API 571:CONTENTS
Now we will look at the last group of damage mechanisms covered by API 571
4.2.3 Temper Embrittlement 4.2.7 Brittle Fracture 4.2.9 Thermal Fatigue 4.2.14 Erosion/Erosion-Corrosion 4.2.16 Mechanical Fatigue 4.3.2 Atmospheric Corrosion 4.3.3 Corrosion Under Insulation (CUI) 4.3.4 Cooling Water Corrosion 4.3.5 Boiler Water Condensate Corrosion 4.4.2 Sulfidation 4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC) 4.5.2 Corrosion Fatigue 4.5.3 Caustic SCC (Caustic Embrittlement) 5.1.2.3 Wet H2S Damage (Blistering/HIC/SOHIC/SCC) 5.1.3.1 High Temperature Hydrogen Attack (HTHA
These are fairly complicated corrosion mechanisms,many of them related to higher temperature and oil/gas industry/ refinery applications
Slide 1
REMEMBER THE WAY THAT API 571 COVERS EACH OF THE MECHANISMS
Critical factors
Related mechanisms
Inspection/ monitoring
Slide 2
SULFIDATION
This is a high temperature corrosion mechanism WARNING: This is a common closed-book exam topic
+ +
=
Sulfidation corrosion
Slide 3
SULFIDATION
What is it?
Slide 4
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SULFIDATION
The main problem is caused by 2 (formed by the degradation of Sulphur compounds at high temperature)
Occurs in crude plant,cokers,hydroprocessor units,fired heaters etc.anywhere where there are high temperature sulphur streams Sulfidation starts to degrade steels abve about 500degF (260 degC)
Slide 5
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HS
SULFIDATION
The susceptibility of steels to Sulfidation is shown in the McConomy curves shown in API 571
As the temperature rises above 500 degF,the sulfidation corrosion rate goes up
Slide 6
SULFIDATION
MITIGATION
Higher Cr alloys(300-400 series stainless steels) may be more resistant to sulfidation corrosion
Slide 7
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316
304
come from?
Slide 9
Salt
API 510 CERT SCC CAN BE VERY DIFFICULT TO DETECT.ALMOST IMPOSSIBLE IN ITS EARLY STAGES UT will not show very small SCC cracks
Neither will RT
Slide 11
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SCC DETECTED BY PT
Surface abrasion may be needed before PT in order to show fine SCC cracks
CAUSTIC EMBRITTLEMENT
The worst offenders are : Sodium Hydroxide (NaOH) Caustic Potash (KOH) Caustic attack in a heat exchanger tubesheet
CAUSTIC EMBRITTLEMENT
Look at Fig 4-85 in API 571 showing how temperature and NaOH concentration affects the susceptibility of Carbon steel to NaOH
Slide 15
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CORROSION FATIGUE
Cracks caused by a combination of:
Corrosion
Cyclic loadings
CORROSION FATIGUE
Stress S
UTS
No endurance limit
Cycles N
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Slide 18
4 damage mechanisms
They affect carbon steels and low alloys steels in wet H2S environments Sulfide SCC Stress Oriented Hydrogen induced cracking (SOHIC)
Slide 19
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The actual damage mechanism for all 4 categories is the permeation of the H2 into the materials grain boundaries
This weakens the material and causes failure
The type of wet H2S damage that occurs is related to these factors(see 570 Sec 5.1.2.3..3.)
pH The H2S level present Temperature Hardness Type of steel PWHT (an important one)
Slide 20
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Hydrogen blistering
The Hydrogen is liberated from corrosion (not the process fluid)
Slide 21
HIC
Sometimes called stepwise cracking as hydrogen causes cracks in the structure
SOHIC
Stress Oriented Hydrogen induced cracking (SOHIC)
A type of HIC in which the cracks are made worse by stress concentrations
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Slide 23
Sulfide SCC
Essentially ..SCC made worse by the presence of water and H2S
Weld preheat and PWHT can help reduce the risk (depending on the alloy)
In simple terms:
At high temperatures,H2 reacts with the Carbon in the steel forming Ch4 (Methane) The resulting loss of Carbides weakens the steel
failure
Slide 26
In these 3 presentations we have looked at all of the mechanisms in API 571 that are in the API 510 exam syllabus
4.2.3 Temper Embrittlement 4.2.7 Brittle Fracture 4.2.9 Thermal Fatigue 4.2.14 Erosion/Erosion-Corrosion 4.2.16 Mechanical Fatigue 4.3.2 Atmospheric Corrosion 4.3.3 Corrosion Under Insulation (CUI) 4.3.4 Cooling Water Corrosion 4.3.5 Boiler Water Condensate Corrosion 4.4.2 Sulfidation 4.5.1 Chloride Stress Corrosion Cracking (Cl-SCC) 4.5.2 Corrosion Fatigue 4.5.3 Caustic SCC (Caustic Embrittlement) 5.1.2.3 Wet H2S Damage (Blistering/HIC/SOHIC/SCC) 5.1.3.1 High Temperature Hydrogen Attack (HTHA
NEXT STEP
Now finish off the module text and try the test questions
Slide 27