdesrgn,operatrondnd chemicaltrcatmentof cooling water syslems
. Desrgnlbr proccassidc Inlcl tempcratuesbclow I 35 F.
. Mrnrmumand max. watervelociticsmustbe maintltrcd.
. C'(ruhngwatr shouldbe on rherubc ardcto minimzc stagnantuear.
I nrpctim rad Monitoring
. Mr>nrior cooling walcr f'or pH, oxy8cf|, ryclcs of concgnfrdim, biocldc rcsrdul, biologir:al a,livity,
crxrlingwater outlct tcmperatwts snd contrminarronfrom pmucrs leals.
. ('alculatc "tf' valuesto chak lor exchangerpcrlbrmancc.
'Ihe Ruf,t Brrltat
Module
6 - Uniform
or Locatized Loss of Thiclrress
::______o
Mlcrobiologicrlly Induced (lorrorlon (MlC) 4JJ (h! f-t6)

( d 'a
D.!.rlptlor
Conosioncausedtry living organismssuchas bocterrr
Aftcclcd Mrtcrirb
CS, SS, Copper,aluminum,and somenrckelbascdalluys.
ar*rcrrr.rcro'
. MIC is found wficrc water n pr$cnt, capccrallywhcrc stagnantor low-flow condilionsallow growth.
. lherc are scveral ry^.trisof organisns that can grow under scveru condilionr incluling lack of oxy-gen,
light or darlq high salinity,ph of0 - I 2, and lempcrarursliom 0 F - 235 F
. Ditfefmt <xganisms thnvc on &lferent nutnens, including rnorganic substrne! (sulli|r, ammonia &
ll2s), ard organic subotans (hydrocarbon:t. All organismsra1uirc a sourccofcarbut, nitr<Ecnand
phosphorouslor growth.
'ftrc RrEt Br8te6
81612Or0
Module 6 - Uniform or l-ocalized l-oss of Thickness

llicrobiologicrlly lnduccd(iorrorion (Ml() 4J.t {Pt. d-t6)
All Mlcrobcr
Muct tlve
Thegc Ecccntirl
Ingredicntr
MIC requires water. This water con be a continuow separatelayer or jwt water droplets,
but the water r:annot be truly dissotved in a hydmerbon. lrw tlow or stagnant water
conditions ar beet for gmwing micnrbiologir:al in very large cnlonier.
'fhc Rut Bulsr
T\
Module 6 - Uniform or t ocalized Loss of Thiclsress
''' _---o
Microbiologlcrlly lduccd Corro,rior (MlC) {J,

1 'd 'a
lPS.,l.t5)
,d .
Attrf.d Uollr or tr4rlp|D.rt

. MIC is moct ollcn lbund in hcat cxchangers,Mtom woter of storsgc trnkr.
. MIC can also bc t'ound in trydro watcr that har not bcen rcmovcd.
Appcerrrcc ol Morpbolo6y of Drne3c
. MIC cormrion is usualty obeeneJ as locahzed prning undcr depositsor tubcrcle3.
' Damagcrs oflen charsdsrizx, by cupshapodpits witiin prtr in CS or subgurtirc cavities in SS.
Prwcotlor / Mlt|;rlftrr
. Mlc requrres*alcr to survrvo.
. Maintaintlow velocitiesaboveminimumlcvels
. Umptyhy&olest watcr.
. Arld brocrrJes
to waicr.
Itrspccli{rnrnd Moritoring
. Measurebrocrderesrdualin curling water system.
. Foul smelling watcr may be a srgnof MlCl.
Ttre Rut
ll6te6
't!
8/6/20LO
{'n
Module 6 - Unifonn or Localized Loss of Thickrress

Microblologicrlty
Induccd (lorrocion (MK)
lJa
(Pg. +{6)
(da
Biological Activrty Reaction Test (BART)
The Rut Butert
Module
6 - Uniform
or Localized Loss of Thichress
Dcrlloylng
('-'a
aJ.ll
What'r De-aIoyingS
.4ppeamncescan be dwiving - espaialty withdealloying!
Dealloyingis the sle(tive corrosion in which one or more elementeis prefen:ntially
removed from an alloy.
A visible change in shape or wall thickness of the alloy component is not always apparent,
although a significant mlor change may oocur. The affected ares h:r:omea weak, brittlg
and pomus. A failure by dealloyrng can be sudden and unexpeded with the nllcy lo<xing
its desig,nprcperties such as strength, hartlness and ductility. Dealloying is also knovm as
selettive leaching,sclertive dissolution, or parting.
.4pryrrrances en be deceiuing
fhe Rw Butcs
(- h
9
8/61?OLO
f:!l.''\
,.
Module 6 - Unifonn or Localized [,oss of Thickness

(inphitlc (iorrrxior4J.12
(Pg.+l0l)
.{Ilerrr{ trnilr or Eqrlpmcrt

. fhis eorrosion cln uicnf rn soll warcr. sall wrter, minc tlalers, dilute ocids atx.l in undergruutxl prptng
as wcll ag hlrlcr lbedwatcrcqurpmcnl.
.{ppcrnmr of Morpholt4y of Drmr;c
. I)amagcmEy bc gcncralor lorcatizedin areasin whrch thc majority of the componcntis unalfetcd.
. l)amtge msy not bc nottccablcupon vrsualinspeL:tnn,cven wtrcrc thc tull wall thickncssrs dcgradcd.
. Damagcd areaswll be soll and casrty gougetl with a knife ff hafl, tool
. majorrty of the compoercntts unalfectcd.
Mlt|3rtlor
Pttrcltlor/
. [i]ccognrzantof th sussrpli btI tty of cenain sllqys lo Srsphilccorroslon.
. lntcrnal gtaphilic corfostoncan bc prwanted by coatingsanrVorccficnl lintngS.
I nrFctlor rad Moritorlt4
. A sigrriticant raluctl(n in trardncss may accompony deolloying althurgh all'etrcd areas nny bc
localizcd.
ThcRurBut6
{k
Module
6 - Uniform
or Localized Loss of Thickrress
'-''_-o*---
Bollcr Wrtcr coodcnntc Corrorioe
fJJ
D.!.riptbr
rcturn plplng.
Gcncrrl ctrrosroo and pining in thc boiler slstem and conde-nssle
.{llcclcd Meacdrb
flrrmanly CS, sornclow alloy stcels,somc.l0OScricsSS and Coppcr basedalloys.
('ritlcd Fr.ton
.Ihrstypeofcorrocionuswuallythercsultofdislolvedg6sss-Ox]'Bpn&carbondioxtdc.
. Critirzl fa-tgrs are rhc conccntrslion of dissolved gar, pH, tcmperaure, quality of thc litslwaler and lhc
spccitic lbcrlwatcrtreo(in8,ryctcm
. Crrnosionprotectim in thc boilcr is acurmplishcdby laying down and conlinud8ly maintainlnga layer
ol' protec'tive( Fe!O,) (magnetile)
. Thc chernical treaErrcnl tbr scalc ard deposit conuol must be adjustcd lo c<rordinatcwith thc ox!-gcn
s:avenger lor the spocific *atcr scrvc.
.{fitctcd Ulitr or f,qllp|l|crt
. Aryvhere in thc Botlcr l'ecdwarcttrcnttncnt rystcm.
f'-'a
Th Run BwteF
{h
11
8l6l2OrO
hv
Module 6 - Uniform or t ocalized Ioss of Thichress

BoalcrWrter condclutc ('orroriol
{ppcrrrecc of Morplolo6r of Drrtrgr

. ('rrrsron liom oxl gen tends !o be a prttrng r)*pcdnmagc and can show up anlrlhcre in rhc systm
. Corrmicr rn thc crndetsa& rclum systerr terxb to bc dnc to (3rhn dioxrdc although sonE oxygcn
prlting problem! can oucur rf thc oxlgcn scatengrnt trc{lment is nc rvrkrng corrcrlly. Carboo rlioxidc
cofrosionlcnds to bc a srv.n$ grooving of lhc ptt w8ll.
PtwcotlDr / MltErtbr
. A arnrncInhibltor rnay bc raluirctl tor thc condnsatcsyslcm.
I lrpcctlol rld Molttorlnl
. Wateranall'srst pFL cofiluctivrty, chlorinc / rcsiduElbrocidc,and total dissolvedsolidt.
'fbc Rut Ewtd
,.*\
Module 6 - Uniform or Localized Loss ofThiclsress

CO, Corrorion {J.6 {PS.&t0)
CarbonicAcid Crrmion
llcrcrtptbr
Carttm rlioxidc (COr) corro*im result! whcn COI dissolvsIn watcr to tbrm carhrnic ocll (H2COI)
Cencral corrosion and prttrng in thc borlcr systcrn ard cordcn$e dum piping.
Allcctcd Mricrhb
CIS& low alloy stcels.
('ritlcrl Frctorr
. The porlial pressurcofCor, pH and temperaturEarecntical hcton.
. lncreasingpartial prcssurcsof CO, result in lower pH condensarc.
. (xcu$ in thc liquid phase,offeir at lcations whcre CO, condensesliom thc vapor phase.
. lncreasrngtemprstureslncreascorrosion rale up to thc
F)rnt where C0, is vaporizrd.
. lncrcasingCr in thc srecloflbrc no major crrrosron resistanr:cuntrl a minimum ol' I 27nis reached.
Allcctcd tlrltr or f,,quipmcrt
. &rrler fi:edwaterand condensalcsvstcmsin all uniB.
t d 'a
ItcRun
BudeF
,t'.-
12
8/6/2010
{:
Module
6 - Uniform
or Localized [,oss of Thiclsress
(iO, Corrorion {.J.6 {Pg.+t0)
.{ppcrrrlcc of Morphology of Demrgc

. trcal izcd th innIng an(ro. prtling corrosion of cartxrnsterl
. Carbonslal msy sullbr deepprningand grooving in areasoflrubulence
. Cormsron gcncrally occurs in an:or of turbulcrrccand rmprngcrnedand sometimcaat the root of
prprngwrldr.
Prtacrtlor / Mlt|'etbr
. [.lscof corrosion inhlbrtor.
. tlse of neutralizers(amin$ ) to increascpH abovc 6
. t-ls{:of 30OSS
. Stcam corxlcnsatc aystems thal experierrceCO, poblcmr arc urually thc result of opcratrng
problemr.
lup.clforr rld Molitorln!
. WateranalysrrlpH & i'e).
' W' UT a n d RT
The Rurt Butt?rt
(e
Module
6 - Uniform
or l-ocalized Loss of Thickrress
FlucGer tlcw PointCorrosion4J.7 (P9.4-84)
_r'-'' __-n'-_
Dtrrrlptlor
At low tcmpcraturcs, llue gas and thc wutcr vapor will {:ondcrue to lorm sulliuuus, sulfuric
and hydrahloric acid whrch can leadto scvercc{rrosion.
Aftccl.d Mrtcrirb
('S, low alloy stels,and 3fi) SeriesSS.
Crltlcrl Frcfon
. 'fhc errntaminanB (sult'ur$ & chlorides) in drc ftrel and thc openting temperature of the
lluc eas mctll surtbccs.
. Sincc t'uek contain sonr amuml of sulfur, acid dcwpoint corrosion can occur if thc mcol
tcmpcraturcaarc brlow thc dewpoint (whctc walcr is formel).
. Dcwpornt of sullirtc acid tkpurdr on tlrc concenralion of sulfur trioxidc in ttre fluc ga.r,
bul is t)pically arotmd2E0 F.
. The r.lewpoint of hydrorchloric acid depenls o{r the concentratron of tlCl. lt ir gpielty
around I 30 F.
'fhe Rut ButeB
{:"h
13
8l612OrO
\
F
Module 6 - Uniform or Localized loss of Thichness

Flnc(irr Dcw Poiot(-orrosiol 4J.7
(Pg.+t4t
.ttYcctc{ llritr or }]qllp|Dcrt

. All hcalersthar burn tirelr conlarnrngsulfur.
{ppcrnrcc of Morplology of Drmrgc
. Sult'uricacrdon CS or low nlloy stecl wlll havegeneralwrstlge ollcn wrth broad prts.
. For -lfi) Serics SSSC wrll havc surfae hrtzking crar,:lsafil ttre gencral appearanccwrll bc
srmcwhal crazcd.
Prwcntiol / Mlr|8rtbl
. Maintarnthc metojlic surfaccaahovethe tcnrpentureol'thc sulriric acrddcrrprrnt eorrosron.
. During Sr'D'r thcre is alwal's thc rlesrre to warcr wash thc deposrts. B sure th tinal nnsc
contatnrsodiurncarbonotcasabasicsolutrontoncutrali2z:theEcrdicashconstrluenls.
Dl.lll!!
I nrpcctlor ||d Monltorltrt
. V-t. UT and RT
. Stressconosion cncking of 3tX)ScricsSS can be lbrmd using Vt & PT
Module 6 - Uniform or tocalized foss nf Thichress

Soil Corrosiol
(
-'a
{.J.9
(PB.+el)
D.'crlptior
Dcteriorationof metalscxposcdto soils is reflrrcd to as sorl corrosion.
Aflccttd Mrlorieb
CS, cart irofl and ductile iron('dtlcrl Frctor!
. Svcnty irrlurler opemting temperaaurc,morsfirrr/ orygcn avarlabrlity,sorl rsistivity (soil corxlition
iuld charactcrislica),s{ril typc (watef drainage), ard homogoerty (variation rn sorl t}pc) cathqlic
protectKln,strsy cunent damage,coatingt)pc, ageand condition
. Sorl resistivity is uscd to catimatcsoil corosrvity, mainly eLaus il's easy to mixurc. .Sorlrcsislivrty
is rclatcd to sorl moistureconteil and dissotvedcle'ctrotytcsrn tlrc soil watcr.
. Sorl-to-arr intcrlb areu are ollan rnorc susccptrble to corroslon than the rest of the stn.K'turcbecausc
of moistureandoxygenavarlability.
. Conosion rat$ lncreasawith increaeingmetal tcmpcralure
I r.rpcctlor rld Mooitorin!
. Masut thc structurc to sorl potential wing dcdicated reltrencc elcstrodca near the strrlcllrrc.
. llscrnlinernspcctiondevices,guided(JTthicknesstools,indire.ctlybyprcssureEstingorvisually.
'Ille Rut ButeB
14
.l
olvl
r'
LvLv
:-\,
ilIodule 6-Uniform<rr
Soil ('orrmiot
lJ.t
1Pg.{-91) cont'd
\tlccfcd tirltr or Eqolpocrt

. t,ndcrgroundplprng.
tppcrrrrcc ol Morpbology of Drtl4c
. l-htt comrsron apFant 03 uxlemal thinnlng mth lcralized lcsscs duc to prning. Thc scventy of
comxiur rlependson the lor:alsorl condiilons.
PErycntior / Mlti|rtbr
. Sotl cornxton of CS can bc minrmrzcd lhrugh thc usc of spourd bocklill, cmtingr and athodic
protcclion. Il|c mott ctlcrlrve proloctlon il a ctrmbrnalr0nof a crxrmrcrn resrslantcoaling ard a
csthulrc pmtcL:lroilrs) slom.
I aspcctior rld Moritorlrt
. McasuJcthe slruclure!o s{rl potcntlal using dedrcoterlreibreneeelcclnxJerncar thc atructurr
. l..iscrnlinc rnspoctiondcvicca,gurdexlUT thicknesstools, rndrrerrtytry prs3urct6lrn& (r visually.
('\
Module
6 - Uniform
Crusilc ('orroalor
or Localized Loss of Ttriclsress

fJ.t0 (P& +95)
Q;-What ic Caurtic?
Cawtic refers to chcmicals that fall in the gmup of stmng alkalie, Ttte mo6t oommon
caustilx are sodium hy'droxide (NaOH) - often called caustic soda - and potassiurn
hydmxide (KOH), sometimescalled coustic pr>tash.Carbon steel,Iow alloy steel, and
3o4 and 316 stainlss steel are subjrrt to uniform thinning or cre\rie corrosion when
in crrntact with concentrated otrstic solutions at elerated temperaturer. Caustic can
also cause stress crrrxion cracking when strss is present (xe Carutic Cracking
mulule). Caustics are used for various purposs in the refining and petrochemical
m*frf,
( d'a
ItE Rut
BurteF
{"\
t5
816/2OrO
Module
6 - Uniform or Localized Loss of Ttriclaress

Soil (brrosion
{J.9
( Pg. +91) cora'd
II
I
{tlcclcd tlDlir or f,qolplrc|l

. tlndcrgroundplpln3.
lpgcrnrcc o[ Morpholo6r ol lhmrgc
. l-hrt comtsron apF:anl iti cxlernal thinnlng wrth lcxxllizrd l<xscs duc to prninS- 'fhc acverity of
contlsi<rtdcpend3on thc locsl sorl conditronr.
Prtvcitior / Mlttrtbr
. Sorl cornxron of CS can bc minrmrzal thnxgh thc ur of spu:ral backtill, u.ootingrard tathqilc
protcclion. IIlc mo3t ctFerllve potcction is a crmbinElron of a corroci<mresiiam coating ard a
cathodlc pr0te|'1rorrt s) slcm.
I rrpcctlor lld Mmiiorlq
. Mcasurcthe slruclurcto s{ril potnlralwing derlicltql relbrcnecelednxrB ncar thc structur.
. l.Jscrnlinc rnspcctiondcvic'cs,gurdcdUT thickncastoolc, rndrrerrlyby prcssurctcsttng tx vrsually.
Ttrfu[{8ut6
(.^
Module
6 - Uniform
or Localized Loss of Thiclsress
(lrustlc ('orro.lor
4J.t0 (P&+95)
Q;-What ic Cauctic?
Caustic refers to chemicals that fall in the gmup of stmng alkalis. Tbe moat common
c'austi are sodium hydroride (NaOH) - often called caustic srda - and potassium
hydroxide (KOH), sometimescalled caugticpotash. Carbonsteel,low alloy steel, and
3o4 and 316 stainlss steel are subje,ctto uniform thinning or crevie cormsion when
in contact with ooncrntrated caustic solutions at elevated temprafurc. Caustic can
also caLrsstresg cnrmcion cracking when stress is prescnt (*e Caustic Cracking
malule). Caustisc are userl firr various purposlt in the refining and petmchemica.l
industry, e.g. neutralizing acids <.rrboiler feed lrater . !odr'.!iYr",f
,l
'$
" 1
t-'FffiHil
lffiq
ritl
,t
-l-,I t
.
t
..: ,"{
a tt
It.-s rl
W.,}l.?,41
( d'a
nP Rut
EuneN
('\
15
816/207A
:F
Module 6 - Uniform or tocalized Loss of Thickness

('rurtic (lorrorlol
{J.10 (Pg.+95)
D..criprior
I-ocalrzed conoslon dtr to rlrncertralion of caustrc or alkaline saltt that usually <xrcur under
craporatrve<r high heat translc condttions. llowevcr, gcncral corrmion can also oocut tlcpcnding
rr
,..,--,,.r,^.,,1,,r:^*
onlrhe
atkalr
orcausrrc
soturion
srrengrh.
"r"--dh
-lL^ti
,,h
- r l "i l !- !{
"4 $ t'
\frftr.d vrtcriab
Prrmartly
CS,lowrlloystecls,
andl0o Serres
SS.
"l$.ttd
I PIIIIE
bOOfUU
( rilh.t !-rcro'!
FYnotuDil
i
I
Contrihring tbdorr are tlrc prcsanceot'csuslic (NaOH rx KOH). Tha lbllowing ane s{ruracs
cauSltc;
. Caustic can be uhlal to pmccss stnamg l'or neutralizztbn
. CBn bc sdded to borler fi:alwalcr (x may cnter during rctcncratron of Dernincralizerr.
.{llcctcd tlnl6 or Equipmcrt
. Mtrst ofren associatedwith boilers and steamg3rtasting equipmnt
. Simrlarconccntratingetfectofcausticmayasurwhcrccausticisarljql!ocrudcunitchnrgc
. UniB thst rclnove caustic 1(r removrng sulfur compounds liom pnxlul sfearru.
TheRrEtBut6
'
.B
':;!
Module 6 - Uniform or Localized Loss of Thiclnrese

('rurtk (lorroriol
or'ii'*:3
Dcrcriptlor
L(Xalizd corrosion duc to concenlration of caustic or alkaline salB that usually oocur under
svapor&tlvc or high heat trdmfr conditions. llowver, general corr<xron r;sn also oocur dpqxling
on thc alkali or caustlcsolutiofl suengrh.
Sodium hydroxrdc(NaOH) dissolvcsrungetile

.l Na()H + t-c2(N > 2NaFe02 + Na2FeO2+ 2H20
['hen.reactsdiratly wrth the rron Fe + 2 NaOl{ > Na2FcO2+ }12
Causcalarge pitting (gougrng).
\Ra\
r'^Y
Vv
.s
E
\a_t-
The RBt 8urt6
,,}
t
16
vt
vt
Lv
-v
rt%
t
Module
6 - Uniform
(-aurtic (lorrosioo
or Localized l-oss of Thickness
(PE. {-951 cotrt'd

^ {.J.10
.{ppcerrnca ol Morpholofir of l}rmrjc

. hprcally charact!'rrzqJbv lq:llized rxtal loss whrch mly appcsr as grrxrvcsln a txriler tubc or
Irra,lly thrnncdarcasundet rnsulatrngdcprxits.
. l.mali:ed goging may resull along a wrtsline whcr corrosivesconcarlrale.
. F,xp<xureto hrtfr solulron strcngthcon rcsult in gcnerslcorrosronof'carbon steelabove I 75 F und
very high corrosionratcsatxrvc200 l-.
Prr:v.Gtlo. / M ltlgrttrr
. In stcom Bcnerstrngequrpmen( caustic corrocron ir bes prcvantetl thru,rgh propr desrgn.
[)am68c san tr ru.dur:el by mrnrmrzrng t]c amurnl ol- lirc eauslrc (cncurinS arlcqulc
waterllooding arxl watcr llow), cnsunng,propcr bumer managprnn'lto minrmr?r hot spo|s and by
minimiang thc ingrcssof alkalirc producrngsal$ into u.ondcnscrs.
. ln prurss equiprnnt,csusticInjqition .lhouldbc &signcd to rllow proper mixing and dilutron oi
cautic ln ordcr to avoid tlre concentrationof cBusticon hot metal surfacq.
|rspccrbr md Morltorht
. StearnBnrationwill rcquirc visual wrth bonrsi:opc.
. Processetlurpmenl- UT thickncss.
'fh. Rusr!urt6
(ta
Module
6 - Unifonn
('rurtlc (;orrorio!
or Localized Loss of Thichress

n
4J.10 (Pc.+95t cotrt'd
(J---Formatting and supporting information

API RecommendedPractice571 First

Edition, December2003
The Rust Brst6
h
r''
1.'
L7
Module 6
GeneralDamageMechanisms
OpenBook
1.
Steamtraps that corrodeare usuallythe resultof what?
2.
ERW Tubeswill developgroovingin what service?
3.
To preventCO2 corrosion,what pH must be maintained?
4.
In causticservice,what materialsmust be used for corrosionresistanceabove 150 F (66 C)?
5.
What is carbonicacid?
6.
Can carbonsteeland 300 SeriesSS be usedin highstrengthcausticsolutionsthat are above 150 F (66 C)??
7.
Oxygenscavengingtreatmentsincludingsodiumsulfideor hydrazineare used to preventthis type of corrosion.
8.
Corrosionfatigueand erosion/erosioncorrosionare relatedto this corrosionmechanism.
9.
This corrosionmay be along the bottomof the pipe if there is a separatewater phase and the top surfaceif
condensationin wet gas system is anticipated.
10. What corrosionmechanismoccursat "dew point"?
Page5
Module6 - Uniformor Localized

Lossof Thickness
RevisedAut. 2009
Caution - This quiz may contain more than one ,,Challenge,,question.
1' Whatprocesssidetemperature
is considered
the maximum
to preventfreshwatersidescaling?
a.
140 F
b.
160F
c.
1 8 0F
d.
200 F
2. According
to the Nobletable,is Zincmoreor lessanodicthancarbonsteel.
a.
More
b.
Less
Aboutthesame.
d.
Dependson the cathode.
Can MIC live in acidic conditionswith no waler ??.

a.
yes
b.
No
c.
Dependson thetemperature.
Dependson the levelof nutrients
available.
d.
4. In fluegas,whatis the dewpointof sulfuricacid?
5.
a.
130F
b.
140F
c.
220 F
d.
280F
Corrosionrates of the anode will be

a.
not
b.
more
c.
less
d.
barely
-affected
if there is a large anode to cathode ratio
6. A tankbottomhasa coatingon it, butthecoatingis scratched

in one place.Willthe corrosion
rateat this
locationbe
a.
thanthesurrounding
material?
Faster
b.
Slower
c.
Aboutthesamebecauseof the largecathode/anode

ration
d.
Undetermined
because
of thelargecathode/anode
ration,
PageL
up to about-F.
withtemperature
rateincreases
thecorrosion
7. In 'Atmospheric
Corrosion",
(4.3)
underinsulation
occur
except
to
the surfacesare usuallytoodryfor corrosion
temperature,
a.
2O0
b.
225
c.
230
d.
250
8. CUIcorrosion
Abovethis
to the pointwherewaterevaporates.
metaltemperature
withincreasing
a.
Increases
b.
c.
Decreases
Becomespassive
d.
Becomespreferential
out?
solidsfromdropping
watervelocity
neededto minimize
cooling
9. Whatis theMINIMUM
a.
9 fps
b.
6 fps
c.
3 fps
d.
Noneoftheabove.
(4-80)
forCO2corrosion??
resistance
10. Doesincreasing
Cr contentoffermajorcorrosion
o/o
is attained.
A minimumof 12 hasto be reachedbeforeanycorrosionresistance
a.
b.
Depends
on thepH.
c.
temperature.
Couldbe,butdepends
on theoperating
d.
is attained
A minimumof 15 % hasto be reachedbeforeanycorrosionresistance
is a measure
of soil11. "SoilResistivity"
a.
Densityandoxygencontent
b.
Densityandcompaction
c.
Moistureandelectrolytes
d.
Densityandelectrolytes
and
problems",
is usually
theresultof "operating
12. Thiscorrosion
mechanism
a.
Dealloying
b.
Corrosion
Galvanic
c.
MIC
d.
CO2Corrosion.
PageZ

'13. This corrosionmechanismis occurs in the liquidphase,and the severityis dependenton partialpressure,pH
and temperature. The corrosionis typicallytreatedwith a neutralizingamine solutionto correctthe problemplant
wid e .
a.
Flue Gas Due Pointcorrosion.
b.
GalvanicCorrosion
c.
MIC
d.
CO2 Corrosion.
14. The most effectiveprotectionfor soil corrosionof carbonsteel is a combinationof :

a.
Specialbackfilland soil resistantcoating
b.
Specialbackfilland cathodicprotection
c.
Flameappliedcoatingand oxygencontentmonitoring.
d.
Cathodicprotectionand a soil resistantcoating.
15. Revised
- For galvaniccorrosionto occur,certaincriticalfactorsmust be met. (pg 4-65) They are:
a.
A noble materialconnectedto a cathodein the presenceof a electrolyte.
b.
An electrolyteand a cathode
c,
Two differentmaterials& water.
d.
An electricalconnection,two differentmaterials& an electrolyte.
16. Revised
- A visual observationcan confirmthis type of corrosionin a cross section of cast iron pipe. This thru-wall
corrosionwill show a charcoalcolor that will be soft. This corrosionmechanismis: (pg 4-101)
a.
GalvanicCorrosion.
b.
M i c ro b i o l o g i c a l l y l n d u c edC orrosi on(Ml C ).
c.
Graphiticcorrosion.
d.
CO2 corrosion.
17. Revised
- Generalor localizedcorrosionof carbonsteelsand other metals caused by dissolvedsalts, gasses,
organiccompoundsor microbiologicalactivitiesis called
a.
AtmosphericCorrosion.
b.
M i c ro b i o l o g i c a l l y l n d u c edC orrosi on(Ml C ).
c.
Coolingwater Corrosion.
d.
None ofthe above.
18. Revised
- What structureis 410 stainlesssteel ?
a.
Martensitic.
b.
Austenitic
c.
Duplex.
d.
Ferritic
Page3

19. Revised
- What structureis 409 stainlesssteel?
a-
Martensitic.
b.
Austenitic
c.
Duplex.
d.
Ferritic.
20. Revised
- What API RP deals with the Protectionof AusteniticStainlessSteelsand other AusteniticAlloys from
PolythionicAcid Stress CorrosionCrackingduring Shutdownof RefineryEquipment?
a.
RP 169.
b,
RP 170
c.
RP 0198.
d.
RP0294
21. Revised
- Which of the followingstatementis not true about CO2 corrosion?
a.
Criticalfactors are CO2 partialpressure,ph and temperature.
b.
A relatedcorrosionmechanismis carbonatecracking.
Corrosionis selectiveto the HAZ of welds.
d.
Corrosionoccurs in the liquidphase.
22. Revised
withwhichof thefollowingunits?
- Causticcorrosionis mostoftenassociated
a.
b.
c.
d.
Crudeunitsand FCCUunits.
Causticgenerators
andregenerators.
Crudeunitsandwastewatertreatingunits.
Boilersandsteamgenerating
equipment.
Page4
8/6l20rO
Module 7 - General Damage Mechanisms - Refinery Industry
r. .{,mieCorroeion
z. Amrnonium Bisulfide Cormsion (Alkaline Sour Water)
3. Ammonium Chloride Corrosion
q. HydnxhLrric Asid (HCl) Corrosion
5. Iligh Temp H2/HaS Corrrxion
o. Hydrofluoric (HF) Corrosion
z. Naphthenic Asid Corrosion
8. Phenol (Carbonic Acid) Corroeion
9. PhosphoricAcid Cornxion
ro. Sour Water Corroeion (Aiidic)
rr. SulfuricAcidComxion
rr. Titanium llydriding
r.r
5.1.
5.r.1.2
5.1.r.3
5.1.1.4
5.1.1.5
5.r.1.6
5.r.r.7
5.1.1.8
5.r.r.9
5.r.r.1()
5.r.r.rt
5.r.3.2
Thc Rnlt 8urt6
Module

AmicCorrodon
The Rut ButeF
ile
5,l.l.l
(P8,5-l)
- Refinery Industry
8/slZOLO
Q'
r. .\mie Corrosion
z. Ammonium Bisulfide Corm.sion (Alkaline Sour Water)
3. Ammonium Chloride Corrosion
q. Hydnxlloric A{:id (HCl) Corrosion
5. I'lighTemp HrlHaS Comxion
o. Hydrofluoric(HF) Corrosion
z. NaphthenicAcid Cormeion
L Phenol (Carbonic Acid) Corroaion
o. PhosphoricAcid Corrusion
ro. Sour Water Corrosion (Asidic)
rr. Sulfuric Acid Cornr.sion
rz. Titaniurn Hydriding
5.1.r,1
5.r.r.2
5.r.r.3
5.r.1.4
5.r.r.5
S ,r.r.6
5.1' r.7
5.r.r.8
5.r.1.9
5.r.r.ro
5.r.1.U
5.r.3.2
The Rurt Eurtm
Module

Am lc Co r r o d on
The Rut Butm
, r\
t.
t.t.t.l
(P 9,5-l )
- Reffnery Induag
a
Modulc
7 - General Damage Mechanisms - Refinery lndustry

.tr o ic ( lo r r o ri or
(P 3.5-l )
5.l .l .l
What is Amine Comrrion?

. Tttere are th.o types of amine, "rich" and 'lean," and as a rcsult rwu [pes of amrne
crrrrnsion. Rich amine is aminc that has ubs{rrM the acid gasessuch as H"S and COo
and lean amine refers to amine that has been stripp.d rf the acid gaser, Amincs are used
in refineriee and chemiol plants to remo/e H*S, CO" and mercaptans from procesg
streamr origination in many unitr. The* include gtreams from the crudc unit, cuker,
catalytic cracking, hydrog,enplantr, hydroproce*ing, and Bulfirr rrover tail ga8 units.
Purc amines arr not rnffosirr. It is the acid gns (H*S and,/or COJ in th rich amine that
makec it corrrxive. Generally rich amine crrrrurion rnrug when the amine abeorbe too
much acid gares, ir heated at trrc high a trmperature, and,/or ftrowr at tm high a velor:ity..
Arn'inadonotcoda.
It't tho annhu c.orrtcmlnan|rthat
cattodo
Thc Rur Butd
Module
7 - General Damage Mechanlsma

Amlc Corrodon
- Refincry
Industry
(Pg.!l)
5.l.l.l
What is Amine Qrrnxion?

. So what maltec the lean amine corrgivc? It is the impurities that makes the lean aminc
corrosive. 'these impurities are often product-sof amine d4ra&tion. Cenerally, lean
amine comxion occurs onlywhen it become hot (>zoo F), such as t}le lower section of
the amine regcneratorl, rrboilers, the hotter leon/rich exchangers and associated piping.
. There are other types of cornreion which may be found in amine units, e.g., rvet CO"
corrosion, ammonium bisulfide corrosion , wet H2S crncking and amine str6E corrosion
cracking. These are discussed elsewherc and will not be discussed here.
.r
ln ls,;r r lr - J
t-.
lrr1r11j
lL----J
{\J
The Rurt Bustes
; i?rr..
'a
t9
v
9l
r3
Module 7 - General Damagc Mechaniems - Refrnery Industry
,tm ic ( lo r r o r ion
Chemirtry
5.l .l .t
(P t. S l )
Background
o The mrxt crrmmonacid gasesfound in the refinery and pctrochemical planls are H,S
(Hydrogen $illide) and C1?"(Carbon Dioide). These are called acid gasesbecausethey
become oodr'c when dissolved in water. Acid gasesare both cormsilc and an
environmcntal hazad, therefore must be rcmoved hom product streams. Aqueorls
solutions of rmines are usd to remorc these undesired gasec.Amins in our amine unite
are actually formally called "alkanolaminee." They are weak org,arucbasesthat can reart
rvith the acid qr.ss..A fo,r,examplesof theseamines arc ME{ , DEA, MDil, DGA and,
I)lPi. Sulfinol is a mixtur of amine, sulfolane,and water and is sometimesused in
hydnxgen plants to rcmove CO".
o
In amine units, an amine molecule (o basp,like ammonia) and an acid gas molecule (on
dcid) ar attracted to each other forming an amine sah. That is how the amine "-treats'
the acid gasesup to a rxrtain loodr'ng or acid gas concentration. Howrltr, heating the
amine salt t:n breaft it back to the acid gas molecule and tlte amine.
(-3
Module

Amlc Corrorioo
5.l.l.l
(Pg. !l)
- Refrnery Industry
corl'd
(lrltlcrl Frcton
. Amirc typc in order of aggrcssivenes!l'rom moctto leastis: MEA, DGA" DIPA, DEA. and MDEA.
. Anirc concctrtrrtLc - thc corrosivenaurc of thc concentrationis depcndcntoo thc typc ofaminc.
. ('mhohrll
hd - l-can aminc solutionsatc gcnerallynoi corroeivc. Howevcr, it's the accumulation
of Heat StablcAmirrc Salts( HSAS) abovcabout 206tharcan significantly incrcasccorrosionratet.
. !'clocity limitl - General inrlurtry standar& orc to limrt velocity to 3 { llr fir nch arnrnc, and 20 $s for
lcan amine.
. Tcttrpcrrt E - femperature! above 220 F can resull rn acid sas tlashing and severc localrzcd corrosion
rfthc prcssurcdrop is high cnoug!.
,Ulcct d Uri$ or F4rlpncrt
.l-hc
honestareasof thc Amin unils arc alTected:
. ThcAminc rcgeneratorreboilet
.
.
Thc rich arninc sideof thc lean/richexchancers.
Thc Rur Buts
{}
.
.
.
.
.
MEA
t)(GA
DIPA
DEA
MDEA
vI
avLv
8/6l20rO
f%
Module
7 - General Darnage Mechanisme - Refinery Indusfy

,lmic (lorrorioe
{ppc.rnrct
S.l.l.l
1Fg.9'l) coot'd
of Morpbolo6r ol Drmrgc
Thnntng wrll bc unrl'ormwhcrc tlle proctss strrarn vcltxity is low, whilc it will bc lrrali:icd tor hrgh
velocllrsassocirtrd with rurbulcncc.
Prtwcrtbr / Mltlrtloe
. Control rcid glr (COr lt HrS) looriingr.
o Moona/qntrol HSAS.
. Uorilor velocltlcr - urully thc raull of 'prrxer crccp'.
. -fcmpcrrturcr - rrolhcr vlctltl of 'proccr crecp".
. lffi SericsSS crn bc ussl in arcls whcrc llaahrngtr*un.
o Soli& should bc removedfrom th systcm. tYI, tiltration is more elfectivc tm th rich aminc srde,but
who wsnts lo open up a rich amrnc liltclZr
lllpccdaud
. UT.
Morhortr3
o C'orrocioo coupons / pmbcs can he used.
Thc Rurt Brsto
'"3
Modulc
7 - Gcncrd
Arnmonlurn
Demage Mechanismc
Btculftdc (Alkallne Sour Water)
- Refincry
S.r.r..
tndustry
(PC. S-+)
Dc!.riptfor
. 'Itis |r a matcrial fhat condcnscs in Hyr]oproccssing rlctor calluc-nawa&r sfi:.m.
. Ilerc y lh. nst of tln story - In tlvdroprocttsfi4 unitt, (.'ot n and I\:CU ,, tlc leed nitrogzn it
comcfiedtoqmnoniaondnattw,thH2StofornNH/iS.
ItWc,pitdnsouoltlugasplaneintlv
rcactq eflIuent t reom at tempcrdues belov 150 E
Affccfcd Mrtcrirb
. PrimarityCS.
.
J00 Scncs SS, duplcx SS arc more resistan(dependint on rhc Ammonium Bisulti& (NH.HS)
concentrslion and velocity.
What ic Ammonium Btsulfi& (NII.IISI) rnrrocion and what are NH.Iltl saltr?
NH.HS r:orrrxionoccursfrom a conoentnrtd solutionof an ammoniumsalt"formedwhen
ammonia(NH) andhydmgensulfide(HrSarabsorbedin liquid rvater.
'[he Rut Bucten
i ..','..}
8/61ZOLO
i3
Mo<
odule 7 - General Damage Mechanisms - Refinery lnduslry
Arnmonium
Biculf,de (Allallnc
lour Watsr)
S.r.r.r
(PE S-4)
dux Ammonium Bisulfide Corrosion Appear?

Howdr
'et NH.HS urmxion tends to be very kxalized and unpredictable. Areasof turbulence
o WEt
artE morE pron to attack.
Thc Ruli
Bstc6
(n
Module
7 - General Damage Mechanigmc - Refinery Indu$ry
Arnmonlum
Blsultldc (Allallne
Slour Yltatcr) S.r.r.r
o;
(PB. S-4) cont'd
(lritlcrl Frcton - Corrosiondepcndsrn

. NH.HS c,onccntration
o Vclocig
. pH
. tcmpcfanttc
. allo/ comFxition
. flow distribution
. Corrosionincrcascs
with increasing
NH.llS concentrstion
andincreasingvelocity. llelow 2 wtolo,
solulionsarc gcncrallynot corosivc. Abovc27r,solutionsarc increasinglycorrosivc.
. Orlgcn andiron in thc washwatcrcanleadto increased
corrocionandfouling
. 'lhc prcsnctofcyanidesincrcascs
sevcrityofcorrosion.
Ihe R$1 BurteF
i'h
8l612OrO
\
Module Z - Gencral Damagc Mechanisms - Refinery Inductry
Arnmonlum Blsuftdc (Alt line llour Water) 5.r.r.e (ry S-4)cont'd
Aflcctrd llrl! or Eqrlprllt
. ftinnrily Hy&oproccssing unrs t lt drotrEarcB & tfdrocrilkrs
. Inlel and outlc,tpipingol Rcactorair c<xrlsr!
l:
Sour water draw prping.
F(ICU UnrB - not as likcly as I'lydrupruxs$ing uni6 due to conccnlration.
NllrllS txnrcentratioo is usually L"rs than 2 wflr, buf high vclourtrrs anVor thc prcscncc of cyanidcs can
rcnrovc protcctivs iron sulli& scd6.
Sotu Wbtcr Strippcn - Overhcad & piping

funmc UniB - Ovcrtrad piping & cordcnrcn.
Dclaycrl Cokcr - Fracliooator Overhcad conrlcnsing ry-stern.
r
.
.'Fir',,
Module 7 - General Damagc Mechanlsms - Rcfinery Industry

ArnmonlumBl,cultldo(Allellnc tlour Water) S.r.r.2 (P& 5-4)
.{ppcrnrclof
Mcrpholo6r of Deur3c
r l{igi velocity - Crencrd losr with lhc potcntial lb ortremcly high lfializcd rstca
o llw vclocity - Extrmcly localizql undcr<lcposit corrogion if insullicicnt watcr is availablc lo dislolvc
tltc NH1HS sallr.
Prwt|tln/
Mlt||tb.
. Ilahmx inlct and outLt flowr t,oair cmlcrs (symmctric piping).
. Mooilor/ conrrol NH|HS ooilrenrrauon. Dcsirable limit ir bclow 2016,
but CS can lolcratc up tio toz6(wro
redu,;edvelocatica). Conccntratioo c8n bGcontollod by adjusting thc nitrogcn contmt of thc fccd, and/or
arlJingwarh watcr.
o Maintain vclocitia wilhio l0 - 20 fps for CS.
o
Propcrdcsi$ofwarhwatcrinjcclionleoiliticaiscritical. Providesufficientcxccaswalcrtoensurethat
an adcquatcarnountof waicr rcmlios I liquid to dilutc thc NHrHS salts.
Ilspctbr
ud Modtorirg
. LJTscanningand/orRT profilc.
o UT dormstrerm of control valvcr due to incrcasod vclocitv.
TheRurt &'[t rt
rh
l.l
8l6l20to
r't"L
t'.+;
Module
7 - General Damage Mechanisms - Refinery Indusu:tt
I low crtn anmonium chloride sultla1p?

. One way sah can form is by molecules of ammonia (NH.) gae and hydrogen chloride
(HCl) gas reaeting in the vapor phase.
It drxxn't take much NH. and HCl. HCI is a contarninant prsent in lery small
qruntities, usrr"lty parb per million (ppm). NH, originatcs with the small amount of
nitmgen pFesentin oil. With thonqandsand thou.sandsof other molecrrlrx presnt,lik
hydrocarbons, hydmgen and thc like, onc may think there is littb chance of NH. seeing
HCl. But that L3not tnre; and NH.CI salt can readily form and can be a big problem.
'fhc Rul 8urte6
Modulc
7 - General Damage Mechanismc
-o--
- Refrnery Industry
Ammonium Chlrridc Corrosioe 5. l. l.l (Pr. 5-8)
Where can Arnmoniu.m
Clrloride
C;orr.oclon Occur?
,A.mmoniumchloride corrosion can occur in numemus placea. Ammonia and chloride

must be present, and for corrosion to occrrr ther must be enough water to wet the salts.
Distillint column upper scctions and oerheads. Fe.ds have ammonia and there are
chlorides from desalter carrysver. There are signifirnnt amountg of water vapor.
Deadle8sthat collect water and salts, Deadte$ have by their naturc a temperature
gradient; thc ends arc cool and non-rrlrrosive, the cunnettions to process are hot and can
be cormsive if they contain wa salts.
HydmpmcessinS raLtor eflluent naturalty has ammonia, trsually in the percent range,
and chlori&s are often presnt as a contaminant in the fed. Also a potential pmblem is
deadlegsthat can spill over into hot lines or equipment.
The Rrtrt Butten
'r"h
8l6l2OrO
Module
7 - General Damage Mechanisms - Refinery Industry
o-- -
r\mmoniumChloridcConosio* 5.l.l.3 tPc,.5-8)
Dct*ipli,o.
o (icncrnlorlocafi2Edcomxron,Oicnprttingnormally<rccumngundcrammonrumchlrridelNH,C|lor
rmrnc asll deposrts.
.\llcctrd Mrlcrlrb
. All commonly usrrl malcrrals. l.istqi in onlcr of incrcasingrcsrslantl rs;
o ('S, low Elloy steels.30OSS,Alloy 1O0,rluplcx tOO,and 825, Allcys 625 lt lihnium
(lritlcd
frclorr
('onccntration- fempcrature- Wateravailability.
o Ammontum chloridc saltsprecipitatcliom high temp.streamsas thsy arc cooled, This &pends on thc
conr:entratioqbut gcncra.llyaroond100 P
r AmmoniumChltrtd.(NHTCIisHYGR.OSCOPIC(itwillabsorbwalercvsnwherethereisn'tany).
lhis
mal6 tl vcry comxtvc, bocausil c8n form a very lu:alizetl arca wherc saltrr/corrosrcncan ole plarx.
o Ammoniurn (Jllori& is vcry watcr solublc, so it r:anbc washcd out easlty.
.
'Ih.
Rut
ButeE
Module
- Refinery
IndusFy
l'-"::::1'::1T'U
:jj :'- :
Ilcrcrlptlor
o (icneml or l<raiiz:rl cormsion,oltcn prnrng normallyu*urring underammonirmrchloridc (NH,CI ) or
amrncaalt dcpositt.
,\flcctcd Mrtcrirb
o All commonly'uscdmalcfials. l-istcd in ordcr of incrvasingrmistanr- is:
o CS, low allry steclsilU) SS,Alloy {x), duplex t00, and 825,Alloys 625 & titanium
(lrillcrl
Frclon
o C(nccntralion - Tempcraturc- Watcravarlability.
o Ammonium chlonde saltr prccipnltc liorn high lemp. streamsas thcy-arc coolcd. This dependson the
concnlralion,but generallyaroundl0O F
o AmrnontumChlotridc(NHrCl is HYGROSCOPIC(it will abcorbrrater werr whcre therc isn't arry;. this
mak6 il very corrogrve, bocaugell c8n lbrm s very localizql area wher salb/qrrNron can take placc.
o Ammonrum Chlorrdc is very water soluble,so it can bc washctlout easily.
The Rut
Rwte6
, ''h
v
8/612Atv
/'a
Module
- Refinerlr Industry
Allcctcd Unit or E4oipllcrt

. HydroprrccJsir! - Reac0orefilunt stramsgoing to lh air coolr!.
o (letelJrtlc Rcformilt - reactorefiIuent streamsgoing to the air coolen. The recycle H, is also
susceptlble.
r ['CCU / DCU Fractionators and top pump arounds.
o (lrrdc To;er - Overhead condcnsers,but also thc fiaotionators top trays as uicll ( if the proces
conditiom {emp. isn't controlled).
Appcrrrrccof Morpholo'gr of Drmrgc
. Saltsare wtitish. grecnishor hownish. Hou,verwatsr waihing during S/D will removethem. Their
presencecan be dctected brypressuredrop.
r Corrosiooundemeaththc salts i3 tlprcally localizcdand rcsults in dccp ptning.
Th Rurt 8ust6
Module
7 - General Damage Mechanieme
- Refrnery IndusFy
AmmoniumChlorideConosio* 5.l. 1.3 (Pg.5-8)cont'd

Prwcntbri
Mlti|rtbr
llydroprocessing
o l.imit chloride in thc Mfu Hr. I{ydroganproduccdby Catalyic Retbrmingwill havc Chloridesin it
(chlorides 8r addd to sctivat the catalyst).
r LIsca*aterwashinthereactorellluenrtotlushoulandncutralizpthcNH.CIsalfs.
Catarytic Refomrt
. Use water wash in the reartor eilluent to tlush out NHrCI salts.
FCC'IJ/ DCU
o Monitor and calculale water dew point temperatures. Maintsin operEtingternperaturesabove the ralt
dep()sition tempernnrlE(dependson th concentration, but gencrally is around 300 F)Crudc t-lnirs
. lmprove desahing- Operationalitem.
o Add caustic to tlte dcsalted srude - (caustic rear:tswith thc chlorides lo prevent the l'ormuion of NH,CI).
Caustic addition is no wrthou its poblems.
. Add water wash to cootad and dilute thc NH]CI sslts.
. Add ner.rtralizaand lilming amind (comsion inhibitors)to deterthe corrosiveelTects.
o Add a filming amine (cormsion inhibitor) and/ornuualizer
tncpc.tior rld Moiltoring

. V-fl_BTt5p+tedar_eas:
_
Thc Rult Butd
l':.r?h
9
8/6l70rO
Module
- Refinery
Industry
o--
HydrochloritAcld (HCl) (lqgpslon

5.l.l.l (Pg.Sl0)
.oftl)stotr f,.l,t,a
D.rcriptfDr
lr.rcrlpttor
\./t'
General <x faalizal corroeim. Damage ir a$ociared lvrth da poiat corrosion in wfiich vapon containing
*rtcr and hydmgen chloride condenrc from the overhcad srcam of a d.istrllatrontourcr. T}c FIRST watcr
dropletsthat condcnsccan be highly acrrlic.
,{ltcctcd Mrlcrhb
r l0O SS arc not rcsistant to llcl al afiy concentrotion of lempcrarurc.
o Alloy 4{n and titsnium arc rcsistanl
.
CarbonStrxl has no resislanr:cbelow a pH of 4.5
Critkrl Frton
. tlCl is noi corrorivc whcn il's dry, bu whcn it gcls w{, it's a terror.
. Concntration-'fctnprarure - Alloy composition.
Alftctcd Urin or Eqripncrt
. Crudc Towcr - Overhcad condcnscrs. Il's a problcrn in thc rfrcuum condcnscrstm.
r Hydropruccssing - Rear"roretllucni strcams going lo thc Eir coolcru. Chloridcr may enter the unit wlth
thc l'ocd or wrth thc hydrogen.
. Cntalytic Reforming- ChloridcsareADDED to thc cEtalystto activatc. As time goson, it k strippd
qE TtE sxcesrmoglrris
sgrrttu futtrrrstrEnr Hyeuprurssrfig unilJ
Thc Rut
Bulrd
Module
7 - Gencral Damage Mechanisms

tlydrochloricAcid (HCI) CorroriX{.1.{
- RefrneqT lndustry
(PB.It0) cont'd
of Morpbololy of Denrgc
Appcrnlcr
o CS and low alloy steclr sulTergeneral uniform thinnrng localizsJ corroaion or undcrdeposit ataclr.
o 300 SericsSS and 40o ScriesSs will sufl'erpiuing attack. IOOSri6 SS can also expcrienceCl SSC
(depcnding on the trempcrature).
Pnrcltlor/
Mit[rtbr
Crudc Unitg
. Improvc desalting- Opcrarionalitcm.
r Add caustic to thc dcsaltd cruda - (caustic reacts r,vilJtrhc chloridcs to prsvcnt thc formdion of NHtCI).
Caustic additioo is not without its problem!.
.
.
.
Add water washto conbct and dilut th NH.CI salts.

Add nutnlizcr and filming amines(conosion inhibitors)lo derrthe corrosiveelfe'cls.
Add a filming amine(corrosioninhibitor; and/or neutraliur.
l{ydroprocessing
r l-imh chloridcs in thc MAJ Hl!.
.
[Jsc water wa3h in thc rear.to.efllunt to tlwh/neulralizc-
The Rust B6td
try,
l.l
10
8/6/20Lo
./
Module 7 - General Damage Mechanismc - Refinery Indusfy
o'-"__
llydrochloricAcid (HCI) (lornrlor 5.1.l.f { Pg.910) cort'd

Prcryeltlor / Mlt|trtbr
(:stslytrc Reformcr
.
! waler wash In thc reaotoretllucnt to tlush/ncutralizc.

'sc
Add a tilmrng aminc anrVorncutralizcr.
I
I lrpetbr
rld Motrltorlrl
. tjT/RTsuspcctcdarEas.
o Scrious corrorion can occur oround mix points whcrc dry chloridc contlining streamSmix wlfh ctselnrs
cr.nuinrng t'rec watct.
o Corrodroneu {rccur wtrcrc a ctr)l slream lirrcca dar parirt of thc l{Cl.
.
Monitor pH of water bmtc.
Thc Rut Dultd
Module
7 - General Damage Mechanisms - Refinery

Nrpbthcnlc
AcidCorrorion(NAC) 5.1.1.7(Pg,919)
What are Naphthenic Acidr?
Industy
o Some crudec ar naturally acidic. Naturally orrurring acids in crurles are not strong
acids like hydrocbloric acid and sulfuric aci4 but are the somewhat weaker organic acids.
Vinegar and lemon juice are typical organic a<yidr. VineSar and lemon juice are soluble in
water, but naphthenic ocidc are soluble in oil.
.
Naphtherric acide - "nap acide' for short - have enough hydrocarbon solubility to
dissolve in oil, and enough acidity to be corrooive toward steel. Naphthenic acids are not
a single organic ar.id; instead thry are a group of various acid.sthat ran have distinctly
different corrooMty.
nr.n*f**
11
8/6l20ro
t - *".r"
"d"t.
Damage Mechanisms - Refrnery Industry
NrphthcnicAcid Corrosion(NAC) 5.1.1.7(Pg.Sl9)
Prncndon
/ Mitigattoo
Naphthenic acid comxion is addrtrscd first by materials seh:ction. Metallurll'is often

shoccnto be resistant to a crude with high nap acids. General prine"iplesare:
Carbon steeI has the lowest rarsistanceto nap acirls of typicat metallurgr uscd in refining.
Cbrumium does not offer much prote(tion frum nap ocid L'ormsion. This is in crrntrast to
suifidic currosion, where chnrmium is one of the main ingredients for the pnrtection
against sulfirr.
,{loys urntaining a minimum af z.g% motybdenum (Mo) show improved resistonr:r:to
nap acid corrosion, such as 3r7 SSwith 3-4X Mo. (the more Mo the better!). ,\llo)'s with
6% Mo are requirEd for very high nap acid s)ntents. Higb nickel alloyr sucb as Alloy 625
or Alloy Cz76 are mnsidered immune.
.
Oncc materials ar in place, things to guard against arc increa.sesin tempratur or

throughput which may increascnaphthenic acid attack (remember that one of the
primery rcarcnr for nap *id rttack is higfu vckxityL
'fhe Rust Butfl
Module
Dcrcrlptlor
7 - General Damage Mechanisms - Rcfrnery Industry

Nrphthcnic
AcidCorrosion(NAC) 5.1.1.7(Pg.$19)
A high tcmperoturccorrorion tiat ocrun prrmanly in crurle/vacuumunitr, and downstrcamunitr thEl

proce33cenain thctlonvcuts lhat contarn this acid
Afcct.d Mrrcrl|b
. CS, Iow alloy src13,
l0O SS, ,100SS, and nickel bosedalkrys.
(lritlci
.
Frlon
NAC Conccntration-'fempcratuc- Vclocity - Sulfur contentlt, alloy.
NeutralizationnumbcrofTotalAcidNumbcr(tAN)isameasurcofacidity(oryrnicacidconlcnt|.7
'lhc IAN mny bc mrsleadrngbecausethis lhmity of acidshasa rangcof borling pornr aruJtendsto
concenlratin variouscuts. Thereforc,NAC is delcrminql by the acidity of the actual strearnnot thc
crudecharyc.
o 'l'hc variour acidsthat comprisethc naphthcnicacid limily can havedistinctly difTerantcomxivity.
Sultir promot$ roo sultidc lomation and has an inhrbitingellirl on NAC.
NAC normally occun in hot steamsabove{25 F. Severityire-rer$swith temp4up to obout 750 F.
Naphthcnic aoids are destroycd by the catatyst in fty-rlrcprocessingand FC'CU uni6.
Th Rud Bst6
?.t
t2
8/6/?OLO
Module
7 - General Damage Mechanisms - Refrnery tndustry

NephthcnicAcid Corrosion (NAC)
5.1.t.7 (Pg. 3-19) cont'd
('ritictl Frton
I NBphlhe{K lcldr are desroycd try thc catahst in t}droprmessing arxl FC('U unrts,
. Nsphthnt srrtls arc dertnrycdbrythc catabst in l-\'tlmpnnuosrngand FCC"tlunits.
. Allovs contsrnlnSrncruasrngamounBof molytxlenumshow improvcdresrstance.A mrnimum ol'2 96to
2 5 % is requrral tlcpcnrlng on thc TAN.
. Corrosronrs mof,1sevcrcln t\ D phalc (vaFx &. liquid) tlo1n,in areasol high vebcrty or lurbulerxr
,\ ffcclcd I Ioitr or Eqllpm.rt
. (lrudc and \hcuum hcqtc rutr6/transt'er lin8.
. Piprngs!slems arr susccptiblcin areasof hrglr vclocity.
.
.
AppcarBnofMmphokrgrot'Dmagc
NAC is charactcrizrdtry localizedcomrsron.pitting corrosron,or llow induccdgooving in hrgh velocity
afctll.
In low vckxrty conlenrrng urnditionr" corrotmo showsup a unrlirrm losr in thicknas afiyoa prlling.
ftc Rut
Bul6
Module
7 - Gencral Damage Mechanisms - Refrnery Industry

Nrphthcnic
AcidCorrosion(NAC) 5.1.1.7(Pg.$19) cont'd
{pparrecr
of Morplolo6r of Drmrgc
. NAC is charactcriud by localizcdcorrooion,pitting conosion, or tlow inductd grooving in high velocity
Itcls.
. In low velocity oondcnsrntconditions,corrosionshowsup a uniform loss in thicknessand/orpitting.
Prrvcrtbr / Mlti6rtbr
o I lsc allo]s that ar morc r6r3tmi... doo't lbrga thc Moty.
. Blend crudcsto atlain a lower 'IAN.
o t.lsc NAC chemrcalrnhrbilors.
I nspcctloe eld Mooltorhl
. UT / RT suspectedarcls.
.
Monitor t'ecxlstrcams tb,rTAN and sulfur contcnt.
fte Rult Busten
13
8/6l2O1O

Phenol (Carbontc Acld) Corroelon 5.r.r.E (PB. S-23)
I
i
D.rrtptlor
. Phcnolis uscrjar a solvent(o rcmovc aromaticcomprunds liom lubrrcatingoil tLdstockl.
.\ffcct d Mrtrrirb
o l.rstedin order of rncrcasrngresistanceis: CS, l(Xl-. l l 6L and allrry C276.
('riticrl Frcton
.
Tcmpcraturc- Watcrconlent,alloy and velocrty-
Conosioo in mrnimal whcn tcrnpsarc below 25OF
Conosron can rrcur rn the recovery sectroo *tcrc spent phcnol rs separaral by vaporization.
o Sullir and organic acids mry lcad to naphthcnrcacrd stlrck and Suflidatron rn thc lr.otextrlct circuit
. CS and lO4/3041.SS conuJc rapidly in phcnol scrvrccutxrve450 F
. Dllutsolulions(5 - | 59lo)
arevery corrosivel
.
High velG-tlresrnay promotc c(xToston.
\
l
Module 7 - General Damage Mechanisms - Refrnery tndustry

Phenol (CartonicAcid)
Cormlon
5.r.r.E (P& S-21) cont'd
AM
Unlte or Equlpment
. Phenol facilities in a lube plant.
. Appearance of Morphology of Damage
. Corrosion will be in the form of general or localized corrosion of carbon steel
. Lrxalized loeein thickness due to m8ion-crmxion may occur,
r Enxion-corrrxion and/or mndensarion corrosion rnay be observed in tower overheads
circuits.
Pwention
/ Midgrdon
. Use alloys that are more resistant.
. Overheadpiping should be deilg,nedfor a maximum velocity of 3o fpe.
. Recoverytower overheadtempratursshould be maintained to at least 30 F above the
derr point.
. Tube and headersin the furnacesshould be 3t6L
Incpcction and Monitorlng
. Ln / RT sr.rspectedareas.
'.dl
14
in"'
8/6/zArO
Module

PborpbortcActd Corrorior
S.l.l,9 (pg. $24)
Dccriptbr
-l'hi3i3 uscda!
'
| catalystin polymenzationunils. [t can ciusc both pining corrosionanrl locali23d

corroslonolCS dcpendingon thc waler content.
Aa?c"f.d Mrt?rhb
. l.isterl in ordcr of incrcasingresistanceis: CS, 1041.,I | 6I_and allov 20.
('ritlcrl Frclon
r Acrd Concentration- Tempernturc- Contaminants
' sohd phosphoncacrdcatal)stsare not corrosiveto cS. . . unlessfiec water iB presol.
o Corrxioo nter incrcascwrlh increasingtemperaturc.
. Corrosioncan pcnetratca%" tub in eight houfs.
o M()stcorrosioo proboblyoccun during water-washingopcrationsat shuldowns.
. ContrilntnanB, srrchas chloridcs, r:n increasephoophoric acid corrosioo.
Thc Rust Eurterr
(,
Module
7 - General Damage Mechanlsms

Phosphorlc Acid Corrorior
- Refinery Industiy
S.l.l.9 (pg. 9,24) cont'd
Alloctcd Ulitr or Eqripncrt

. Piping and equipmcntin thc polymcnzationunn whcrc watcr mixcs with cltalyn.
r
r
corrorion is usually found in low velocity areaswhcrc there is little or no circulation.

Appcaranccof Morpholog of Damage
o l-ocalzcd or gcncnl thinning of CS.

Prwcrtbr/
Mftf,rtbr
. LIsealloys that are morc resisnnt.
. -104Lss is good tbr | 0o7oconcenrrationup to about I 20F I l fL ss is gmd liom 120 F
to 225 F
o I l6L 5 arxl Alloy 20 are goorl at concntratioNup to 85% al boiling tanperature.
Inspoctlon rnd MoDltorh:
. UT/ RTsuspcctodarca!.
o Sample iron (Fe; in water li.om tirst overfiead receiver.
'Ilte Rwt BucteF
15
8/6/za1o
Module
7 - General Damage Mechanisms - Rcfinery Industry

(Acldic)5.1.1.10
(Pg.S'25)
SourWrtcrCorroslon
I
i
Dcrcrlptlol
. (irnnsion ol'srccl tluc to acrrJics{rurwltcr contsining llr.l at a pH bctwEcn4.5 md7.0. Carbondioxitlc
((,'(.)2) may ulso bc present.
.{ftc(tcd Mrlcrirb
. PnmanJyalfecr CS. SS.coppcr allrys and nickel bascdallorysare usually resrstant
('rillcrl
.
.
.
Frctorr
I lrS ('oncentratron-pH-Tempcrature- Vlocity - ()xygen content.
I'hc HrS concenlralronin ttrc sour walcr rs dependento{r thc ll:S portla.lpressurcrn thc gs phar as wrll
at tempcraturcandpH.
At a grvcn pr6surc, the HlS conccntratDnln thc sur' walcr dccreas!ili temperalurcincreascs.
lncrea.singconcntratonsot'HrStcndtodcctcascthcpHdowntoabout4.5.
StreamswrlhapHbclow
I 5 indrcslo th prcacncr ofa stronger a{id thrl could bc thc real conosion coocern.
o Above a pH of 4.5, thc prot4clive iron sulfidc laycr limrts thc corrosionratc.
. 'fhe prcrenccof arr or oxidmts may increascthc corrosionand usually produccspining or underdeporit
attlch.
fte Run Buren
a.
ra
Module
7 - General Dannage Mechanisms - Rcfinery Indusby

(Acidic)5.1.1.10
(Pg.$'25)cont'd
SourWetcrCorrocion
Ol'
Affcctrd Llnltr or F4ulFt|.rl
o Acir.lsour wttcr comxion is r conr;ernin ovrhadsl5tcms of FC'CUand Cr*cr Egsfractionationplants
with high levelsof HrS and low NHr lcvcls.
..tppcrrrrec of Morplo&ryy ol Dmrlc
. D8rn8g,cis tlprca.lly general thinning. llowcver, localized corrosron or localized undcnlepoail anack can
rxruur,cspocially if orygcn is prescnl.
Prwcatlor / Mlt[rrbr
. l0O SS can be usedat temperaturesbelow about 140 F whcrc Cl SCC is not likety. (bppcr alloys and nrckel alloys are gcnerallynot susceptibleto acrdsour walcr qrrrosicn. Howcvcr
thescalloys arc vulncrablcto the ammonn.
. InsFrqutlonand Monitoring
.
.
lrT/ Rf suspededareag.
Monitor water draws t'oroH.
Ih nurt Bwters
"**tt
16
8/61zorc
Module 7 - Gcneral Damage Mechanisms - Refinery Industry

Sulfuric Acid Corrocion
S.l. r. r-r (Pf. S-zZ)
Q,
SulfirtcAcld
A wry rts{ftrl but dlrngcrotn cltcmlco,U
. Sulfuric acid is a very useful chemical. It is the most common chemir:l pnxluced in
North America. Most manufacturing planE use strlfr.rricacid in somc part of thc
manufacturing prooesa. In refining and petrochemical plants, sulfuric acid is usd to
cuntrol pH, as a catalyst in Alkylation planB and various chemical plant unib, and to
"pickle" stel prior to ertain coatingr
CortoclonBarlcr
. Sulfr.rricacid reects with the iron in carbon steel to form ferrous sulfate (FaSO), \\it
crrrrosion product normally stap on the surface of thc maal forming a mildly prutective
film. If the film remains intact, the sulfuric acid ia prwented from reaching and reactint
with "barE' metal, so the rnrrosion rate is relatively tow. If the protective film is
rrmovd "ban:' mctal will be expsed and will react/corrode with the sulfuric acid.
'ItE Run Surtm
r^
Module
Z - General Damage McchanismE - Refinery

SulfurtcAcidCorrocion i.Lr.n (P* S-zZl cont'd
lnduslry
o'tr__
IF
E
l zo
a
I r75
-!
I
r- r2ll
f5
60 it
to
rt
F t3 S $
?r Sdfrrrlc Acld
tO16i l o
ftrc nu* Sut;
t7
8/6l20to
Module

Sulfuric Acid Corrosion S.r.r.rr (PS.S-aZ)
Ilcrcriptloo
e Sullinc ar:rdprumotesBcncraland locahzerlcorrosionof CS and other alloys. CS heatall-ectedzones
mty r'xpcnn(l SvetfcolT0sl(xl.
,\ffcetcd Mrtc.irb
. ln ordcr ol'incrcssinSrcsrstancc,CS, 3l6l- Allry 20, high srlicuc cast rrm, high nickcl cast iron, All<ry
t)-2, and alloy C276.
(lriti.rl
.
Frctolr
and prcs4'nc
of oxidizers.
Acid Comcntration - Iemperaturc- Alloy- Veklcir)--Contsminalion
o CS corrosionnrtesrncrcasesrgnrticanttyiithe ilow vclo,cityexcecdsabout2 - 3 fps or at acrd

conccntratronsbclow 65%
. Mix porntr with catcr causc heat to bc relcaserianrl high corrwion nlcs can rrcur \,rtcrc thc acrd
bcl:omcs dilutql.
.'l'lre prusncof oxidizerscan gre:tly incrca.rcthc corrosionratc.
'fh? Rust Bultert
Module
7 - General Damage Mechanisme - Refinery

SulfuricAcid Corroslon S,l.r.u (PS.S-zZ)cont'd
Industry
Q'
Attcct.d frnan or lholpncrt
o Sull'uncacid unrtsand wastcwstcr lrcatncnt planB are attbctcd
Appearancc of Morphologr of Damagc
Mostly general in nature, but attack! ca6on stccl wcld heal atlocted runcs raprrlly.
tlydrogcn grxrving may mcur in low flow or $lgnant areassuch as in a storagc tanl.
I[ thc corrcsion rdlc Bnd velosity are hig[ tltcrc will bc no ccalc.
Corrosronof ltecl by dilutc acid ir usually rn llrc tbrm ofovcrall metatloosor pitling and bccomcr morc
scverewith rncreasingtemperatureand velocity.
Prwcuti'or i Mlt[rtlor
. ( lsc alloys that arc more resistant
o Acrdrfied prxluct streamscan bc wuhed wilh causticto neutralizcthe at,id.
I nsDcctlonrld Monltorlng
o tJT / RT suspcrutcdareas.
'fh Rurt Bust6
"\{
J
18
8/512070

Sulfuric Acid Corroclon SLr.r.u (pg. S-zZ)cont'd
c'
V
Efiect of Velocity on Sulfurtc Acid Carbon Steel Conoclon
tatec
ttrai6&fi.dcAotdnhn*d
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Module 7 - General Damage Mechanisms - Refrnery Industry

Sulfirric Acid Conoeion
S.t. r. lt (p*
S-zZl cont'd
Ily&ogclrnGraoalrng:
when carbon steel corrodee in sulfuric acid servitr, hydrcgen gar is formed.
The
hydrygen gar riseg and the ngrr.of
hydmgen can disrupt the ferrou.r sutfate film,
lhe
causing increased corroeion in the form of groove. A normal location for hvdmcen
grocrvingis the inside surfa<x on the top of a horimntal pipe.
Itle Rust Euterr
,'"?}-'t
19
8l6l2OLo
Module 7 - General Damagc Mechanisms - Refrncry Industry

fitanlum
l).'rriDilor
Hydriding5.l.3.z
(P& 5-6r) c'onfd
o-
1[ dmgen dilfi$cs into thc titanium and rcact! to lbrm nn ernhrrttlinghyrlridc phasc. 'l--hecan rcsult in a losr
no noticcablcsrglrof conoston or loosrn thrckr s.
ot'ductrlrry--wrth
Atlcct d Mr(crlrb
. Titentumall(ry3.
('rltkrl F.ctort
'lbmperaturc abovc I65 F wrth I pH below .Jor abovc t {wrth . hith HzScontefil}.
.
A(lcc..d Llrltr or l4ulpmcnt
. .clourWaterStrippcn & amrneunit OH condensers.
,lppcrnrcc or Morplolo6r of Drmr6c
. 'l-his is a mctallurgical changc that is not readrly oplrarcnt and csn only bc ccnfirmul through
mclsllurgicaltqchniqur.
'fhc Rut But[
'\,
v
Module
7 - General Damage Mechanisms - Reftncry Industry

TttantumHydridinf S.r.3.z(Pg.5-6r)ont'd
Q,
Formattingand supportinginformationfor this
Modulewereattainedfrom
Practice571FirstEdition,
API Recommended
December2003
Th Rwt BsieB
4:1
20
Module 7
GeneralDamageMechantsms
OpenBook
1 . H2S concentration,pH, temperature,velocity and oxygen concentrationare all critical
factorsof what corrosionmechanism?
2 . What materialsof constructionare increasinglyresistantto sulfuric corrosion?

).
What is meantby "dew point"?
4. Witl NaphthenicAcid coryosionbe foundin the gasolinesectionOfa prudBunit?

5 . What are the chemicaldifferencesbetweenAlkaline Sour Water and Acidic Sour water?
6 . What is another name for "neutralization number"?
There are two corrosionmechanismsthat are reducedby the addition of sulfur. One is in
this module, and anotheris in a prior module. What are they?
8. Whatis the formulausedto calculateRE.

9. Whatis anothernamefor CarbolicAcid?
10.Why do mix pointsin sulfuricacidsuffercorrosion?
Page4
Module7 GeneralDamage
Mechanisms
- Refining
Industry
Revised
August,
2009
1'
lncreasingCr contentin the alloy increasescorrosionresistanceto high temperatureH2IH2S. What level of

Cr contentdoes this increasebecomeeffective?
2.
a.
3%
b.
5%
c.
7%
d.
15 %.
W he n ru n n i n g h i g h T AN c ru d e , w hat l evel of sul fur i s desi red?

a.
None
b.
c.
d.
Lesssulfuris alwaysbetter
More sulfur is better
Dependson the TANcorrosivity.
3. Velocityis a criticalparameterin aminecorrosion.What is the MAXIMUMleanaminevelocity?

a.
10 fps
b.
20 fps
c.
30 fps
d.
Allthe above,leanamineisn'tcorrosive.
4. Revised
- Alloyscontainingincreasing
amountsof molybdenumshow improvedresistance
to
this corrosionmechanism.A minimumof 2 - 2.5%molybdenumis typicalrequiredfor
resistance
to thistype of corrosion.
a.
TitaniumHydriding
b.
Naphthenic
Acid.
c.
AmmoniumBisulfideCorrosion(AlkalineSourWater).
d.
Noneofthe above.
5. Velocityin richamineis a criticalparameterin amineconcentration.What is the MAXIMUM
RICHaminevelocity?
a.
6 fps
b.
10 fps
c.
20 fps
d.
30 fps.
6. What is the levelof HSSthat renderleanaminecorrosive?
a.
t%
b.
2%
c.
3%
d.
s%.
7 . Wha tisDNB ?
a.
Department
of Non-Binding
Refractory
b.
DoesNotBelong
c.
DyneNuclear
Bonding
d.
Departure
Nucleate
Boiling
Page1

8. Revised
-lf carbonsteelisn'tworkingin the richamineservice,
whatisthe nextstepup in
metallurgy?
a.
Lowalloy
b.
400SeriesSS
c.
304SS
d.
Nickelbasedalloys
9. CanNH4HS
causeplugging??
1.
Depends
on the temperature
2.
Yes.
3.
No.
4.
Gosh,willthesequestions
everend?
L0. Whichof the followingaminelistsareincreasingly
corrosive..?
a.
MEA,DEAandMDEA
b.
MDEA,DEA,andMEA
c.
MEA.MDEA,
andDEA
d.
DEA,MDEA,
andMEA
e.
Noneof the aboveis correct.
10. Whatisthemaximum
desired
NH4HS
velocitv
forCarbon
Steel?
a.
6 fps
b.
10fps
c.
20fps
d.
30fps.
11. Revised
- Whendoesthe highestcorrosion
rateoccurin a sulfuricacidalkylation
unit?
7.
Duringcatalystactivation.
2.
Duringoperationat highrates.
3.
Duringoperationat low rates.
4.
Duringlowtemperature
operating
conditions.
L2. At whattemperatures
arenaphthenic
acidscorrosive?
a.
4OO-425F.
b.
425- 500F.
c.
450- 600F.
d.
lt depends
on thevelocity.
11. Whatisthe maximumvelocityfor sulfuricacidin carbonsteel???

a.
3 fps
b.
6 fps
c.
20 fps
d.
30 fps.
Copyright
O 2008TheRustBusters
PageZ

12. lf CSisn'tproviding
the desiredcorrosion
resistance
in a servicewith strongsulfuricacid,whatis
the nextlevelof suggested
alloy?
a.
b.
c.
d.
e.
3161.
Alloy20
Titanium
c276.
lt depends.
13. what is the criticaltemperaturewhere richaminebecomescorrosive?

a.
Above200
b.
Above 220
c.
Above240 F
d.
ell of the above.
1.4.Titanium
shouldnot be usedin knownhydriding
services
suchas_
a.
Caustic,
amine
b.
Amine,sourwater
c.
Sourwater,Alkylation
d.
Allof the above.
or
.?
1.7.TitaniumHydridingis a damagemechanism
that is uniqueto a few materials,includingalloysof
?
titaniumand
a.
Gallium
b.
Gadolinium
c.
Sourwater,Alkylation
d.
Zirconium.
18. Aminechloride
saltsarehygroscopic
andreadily
absorb
water.A _
amountof watercan
leadto veryaggressive
ammoniumchloridecorrosion.
a.
Large
b.
deoxygenated
c.
S mall
d.
Proper
19.A type3041SSis satisfactory

for phosphoric
acidconcentratio
n of L}O%up to about
Type321isrequired
fromthereto 225F (107C).
a.
120F (4eC)
b.
140F (60C)
c.
1s0F (6sc)
d.
17sF (7eC)
Page3
6b*rfl{}ll'o'o
/",\
Module I Refrning U
Module I Refrninr Units
'}F?eB
-0
@
Hffi
zt|E
il'
{14
I J!<,-
r'--.etJ
/fr
The RNt
1":
Bwtd
816laOLO
Module 8 Refrning Units
Qr
Yields
Yield%
Coke
8.o
Butane& lighter
3S.o
Gasoline
55.o
Kerosene
l2.o
Diesel
8.o
Fuel Oil
r2.o
FCCU- CatalyticCracker
-leil
Module I Refining Units
The Rut Bulta
"'%l
'l
8/6/2070
Module 8 Refining Units
Thc Rut Brstcrr
Module 8 Refining Units
Tbqlurynrnh
ryil@.d
qtu.tur*I
ffitqbecryi
The Rust Busted
r'",.&
{.;
DCU - (thermalcrackins)
8/6l2OrO
Mndule 8 Refrning Units
'ftre Rut Bu*m
It
Module I Refining Unitg
\
4C
AlkylationUnit
fF,
r-t
5.'
4
8/6/zorc
Module 8 Refining Unitc

SKd
rl,Paed cPrrilng
mrrr
9u
PuttF
6sbI
. 35to 30 .C
5 to 2txt &n d rbrcar.ar q6s.
rC
R.Offta
: t't5 io tir6
-rd r t.a to f .Z fm A rtiAUr
t tor
b(do.n
prcur
Amine Treating
The Ruct Bud6
I
I
Module E Refining Units
R.qcL
O-
;*-6ql
l-*-.
.=i?
i
\
I a-*-..'.
-;iir\l
sarf
" -r, TI
fo ilphtt
Sr-+r
IttdryNbr+
Thc Rust Eurten
8/6l7OtO
.}
Module 8 Refrning Units
SulfurRecovery
Module I Refrning Units
-=s*
*"
8/6/20rO
ra
Module 9 - Test Preparation
f-\
{\
8/6laOLO
lntrnductiol
o What to bring lbr the API test - Bring severalpencils,and yor brain. lhis is an entirely
cl<xcd book test and there arc no calculations that require a calculatrr.
. .l-hcrewill bc 70 questirrr on thc tcst.
r What to exp'ct- By othcts estimatca,abor$ 75%of thc questiorB rcquirc {31p9!y
reasonint. Ihcrefore,onlyabout25YoofthequestiursarestraightoutoftheAPI57|
documcrtt.
. Passingthe test requiresa basicknowledgcot
o
Mctdhrgr
o
Tbomcchanicrofcorrcimmcchnnig5l
o
Corruiomcchmimrspccifictovariouudtr.
fte nrut Sutrt
o
Whenyou finally getyourtest:
I. Dsdcganis! Wuill
ftnnutffipoufr,Wnnfeilol!
gb
'%,
I
8/6/z0to
o'
When you finally get your test:
l. Don'tPanic!
2. Remember
to fill in you answerkey last. Do
thisafteryou havecompleted
all questions
in
yourtest. This is a big time saver.
I
l
Module 9 - Test Freparation
Whenyou finally get your test:

t. Don'tPanic!
2. Remember
to fill in you answerkey last.
3 . Readthequestion....really
readit. Don't
assumethatyou know whatthequestionis
asking! Look for wordingthatmakes
distinctions
suchas"metallurgical"
failure
versusa " corrosion" failure.
816lzArc
Whenyou finally getyour test:

l.
2.
3.
4.
Don'tPanic!
Remember
readit.
Readthequestion....really
If you don't knowtheanswerto the
question,moveon andcomebackto it later.
o
Whenyou finally get your test:
l.
2.
3.
4.
Don'tPanic!
Remember
readit.
Readthequestion....really
lf you don'tknowthe answerto the
question,moveon andcomebackto it later.
the question,
5. If you simplydon't understand
just try to think like the engineerthatwrote
it!
The R6t
ButeF
,flrio
|,.1;
,i n'
8/6/ZOLO
Module g - Test Freparation
SampleQuestion
A cokerheaterwith 9 Cr rubeshasbeenin servicefor 20 years.
you aregoingto call for whet inspection
As theInspector,
during
thenextpit stop'?
.Carburization
.Creep
c. I
lon
.Oxidation
.Any others??
Q'r
SampleQuestion
What material of construction ir not commonlv used in
hydrofl uoric acid alkylation units?
.Carbonsteel
.Stainlesssteel
oI
I'
ari
3/
8l6l2OrO
SampleQuestion
Sulfuricacid alkylationunitsarebuilt primarily of what material?
ool
.PWHT Carbonsteel
.Ni-Cr-MoAlloys
.Type316SS
al
fhe nun funcr
Ar
_\_1,/
SampleQuestion
Valvesandpumpsin sulfruicacidalkylationunitsexposedto
concentrated
and spentacid aretypically madeof ?
.Carbon steel
.Allov 20
.Ni-Cr-Mo
ai \
..
al
Tb RBt Butsr
8/6/zoto
Module 9 - Test preparation
SampleQuestion
In catalytic reformers, small amountsof nitrogen in the feed react
with chloride releasedfrom the catalyst to form ammonium
chloride. The presenceof ammoniumchloride can cause:
A . Corrosion
B . Fouling
C . Fouling, but not corrosion
C.
and -,8"
@o*irA"
SampleQuestion
Increacingchromium content in the alloy improves resietanceto
sulfidation.
Howwer, there is little improvement with increasingchromium
content until about
Cr
A .3 -5
B . 5 -7
c. 7 -9
D .9 -t2
Ttn Rust BusteF
f'
816l2O7O
o*
SampleQuestion
In piping and equipment, creep cracking can (rccur where high metal temperatures
and
occur together. Creep cracking, once initiated, can progres{t
rapidly.
A.
B.
C.
D)
Pressures
Stressrisers
Velocities
Noneof the above
Of course the answer is "None of the above",becausethe real ansr,veris ctreca

conccntrtdon.
Thc Rul Butcr!
O;SampleQuestion
A carbon steel bundle from thc ovcrhead condenserin the crude unit operales at 30f F and
is in hydrochloric acid service. It showed severe pitling type corrosion when pulled for
inspection. Whal typ of marcrial would be bcst suited fot this servicc?
A.
B.
C.
rf)
Lu
5 Cr-0.5Mo
3I6 SS
9 Cr-lMo
titantrn
Ttle Rust 8Bt6
816120rc
r-\
SampleQuestion
A 3oo seriesstainlesssteel heater tubes in an oil-burning furnace in the
hydrocrackerjust came up from a T/S. Upon S/U, it beganto leak and the furnace
was brought down. What war the probable causeof the cracking?
A.
Chloride stresscracking
Polythionic acid stresscracking
Amine stresscorrosion cracking
D. Stressorientated hydrogcn induced cracking.
,-V
(uC.
Thc Rut Burtcr|
SampleQuestion
Whichof thc followingaresusceptible
to thermalfatigue?
A. sA-51G70
B. SA-182Cr B
C. SA-53Gr B
gPNt
theabove.
Thc Ruct BuGil
8l6l20rO
SampleQuestion
For tumaceg to prevent PASCC, keep the firebox heatedabove the dcwpoint to keep _
from tbrming.
h'tr\P{
SampleQuestion
.Ammonium chloride corrosion

._HighTemp H"S corrosion .
+-_:
.Ammonium sulfide.
TheRutButefl
-%
I'Y
10
8l6l20rc
SampleQuestion
q
rr$o:tsJl}'!.b
=
\
**\
ae^c<tenr..Vc\$\*
'
AFrr,.'cJr".ii'r,*l
Ct-0onCerfl
,n'*t.-.t, u+ $e $t\.-,:.ta5t
'Alky reactor
. Crudeunit desalter
oL_
SampleQuestion
Ametallurgical treatmentwhich has worked well to prevent{
./
or@plantsis:
ld heat treatment(P
fzt'r\hltEt
. Useof HIC resistant

steel.
(-\
11
8l6lzOtO
o,
SampleQuestion
What is the best NDE method to use to detect Creep in the
advancedstage?
'Cali
. WFMPT
.D P
.ACFM
Thc Rrst 8ute6
SampleQuestion
Whatmaterialwould the liner be madeout of in an sulfuricacid
reactor?
rf
SeriesSS
.100 SeriesSS
. 2.25Cr
The Rwt Butes
-s
L2
81612OrO
n'
\-ll
SampleQuestiorlr*'
For CUI. corrosionbecomesmore severeat what metal
temperatures?
@.l 8- 0 F to 2 6 0 F
.l 9 0 F to 2 5 0 F
. 1 7 5F to 2 7 5 F
'Ih Rud Bultcn
O'F
Lets Review
Dealloying - What color will bronze turn?
. Green
ffi
.Black
ThRurt But6
{"q
13
8/61zarc
Lets Review
LME
Surccpdblc
Alloy
3oo SeriesSS
CopperAlloys
Alloy 4oo
Aluminum Allow
High Slrength Steels
The R$t
Mnlten Metal
,/-'t efl
rl\p C
(Wp(
nLd| -aznl
Bute6
LetsReview
LEM
SuccepdbleAlloy
Molten Metd
3oo SeriesSSi
Zinc
Mercury
CopperAlloys
Alloy 4oo
Mercury
AluminumAllow
Mercury
High Strength Steels
Cadmium. tead
'fhc Rut Buts
f,f
L4
8l6l2OLO
Lets Review
Cl SCC - What material is least susceptible?
SS
'300 Series
t
\lickel basedalloys
n
Lets Review
FormsofAlkaline StressCorrosionCracking are:
. CausticStresscorrosionCracking
. Amine cracking
'CarbonateSCC
. PTA
Th Rurt BuJtc6
(",^
15
8l6l20ro
LetsReview
VibrationFatigue.Whatequipmentis not susceptible?
tcjgntly gussetedsmallborepi
. Safety relief valves suSECIToT
. High pressuredrop controlvalvesandstreamreducingstations

. Heatexchangertubeswith vortexshedding
Module 9 - Test Prcparation
O,,*-LetsReview
What is another term for erosion?
:Eb
t6
816lzOtO
Module 9 - Test heparation
Lets Review
ERWCS tubesusedin coolingwaterserviceresultsin ?
corrosionalongthe HAZ
corTosronrn
Lets Review
SulfuricAcid corrosionincreasesignificantlyat what
concentration?
- A t5 0 %
. Above 957o
t:F
t'
t7
8l6lzOtO
LetsReview
What is the best way to inspect & monitor for Oxidation?
\'
.e
18
816/aOLO
LetsReview
Atmosphericcorrosionis mostseverin what location?
'Up wind of a cooling tower

.ln an arid locatioh
n
Qr
Lets Review
What is not an Inspection and Monitoring method for Cavitation?
. Cavitatingpumpsmay soundlike pebbles.

. Acousticmonitoring
. UT and RT
a
'Ihc Rult EutcF
19
8/61zOtO
o
LetsReview
What material is least resistantto HCI corrosion?
. 300SeriesSS
.400 SeriesSS
'Nickel basedalloys
ftrc nut nutss
LetsReview
What makesammonium chloride extremely corrosive?
. The presenceofoxygen
. The presenceof H2S above 50 ppm
. A lot of water
--T
20
8/6/2OtO
LetsReview
What equipment is most susceptibleto Decarburization?
*/JNi
. Pipingin crossplant hydrogenservice[.,

. CokeDrums
DkcefulrllicrrQor*o
Thc REt ErEtcr
f^
LetsReview
Strain aging effects are observedin what type of material?
materialthat hasnot beenPWH

. Fully killed stEE
. Finegrainsteel
2L
8/6lzOLo
o
LetsReview
AII metale are crystals. A metal can have severalcrystal forms depending on
where the atoms are locatedwithin the crystal. When other elementsare
added- which forms an alloy - these additiond elementsaffect the shape of the
crystals. The different crystal stmctr.lres have different percentages of each
alloying element. Thesedifferent crystal structures are called "phasea". They
are given Dameslike "austenite","fernte",or "sigma"for example.Sigma phase
formation occurs only in stainlesssteelswith morc than r7% chromium. What
material is most likety to have sigma phaseembrittlement?
. Carbonsteel
.400 SeriesSS
. 300SeriesSS
.1!
LetsReview
When can brittle fracture occur?
. During an autorefrigerationevent.
' During startup
. During Shutdown
. During hydrotesVtightnesstesting
19.
J"'.
22
816l20to
Lets Review
This corrosionmechanismprimarily affectsfired heatertubes,
thermowells and furnace componentsoperating in high
temperatureswith a reducing gas such as hydrogen, methane,
propaneor CO. Metal
a
. Sulfidation
'fhc Rut Burten
LetsReview
Which of the following are related to poor techniquesthat could
lead to Steam Blanketing'l.
. Proper BFW treatment

to minimize flame im-pi
.Maintainburners
23
8/6l20Lo
"?1
-;te
Lets Review
Which of the followins statementsis not true about Reheat
cracking?
WHT hasno effecton thereheatcrackingsusceptibility.

' Grain Size has an important influence on the reheatcracking
susceptibility.
to ReheatCracking
2100 seriesSSis not susceptable
o
Lets Review
Which of the following is not a Critical Factor for Hydrogen
StressCracking?
. Steel hardness
'Strength
. Stress
The RBt 8uat6
"b"
1;
./
24
8l6laOtO
LetsReview
Which of the following is a true statementabout amine corrosion?
.Amine corrosionis caused
a resultfrom dissolvedacidgases(CO2and
Lets Review- The lastone !

Carbondioxide(COJ corrosionresultswhenCO, dissolvesin
waterto form Carbonicacid(HrCOr). Whichof the following
statements
is tnre?
systemsthatexperienceCO"problemsare
Steam condensate
usuallytheresultof operatingproblems?
400 SeriesSSarehighly resistant.
'0400
SeriesSSandduplexareresistant.
I
25

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8/6/20L0

Thc Run 8urtcfl

Rwiov Malulec e,3

Hil.h Temp.r.ture (bmion (ootinutd)

lJnifr)m or lnslizal krss of Thic&n'la

Puttint it All ToSetler - Prmesr Unitr

Module r - The API 57r Test Overrriew

llE Rut Butm

Module r - The API57r Test Ovenriew

Module z - Refinery Materials of Const:uction

Prrt lll - ()cnl

Slel aDd Crl

'nr Rurt 8u!t6r

Module z - Refinery Materials of Constmction

Whcnslcelrsmade.the rrondissolvesthc carbon.Approximatcly2o/ocubon is thc mostlhst crn

Module z - Refinery Materials of Construction

l-lighercnncentrationsof carbonand other alloyingelementrsucha.sruu8aog1E"

CE (Carbon Equivalent) = C +Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/r5

Module e -Refinery Materials of Constmction

Strcngrh- Ability to wilhstandlords

Metalsand thcir alloys are alsosclcctcdfor thcir chernicalandphysicalpropcrlics,suchas:

'Ihe RBt 8ust6

Module z - Refinery Materials of Construction

Mctals and thcir alloys also must bc selcctcd 1'orthcir t-abricationcapobilitics,

Thc Rutt Btstdr

'It Rurt lutter'

Module z - Refrnery Materials of Constmction

provrdcasstrst4llory.lnctrlity antl rcrlurcqlthc hkclih<xxllir tcmpcr l.lnbrrnlcrncnt.

Gcsenl sdc - Chnta addlton- fl'c ad&ln dafu

Ttlc Rud Burtdl

Module z - Refinery Materials of Constmction

rhclem KILLED STF-EL.

Minmal voidr arxl irrclusiom, ard

Thc Rurl burtd

Hor lilhd h tinGd ??

Module z - Refinery Materials of Constnrction

-fhc nut burt6

Module z - Refrnery Materials of Consbmction

Module z - Refinery Materials of Constmction

The Rwt Busten

- lhis involrrs a m(rc rapd cmlrng pacss tho aunling.

Reducg intrrnal strJse3

Thc Rurt Buttcrt

Module z - Refinery Materialc of Construction

Rapid cooling proocss

Module z - Refinery Materials of Constmction

Thc RrBt Bwtd

o}--Test Your Knowledge

Ttre Rust 8u'tffs

Wcrvs. Dry rxmxion

fhc Rutt Sutd

Module e - General Corrosion Tips

Wet vs. Dry Corrosion

Corrosion can be dividd into to distinct pntcesses.

Module a - General Comosion Tips

Damageto the PassiveLayer

Reduction of lonr or oxlgcn

Metd lonr Fe++

Module z - General Conosion Tips

The rate of corrosionresulting from galvanicaction

fVfodtrt. z - General Corrosion Tips

U"aU" z - General Conosion TiPs

illustrate" q" t'?igtl

'thc Ruli Butert