Professional Documents
Culture Documents
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 !
,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:
MqtuL 4
Modulc I
Dry I
r
.
Moduh4
Dlodub s
Moduh 8
Dry +
.
.
Mfllulc 6
Mqlul 7
Modui. S
D.y S!
Modul8
Dry 6:
TL|stPreporsti'otr
'fest
MotIuIe9
TheRurt Busterr
,"\
Day r:
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8/6l20LO
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.
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'\
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.
lm
i]bfli:
and mlzng
Corrclor
of 'fcrrr
Tlpr
,, rh .
,
l1
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.
2o/o
ic
li Carbon
ThcRust Buts!
'i
Cast Inrn
8/6/2010
(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.
Steel
0Yo
Cast Inrn
I
2V.
3Yo
9( Cerbon
Tlt Rurt Bullcf!
'.?|,
|:il
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:
.
.
.
.
.
.
8/6/20tO
f]%
)
)
!
('rrbor Stccl
l,css cxpengivc
Fcweralloys
Fcwcr spccialpropcrrics
,llloy Stccl
>
>
>
Mora expensivc
Morc alloys
Spccialpropcrtics
fh
Module z - Refinery Materials of Construction
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.
i '&
8
816/20rO
to a d
olloy ho ba
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,
Bcocfitr:
l.
2.
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!$Eh er
rlnniriur
rrd rilku. ln thc crsc of alurunium, thc disrohrcdoxyt. ru6i! with it to form aluinium ori&
{Alumina Al:O!). It fmutrm of alumur mt only prwcntr thc lbrmrtion of bubblcr u prxolty, hrt Sc tiny
partrclcr or inclwions also pin grarobflDdsric &nnB hcrl [cabncrn ptrcsrcr, prevalug gratngtow6.
o Alminum b a bctLr gran rcfining clcrmnt lhan silicon (it mal(ertighEr/smdlrf gratm).
''ih
10
8/6/2070
Str|llcs Slccb - l'hrs rs an alloy wrth flt lcrrt l l.5% Cr. fhcre ar* MANY drllbrrnt gradcsol SS.
l hcre arc lbur categoriesof SS that are charartcnzcd by their rnaallurgicsl Btructureat flx)m tcmpcrsturr:
.
Auslenrtrc
.
lerrlttc
.
Mdrfisltic, an{l
.
Duplex.
,ft-1
.+aI
*1
.f'
l'errtrc - Founrl
rnt'"rt.-,1'i1un-o,-;**doo**.*$,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 $lrul'turc.
Tr?
%c
%Cr
%Ni
304
(Austenitic)
o.o8 Mex
18-2()
8- rz Max
304L
(Austenitic)
o.o3 Max
18-eo
8- rz Max
316
o.oB Max
r6 r8
to-14
4o5 (Ferritic)
.o8 Max
11.5- r4.5
o.5 Max
4ro
(Martensitic)
o.15 MaJ(
r1.5- t3.5
416
(Martensitic)
o.l5 Mil)(
L2-14
Duplex
o.o3 Max
18-eo
3-7
% Mo
2-3
l-3
i 't
11
816/20to
f"\
Module e - Refinery
Materials
of Constnrction
o
Prra ll
llor Slccl rnd (-zrt lmr Dillcr
ll rs tmponarn to understanl the rlillbrcncc bctwen slel and casl rron.
Whm stcel rs prtxJucal.the carbondrssolvesrn thc irtn- Eventually,as )ou
adl cnouglt carbon,thc irm canmrtdrssolvcall ol'rt and sonE ol'thc carbm
precrprtalas
oul.
Stecl is inn wilh th. cartm in silutroq which tr,curs below I 6 - 2%. Carl iron is rrsr in which scrrc of
thc carboo has prucrprtatal mt and appcan ai llrk6 (x liulc sptrcr6. TlE cllirts of thc precrprtatcd
catnn are both good and bed.
fhc gtxtd - f'ttc llslca providc a cushioorng ell'er,r lbr irtn when ,t recarvql high comprelsion lo.&. n.
Dod- I}|e tlalcs makc thc (nalrirl m<re bflnlc than stccl, ard har very pflr stlngth whcn 3ffichcd in
tcnslon. l-hc prcciprlaledflakesncouratc the lbrmatronof cracksand cawc breekag,c.
ThRult Buttn
f""\
ee
sbesRelirri4 - (PoawctdHcrrTrc+marr-PwFI) 1--
r--r-5q**1'
Stror relieving is pnmlrily pertbmcd !o rclicvc stascr that hrvc bccn rmport[Ob iccl dE to lorming
rolling, mrhining, or weldrng. Ihc pnrccssinvolves hcating thc stccl to a prorxtablishal tcrnpcraruE
kng enrugh to rqJuc.eresrdttd sttesscso an acrccgablc lcrcl. Itir ie a trmc ard terperaturc dcpcndcrn
o;rration, which is tbllowcrl try slow cooling to svoid crcationol'ncw sltcs3rs.
'lhc amountol'rcsidul sr6r playr a cntical rolc rn tlcterminrnSits ru$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.
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$nsh puircr a herd Inrl skp c(x)ling pwc*rcr pnrda r
rulla ul w,xc dwtih pdt.
Amli4ir
thr involvcr hcuing a marl arl than slowly rcduing thc mling
a crntrulbd ctrling prwg
lt i! cffiilnooly
m a trvcn of funre.
tcmpcrarurc to anain a hi3! rlagrcc of rthcrr.
In an'Edrng dE mdrl is 6rg hcrtcd rbryvc thc tsrycr tralsfrrmaioa
tcmpcrrturr Nrd lc0 lo so* d frr
tmpcranr fir a pcnod of tnrc. llrcn tlr tmpcmhrc is slowiy knercd to cu{ thc nrdd.
Nanrlbiry
D
)
>
Slow c'rxrlingpu;css
Soltcns and urcatcru mctd
('awcaducrility
>
)
Rapidcrnlint procat
)
Har&nsandstrcn$hcnsmc[l
D Causcsbnttlclx
> Caucainlernrlstrcass
D Increag chanccsof crackine and dirrdion
,.h
1
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.
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
f'T\
Module z - General Corrosion fips
i1
L4
816/29ro
"h
Module z - General Corrosion fips
Prrt lll
.:.-
f'"'B
15
8/6/2OrO
t'"\
\/
C- r th o d e cethodet
tr'{fi
/
-^-^L-,
Anode '***--+cathode
^i}o*=-
{ .q
ffi'o""
GalvanicCorrosion
c"ttt"dffi----,ni*o
fr,c"tn"a"
,. -\{
!i
16
8l6lzoLo
{\
llighFlowVelocidecCanBrodcPa.ssivel,ayerrandAccrclerateCorro!.|on
,tft
Ttris faPh
corrosion rate of
a
B
,h
, ";*
Y
L7
8/6/2010
---l
grscc)
. Tempcrature
. Presaure
. Velocity of the flutd
r'\
Module z - General Corrosion Tips
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
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ha6tnlds
aTlu{ru.lrF
Th*
crelt
!E wlly
miatcd
JA
rds-
.<.:-
f-t
(
tdw
6fra
H
I
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19
8/6/?OLO
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i-
)*"
:&,..1
f,l,h
0
.-1
A
{)'"s
OF-.o.
Iv-\
l1
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.-:-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
--o
t:f;.
F
2L
816/2OrO
t-\
'{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).
1\
Module z - General Corrosion fips
Gloccary of terrru
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
amut!
or uy
rct be dsinblc
i1
22
8/6l2OrO
'L
jF
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.
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
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
...-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
- A neiwl
Sc
,)r brc6l
(h
24
8/6/20rO
=b
Module z - General Corrosion fips
Gloecera of terrns
O)-
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.
,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.
'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 $nstitucnt! are
Cnphidc
cornrrion
seledirrly leachcd or conwrtcd to corrosion productr lewing the gaphitc intsd. Secabo deolloying
and se/edrrr?leoching.
Orrphttiadon
- A maallurXjcal rcrm dccribing thc formation of g:rphit
fnrm drrumpocition o{ irun ortidc st la/atcd tcmprrrtunr.
Crry (-'rd inrn - Grc;r cert irrrn ir nanred aftcr itr grta fnc'tured surfacc, which ncrurt br:cau,r the
rraphitic flakca derlrrt a passing cracl and initiate eountkxs nw cracks as th rnaterial breals. Whitc
trrt iron ir narned afier its white surfae whcn fracturud duc to its erbidc imptrities which allow
cracks to pels streight through.
Hrdcnrbilfg
- Ttrc reladw abi[ty of r fermu dloy to form martemite wlren qtrencied ft,oar a
temFEtuac abd! the uppcr sithal temprratrre.
Herdnes
(o
Module z - General Corrosion Tips
Glocerrly of terrns
,"..o* on*-^-;;
Hatrfi..t
d EF
of th. b.*
- Tht Fnid
prcF ikr w
mimndn
rnd rEtunirl
ou*l
micmnrdunl
whii tcenlly
chr.{g
"*,,* *QJ
rfiuiq broirg,
mrtrl th|t w fftltrd
rttrRi by ih" h.a.
R'frr to rm rliml
rftc min
bchrvir.
oniq.
c rcklirq, brr rlxc
io. rld rh.F thc th"ml
HtHmpanen
hydnla
rtrrA - A lB of rtFluth a.d rlucility of .nccl by hith-tmFnturc
wrh 6.biL. ir th. nFl nrultin6 in &turburiarioa rod int md fforina.
}lot thortnd
- 8.ittlM
F{ti.n
ctdc hr
of rborb<d hydmgcn
tfydrof:a bllattl
- Th. ftr.n.tb. of blLto m or bdw r ottd orfioc from aoin
of blitq-lil. b.rlta on r drnilc nanl orfu 6rKl by intcrul hydmao p|q.|rm
intrnrd hfln;rn
9ra6
Fomrti.n
fb,&otrobrfflo-t
- AtffiF$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($C), hr lhdfd |@ pogcdy bc ellcd
gcl
hyd.ogndirtld
ct@|ubn
mctinj (HSCC).lts HSCend cletchcoiclrll
loodic
6n ogcEtl *gaotcly or in
ombiortidHsCC). In pru rrtdr. ruh a hLlF.trntth neb, tM rehenbn ir bd'ped to bc rll, or narly dl, HSC.Tlrc
psnidFtint trrchinirm of HSCir m{ aluyr rruSnial ud mry b( ?vilurtcd unld th. 3cmrb halirg of sCC.
-ItE Rust 8wt6
,r'".h
26
8/6l2OrO
B
*3
HvrcoDic
r mrrtat abiliB to qrdcntc thr onrbnrltion of Frter vlDoc apolhl to
- ( l ) PlGim
co'nderurn6nnuchi r:ompocfof s<! th.rt yiclil s<1lrout srlutiotrr of r very lov equlibriuri wpoi prtcaut
trrmnnrcd witlr thrt of Durcnter rt tltc srBa tem[ErstuE. (2) Pertriniru to r suixtrncc *{rooc ohviicrl
eharirrcristhr arc appicclablyahcrtd by eftctr ofwatcr rnpor. (3) Pertoiningto wltcr lbeorbcdby drv soil
rnrnenb from tbc ulmmphert; thc omountsrlcpcill on tbc phyrimhcmicol chomc'lero{ thc aurftcer, ond
rncaar nti rising rclstiw hmdity
lnclurionr - Particler of foreirn mrtcrid in a rncirllic mltrir. 'tlc prrndcc arc usuully crmDoundr (swh as
rr$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
st train boun&ricc,
- Craclingorfnctuin8thrtrourrbrtwenthetninr.
Cuntrastwith
".{Elt+
|
..
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)
- Stress
diriortion
to uderSo
permsnent drformation
strffi
to fuE
$mosion
without ruptw.
Thir renerallv is
of nrtals (oftcn stek) from a suitsbh elartod temDcntw.
b wrtu, oil polymcr solutioa, or sah, although for<itl air is mctimes
wid
thst rcmrin within r body u a rerult of phst c defbrnotkn.
_:",..
27
8/6/20L0
ft\
t,
of terrrrc
Sifrne-phera crnbritdcrncnt
- Embrittlcrncnt tf irgn-chmmium allrSa (moc notrbly aurtenitic
stainlecc stceb) couscd ln prer:ipitatidr ot trlin borndaricr rn thc har4 brinlc intermetrllic sigru
pharc during long pcnuil ofexpocurc to temp.raturcr bctwecn appmximately 56crBnd 98oC (toso
and tSor;F). Sigma-phnrcembrittlement rtrultr in sel'ereloeein torrghnerrond ductility, and can
rnake the embrittled nraterial cuscrptible to intergranular corrogioo" Seeoho ecnsitir,stion.
Strrln
llbcr
- 'the interuity of tllc interndly dlrtntuted forcca or componcnt| of forccr that n-irt r change
in thc volumc or shapc d r mrtrrial tbst ir or her hcn rubjettcd to stc'nrl forttr. Stn:$ 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.
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
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
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
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$re r yrald F)id. lf tlFrt
bofi cfuitic deJomuott lo plo.ttr th/onoriil
hctaroFnaou! typo of trmritlm
rn rtrerg aftcr vrcldrng a dirtmction rny bc nadc bctwcclr upper ald lwcr yrcld prir*r. Thc load
is a &crcar
* whrch a uldcn drop in thc florr crrvc Gun! ir callcd thc uppct'yield pornt. Thc c(x[tari load shown on th
florr cunc rs thc lwcr yicld point.
Ylcld rFcrftl
strdn.
YLfd rtr6a nE IrcJs lvcl rn e alsrcnel rt (x abow ttc.vre ld stnngth btt bclo,tt llrc uhiwxc
strcss in rlrc y'xtic rangc.
tEatc4 coH
- l-iquit mltrl porned itrlo r big sleb mold Sleb ir hca bor vrrtcd lrolling mill), h
lhat ic nr)trRcsull is a urulirm mt6l struchnc. Itir ir opp<red lo Crst thd rcrulB ro r|ctd stnrtre
has big-grainr, groaity, and possibly <lhc problcru
- Evidmo.
of plasuc delomonm
in strwhral
from proputronality
of srre$ and
ilrungth, i.c., t
Th Rut Bwt?a
i.lhq,
.:jiP
29
Module 2
RefinervMaterialsof Construction
ClassQuestionsfor Part I
OpenBook
L
2.
3.
4.
5.
6.
7.
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.
Copyright@2008TheRustBusters
Page3
Module2
Refinery Materialsof Construction
ClassQuestionsfor PartI
OpenBook
l.
2.
3.
4,
5.
6,
7.
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.
Copyright@2008TheRustBusters
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 -
RefineryMaterialsof Construction
Revised
August2009
ClosedBook
Quiz#1
1.
3. Revised- Thecarb6nequivalent
formulais comprised
of 7 elements.Whatsingleelementhasthegreatest
contributionto the resultsof the overallformula?
a)
Cr
b)c
c)
Mo
d)
Ni
Page1
7.
8.
Is Fenitic SS magnetic?
a)
Yes
b)
No
c)
Dependson the grade.
d)
Dependson the temperature
9.
CopyrightO Z00BTheRustBusters
Page2
8/6/20LO
ThrRut E(!td
HZS from
-he
.lbrrybd
sorrr gas
Pu.ig
P.gffi16
' ltn
r .h
8/6lzOLo
p,fig
F.gff*d
Purpose
of Amine
Treating
lrlc
t'ryb"
i&
8/6/20rO
f*'
r:o.ntmr{
tH.Srlorl
P1r!+
Rcflu
P.96(ild
r:trrjanllr
5.1.2.2 (pg$Jl)
o!--
-l
q
('rltlcd Fector
. lb cxpenencc Aminc SCC, a combrnation of things must occur:
o Aminc gpc. Cracking rs mote likely to occur in lean MEA and DEA.
. Tempcrature- Craching can occur li'orn ombicnt tcrnp to highcr tcmp, but it rnorGlikcly al highr tcmp.
. Stres! - Rcsrdual, Xclr/,&td firrr;,a - Examplcr are hnding or nalding. Odrcrs ore urrcrcn hciling or
cooling
Appornrcc ol Morpbolo,gy ol thm4c
. Crackrngis INTERGRANULAI.-",Ttuabdel
. Crackrng tlTically developc parallcl to the wsld. In the weld metal, the uracks arc either trancverseOR
knginxlinil wrrh-frc rrcld.
(Xlcr
. TrucAminccrackingisonlyaslociatedwrthf,.E/^/aminc.CrackingassciaterlwithRichamineis
another corrosion mcchanism
Th Rutt Bustert
I -.: :1''
!;'
8/6/2OrO
{'"m
s ' 1 .2 .2 ( pg$Jl )
l:ll1
lrrl
I
Ir
i
.
'a-.U
Ii
I ; '
i
|
!
i
|
--;
.
--'-r
iaJ
:-..!r-.
L_.i'
L
r<
(h.1
Th Rutt Butlc.t
(r'h
5 .l.l.l
(Pc.tr)
Oi-----
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
,",.-
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.
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
(\
( ritlcd
5.l.l,l
(PS.$t)
F.cioE
.\nir.
o
.
.
.
MEA
DGA
DIPA
DEA
MDEA
5.l.l.l
(Pt.5-l)
Prtviltio! / Vlthrtbr
. ('onrrol acrd gastCO! & HrS) loadingr.
. Monrtor/controlHSAS.
o
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.
.
ftenut
( r?,0
md Morltorl.!
Suac
''
2.
3.
4.
5.
6.
7.
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?
Copyright@2008TheRustBusters
Page 1
8l6lzOtO
ff
Moduleg
Frlifre
(Prn I ofJ)
I'hermal Fatiguc
o Mechanical Fafig,uc
1-21
.r-51
1-59
1-135
Strcr (lorrodor
.
Cncllrg
(Prn 2 ott)
Chloridc SC'C
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
r,
\j-
4- 152
5-13
5-41
5-50
5-56
8/61zArc
Module 3
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''---
ldtngrhte
to vibrotion
flov
Husband
Fatigue
,rfu.
Module 3
(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
Coke Drums
tueroa\faugue
r,h.
/i.dhf
(n
4-4,
fl -
t-
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.
Atrythi[
that vibrater. Small bone
pipiry PRyq Heat eachanger tubes, etc
('-\
8/6l20rO
Module 3
Thermd
(4. +nl
T\rDG
D6criptioo
Aft:rled
Motenalg
Critical Facton
Fetlrrra
| lnir.
Mechanicalloading- Rotatingpump
shaftr,smallborc piping,high
pn:rsun: dmp control vaheg
Prerrention
/Mitigation
fudr:rig!
- Minimizestrcsr
cotrceDtratbnof compoDentr
i- h
f,'rtlcrra
I Vlbrrtlon
816/aot0
Module 3
e
Mechenicrl
di.l
Whu ls
'|{cchanlcalFalguc?
hf
-o
F atiguc
copyrightrOaoog'n nuisurtn
Module I
Dcrcrlptior
. 'Ihis is a mechanical form of dcgradation that
occurswhen a componsntis exposedto cyclical
stresscslbr an extended period.
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
.
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
(lSrd
Trndu
Hevc n cf,drurnca limit bclow whicb fangrr cracking wrll not occrr. regrrdlerr of thc nurnbcr of cyclcr.
A!|ttiialc
.
strlrh$
limit.
uf cyclcr a . grto 3trcsa
Carbonsteel
')::
magnitudeof
cyclicstress
csrtd
sFatiguclimitfor X
numbrof dcsign
cydcr
stll
Enduranca
limit
Aluminum
alloy
N
8/612O7A
Module s
'3
Fatigue/SSC/Hydrogen
(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{
th
Module S
(P:. +5t)
tlrpyritht
l- \D' t ll\\
/.
' ':l
8/6/}OLO
(*
Module3
Corrocion Fadgue
re
ll'hd b Comnion
o---
Foigtrcl
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..
Corroeion Fatigue.r-d
Artrr ofConcctrr
'fhc term 'cprnnion farigrF" hrt bcqn ured to den'bc
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)
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 g
C8rbonoteSCC
4-ll0
4-ll8
4-t44
+1 4 8
5-3I
5-l 7
5-52
{"-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
!t
'a
(:)zqryThcRutBui6
Ci)pyriSht
Ti
Module 3
ChlorideSCC
.dbaa
Dcscrlptbr
4.5.r
o-
(Pg+-rso)
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
'_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'
Module 3
ChlorideSCC
4.5.t
(Pt4-rgo)
Copyright,O
2009ThcRwtSultert
/'*\
ta
13
8/6/2OrO
.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
Copyntht'q
C@rj.aSu,,q
MCE.
lgag
2(x)9 ThrnurtButctr
.'"\
t,
,'.
1+
8/6l20LO
("'*
----j:=---
(Caucdc Embrittlement)
n ---
{-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$)eratdlwrthweldsandaretyprcallyrntheboscmetllatthcwcld'sllcatAtfectcdZonctt{AZ).
Stainless
stcclhos marnly highly branchcdtransgranularlthrou8rFgtain)sracksthlt lo* lilc chlqidc strcssco.rosion
crackrng.
t**
^,
ffib
ttM
Crackin;
(Caucdc Embrittlemcnt)
t1*lensile Slftis: ('austic crar^kingonly occurs rf tenl#stresscs are prcsqrt. lEnsrlc stressca"pull- thc
matcrial. As thc caustic corr<fcs thc grain hrundarics, th teflsilc stress pulls thc grairu apfft
allowing the caustic io reach nerl grain boundaries,causing further corr<xiorVcracking. lncrcasing
tcnsilc strcsse3increasesthc cracking growth ralc.
.
Tensilc strcascsarc always prescnt in our pressurccquipmcnt. Tcnsilc sEcsscaarc thc rcsult of:
o Residual stresvsJrom welding
o Resuluol sttzssesJromJorning
o ()peratingprcssure
o
extruding, etc.
Thermol grou'thishrinkage
A
4
f*$n
f*gm
hh
t,d.tA
CopyrightO zuNr'fheRutgut$
i\
15
816/7OrO
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.
3
Module 3
4 ArnmonhS0C
(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
.
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
Fatigue/SSC/Hydrogen
f.-{.5 (pt {-l{E}
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
('h^
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
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
LirpFighl
,:'\
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
(:h
(lrrboartc !JC'C5.t.2.5
(pG$52)
i ::q
19
8/6l70tO
Module 3
tl
Fatigue/SSC/Hydrogen
CaEb&icsra!:kinsuiF
There is sig,nificant CO, prr:duced by the catalytic cracking pro{Jcss,and water is present
in the condensingsystems.. 'Ihe areassusceptiblearc the main fractionator overhead
piping and condensing qstem, reflux ryrtem, downstream rvet gas c'omprcssor system,
and the sour waters emanating from these areas.
Thrxe waters are qlled'alkalirrc sour waterr' hr:use thcy ontain ammonia, sulfidcc
and other contaminantr in addition to carbonatec, and arc ma& allaline by the precencc
of the ammonia.
'9t'.
Module g
ll
"f
Q,
Allcctcd Mrtcridr
. CS and low alloy stcels
(lriticrl
Frdon
o Stre$ levcl and n,alcr chcmistry rrc thc critical factors.
. CrackinB susceptibillty incrcasegwith incrcasing pH and carlnatc
curcentration. It cm occur
r ::'\
20
8/6lZO10
Module 3
.t-130
4-l3t
1-144
4-l4t
5-3I
5-t7
5-52
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
"t!:r,
a
a
a desu{urinr)
bpyrBht
(9 2n)9 TheRut8urm
r' l'
s
22
8/6/20LO
(:=
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.
Tlv HyfuenMysteryIt
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.
'''h
23
8/612010
,.\
"' . f r
The Hyd;,rtgen
Mysteryll
C'ondit{oar
ltlrcowngc
Blf,ttering /Cttcking?
Sr
'.i':
Module 3
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
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.
Module
_" - r
- Refinery
Industry
--..\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
l{)0 SeriesSS suuhas J04L, J I 6L, l2 I and 147 are hrghly rusistant.
*l'$
N$fue^
\'u
.\
t
Module
n
1"'
t
*---
--f k d Fd b *
. --F, . . s d -
l do'F .ft*
tl 6J r * dt* @ l * t
o@ dr .
bs i
lo.d4.
-rd d Fd * 4
hY-
i,?
19
z\
8/6120L0
.."'q*q\
t
_ -,r*:Tb",
/. .r$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
$)
J \ l''
. r[\
rt'\
rm rorrrrarr
S)trtem hecanrc
PtlI
25
loo
5o
too
loo
5o
loo
loo
t HrS
Sptem
Prerrure
25
PSI
Prrtid
Pres.urc
lo
I,OOO
20
I,OO O
2()()
3o
I,OO O
300
PtlI
too
f"\
27
8/6120L0
Module 3
Y1]Y
Aflcctcd Mrtcrieb
o ('artnn Sterl and low alloy stccls.
('rlilcrl FrctoE
o'[o expcrienccWet llrs .Jamagc,
a combrnstionof thinggmustuccur:
o l:nvimnrnenlalc{rndilioff(p}l HrS levcl, contarninmt* & tcmpl:rilurc).
. | l)'drotetr permeatiql incrcrscs wrth irrreasing HrS porriol pttssutc.
Partrd Pressutt * HrS concertratrcn X opcrating presrurc
'l'cmprstutc
- lr must bc WET (rltl trtc?), so thc susceprrblitytcmpsraturcis bctuecn ambicnt and
l{n l' SSC gencralty rxcun bclow about I t0 F.
l lnrdncsr- fhis rr pnmarily an rs:tucwrth SSC. Wcld hardncsrshould bc cootrollqJ to bo < 20OllB
(Rrincll lhrdn6r).
Brirull llardncss = t sl / Surtbrx arca.
Module g
"igr\
-" '".:.i9
.2
,. :"X1.
2b
8/6/20L0
Module g
:_____-_nv
'lypcsof craclingtbund:
r.-.---.*
\-_f--\_
.--....'--_t
LIIJ$
(*
ttcl'ut8ut
tr
Module g
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
HPC}W
,M
-'
wlth ctnl'.
dltrolu-:
ll'**
F+!Ctl-*
IrI.|(
F.t Hb
r.(Cil0f,8'
Module 3
o)
tl-.h
't
30
8/6/20L0
("\
ModuleS
9
/}{
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)
Blistering,
HIC
and SOHIC
damage is similar to that found in wet HzS.
".\
Module g
HydrogcnSbctc
hwcntion / Mitigatirn:
.
.
.
o
'fl
Fatigue/SSC/Hydrogen
Crac∈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:
% carbon
-IhcRutSut6
Copyright O 2009
i.
n?
5-
816129ro
llydrtrgen
Attrcl
5-56
2.
Some of the alomic ltydrogen (H+) ditluses inta the steel (that r could be bad).
J.
The Rcactlon:
+ Fc, (iron)
4H + FerC (ircn-carbide)
- CHr(methane)
Continued on the next pege
llydrogcn
Att d. 5-56
t(
.\\
Thc Reeulon:
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.
(.%
33
81612O1O
Module 3
t f igh Tenprattue
Hydrqcn
Altet*
5-56
4II*
+ Fe"C(iron-cvrbide)
= CHr(methane)+
Fer(iron)
,/--i /
| 4Z'
) \/.-' L-'-',
..) +-\r\
rl F
'.\,
Module 3
'?',,
i, l
Illgh Tempcrature
Hydrotco
Altadt
S;-S6
(/
t\,
'the wil villain HTHA is prwentable thanks to Mr. Nelsen
who invented the Nelsencrrnrcs (se pageS-S8)l!
z.
(})p}{idtl,r,) 2oo9'IteRurtBr$6r
fl
3c
;/
8/6/2OLO
{-^h
Module 3
f)*
Co!ryri8ht O 2o9'fhdlult8wl.rt
llitl
fbnpcntrr.
HydrolcrAttrcf
(Fftl^)
s.lJ.l
tFt. 356)
oI-HTHA damage is permanent and irrevereible. When operating just above a material limit
cunre shtnvn in ltigure 4 Opmting Limiain Hydrqen Servicr, it may take years for the
damage to oi'en start to occur. But when operating significantly abore the curve, the damage
may start to (x)cur within a fer,vhourg.
HTHAdonogc
.Flisururil
'.-\
(R
35
8/6/20L0
3
lligb limpcrrturc
llydrogcl,lltrcl
{ll"l'llA)
o*
(Pt. 5-56)
5.lJ.l
t;
F")Il
Itd4
ZE
tnNt
Waa',..ai--
'fhc Rlrt
6upd?
ilttalalb
buters
'...\!
,,,
lligl'fcnpcnturc
What is PartialPrcssurc?
(PI. }'56)
r:_
J-r4.
{t4-
Hyttttt
re Go
Hlalrtil
t;s
e,dvd5Hr*r-tpra
llfbotq
lit
Suppocc thcrc arc two contEincfi of cqual sizc fillcd with diffcrcrrt gascr andmaintaincd ar thc
sarnc tempcrdunc. lhc tirst containcr is fillcd with a hydrocarhn g,asand has a prcssurc of 300
psig. Ihc sccond c<rntaincris tillcd with hydmgcn and has a prcssurc of 6O0 psig. (Notice tlvft
une mone molecvles in tlc vcotd contoirer lncrcasing tlte nunber oJ molectles im'rcases ile
prcssure.)
lf thc contcnts of bolh conlainers are put togcthcr in a conlaincr of thc samc sizc. what is thc
prcssure? lt will bc XX) psig the hydru:arb<n e,.c contrlbutes J00 psig and thc hydrogen gas
contributcs 600 psig. Even though the containcr is 9O0 psig thc partial pr$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$urc. Partial prcssurc is usually calculated
by pmcess firglncers.
t,*:
3b
8l6l2OrO
/'T"!h
llfuh Tcnpcrrhrt
(Pt, 5-55)
Opcrrtbr l!$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
(}
fimeto
s.lJ.l
(FS.S56)
Ponder
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
tB'!,
',ri
Module g
o
Formaffing and supporting information
for this Module were attained from
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)
c)
Fractionatortrays.
d)
CopyrightO 2008TheRustBusters
Page1
Module 3
CorrosionCracking(Part2 of 3)
Stress;
OpenBook
l.
Page4
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.
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
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
lt
what rnatelials?
Revised
-Liquid Mctal Emblitt Icnrc nt (LME) af'f'ects
a)
CS
b)
300 SeriesSS
c)
Low alloy sleels
d)
HSLA steels
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)
fbr CS?(Pg5-52)
is reqtrired
14. StressRelievingabovewhattenrperature
a) 1150
b) t2so
c)
d)
1450
1050
Copyright@2008ThcRustBustcrs
Page6
Module 3
HydrogenCracking(Part3 of 3)
OpenBook
l.
Copyright@2008TheRustBusters
Page 7
2.
3.
HydrogenEmbrittlement.As rnrrlcrialstrengthincrcases,
susceptibility
to HE
a) Increase
b) Decreascs
c) Changeswith the opclrrtingpressure.
d)
Doesn'tchangeat irll
4.
5.
6.
PolythionicAcid SCC.
a)
b)
c)
d)
7.
Polythionic Acid SCC. What is the descendingorder of materialsthat are affectedby PTA.?
a)
b)
c)
d) cs,321.304L,304H
CopyrightO 2008TheRustBuster',s
Page8
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)
14. Amine SCC. An umine towcl is going to be stearnedout to get it gas free. What specialprecautionsshould be usedto
preventAmine SCC?
c)
d)
a)
b)
copyright@2008ThcRustBusters
Page9
16. Which of
a)
b)
c)
d)
e)
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
Hydlog, n InducedCracliing
d)
Hydrog,'nblistering
No
c)
d)
milE
Copyright@2008'f hCltustBuster.s
Page10
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
CopyrightO 2008ThcRustBusters
Page11
8/6/20rO
, 'qF r
{.
Sulli&rim
I
l
l}cubunlatkm
t- 109
{- t3
c(xcrcd)
{- il.1
-"&
Mctal Du3lrng
O\rdattm
t
u
NrtndinB
(iraliutizlron
to
Srrllcnrng(Sphcrurdi2ation)
II
l"dnpcr ltmbnnlcmenl
12.
StBn Agrng
l]
8t5 F Embnnlmcd
ta
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
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.
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/
I
t
''4
816/zOtO
1+
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,!
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..
lq.
Prwention/
4.4.2
(pgl-roS)
Mldgrdon
.g{ n
Ttc nrut gut6
\,\i'.
't
816/20LO
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.
("*
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.
:.
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
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.
'%
':4
44.3
(ptl-rrl)
N
(
,"W
816l20to
r'ru
L
4.4.3
(pt4-rrl)
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
a?!tr.
j'i i.i
*o
Whrfr
Uatrl
lludql
fom of cartuiado
Th. tcmlEatw
Mcta.ldwrinlm
lo4H dainlllf
lemlHtlE
tEw
efuo'
|hc
rl''B
v
8/6l2OLA
i "\
PraYantloD
fcmFnaE @drol . wh.ffi
wls.di
dlaio3 my eil
u to rvod .'palirn
io thc tcrnparc
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
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
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
Hdadon
What is Oxidation?
.
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
* 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|'-
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
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
veildlnt
lim
ue su*cDtrble.
Frcrorr
c{nlminants,
2 ) 'Icmpcranrc
| 700 -
of Mcrpto|oaf
of llrrrgc
Appcrnxc
e Corrorion rarcr of l(D - 1000 npy cu bc cxpenmccd.
o
Prwcrrler
o
Blcrtding to conttolhblc
bvch.
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
('ridc.l
ircluding crhn
st l ltd lN
.lby
ncck.
Frcton
Ilrcc
Alloy compogition
Timc
Partial prcsre
cuditioilt
muC bc mct
wr
above 9fi) F)
ofnitrogen
L i{''*l'
10
8/6l2OrO
r:q
-*-c----
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.
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.
'fteRutBNt6
i3
11
8/6l2OrO
'ro
-
l:*
dl
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
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.
bnftleu$
(B
Module 4 High Temperature Corrosion (4oo+ F)
lroftcnlng (Sphcnrldlzrtioo)
Procar
M?thod
Grrin Sizc
Rerirtrncc to
Frrclurc
Anncrling
l^argcGrain
Sizc
ElJy lo tcar,
brcrl or
fracturc
Normrlizing
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
f.2.2 (Pg+5)
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).
.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'*
_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$ipm6t? (li!i sll thrt apply)
'Yc* and th. cquiDocnt ncGdr to bc cphcd
.No, u rphcro4dlntim rtrmc urully d6 no( had to fsilrra
@frlitima rsh er pffi
wlll be char4ed
and temtfrstw
'Yr., if sicc
6.*
Tcnpcr f,nbrittlcncrl
.d
Ilcriptic.
o
.tftcclcd MrGrirL
. ftimly
2.2J C-'r
. ()ldcr gsrahon
2.2J Cr-l Mo rnenufrtud
('riticrl
.
bcfrn
sucpriblc.
Frcle.r
fhrEc qrxfitruor
muJt bc nEt:
2.
Alby crnry.ntion
'fir of crfxurc
ICS arrl lw
alloy stcclsl
Sutplrbrlity
is largsly &tlrmind
f?*
15
8l6l2Aro
'3
Tcopcr f,mbrittlcncnl
c..ha
OL
Prcttion
.
it lo limrl thc lcvclr of mmgarr:c
t'mhrnlcrncd
lllc bed w.y lo mimmiz? thc lilelihxrd and carcril of tcnF
rMn), siliconc tSi), drospll(rla tP), tin t$), 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:
Wcld Mad
,ry
Drrilig
(lupy Tmitiuono
fa flil
f.2J (Pca-t)
sd E adlld
Sbd
rffifd6
r'trEfn
.rfl
+>:
Ns*
Td (OpaditT,)
Tqrpanm
/.'h
{
16
8/6/2070
t'*h
\,
fcmpcr fimbrittl.mcot
Tlm.
to Pond.f
Whrch piu
[cmpcr Fsbritllcm"ot
of
(Pg4-rzl
4.t.4
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. $rtgnbb
Srch |tidtLuc{
by rh. Bffi
rtwrlicud
by rhc Bsic Orygd
Srcdr mado nth
BOF c
srnir urtt
ctltTil rc obsrcd
wittr[
{@
rdidir[,
slnin |!ir3 it I mid
cwm
ro inamaliuo
ropaltul''
Prw@aL.
.
fh. bcrr u'
\ppbin!
tutaing
lo.IKth.
higls
ld"lr
ot oitic.l
inrp.r.ity dcrilt
th!
tffi
n.dt
Furo
il rorsidr
tl|t
hsE b.ri
lc aluipmn
th.t cortdrE
lha ,m of dalirnr.d ruod
cold worid
ino Ficc
crulr
lf arlrrblc
mtaidr
my bem
h.td6r.d .[d ls
thc Flwidio
.rd dald
wi0 climinc
qSrc
ilrc cdirt
at iflFtrr.di.tc
rc y'uiol}y
6.Eirb.
tmpqrnG
dclirurd
urd ogrod
impquul
o4'r.io
rgrf,
WhdE PwHT it d
polt$lq
a MilltEbt
InqEtio
Bh! Bri(krE$
ud trMiruing
tr e(hq
w
t-m
n* urcd to codrol
of Slnr
*nin
aging,
AlirE-
,.'-\
(" ,,;r
L7
8/6/2010
{.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
apou!
Thi, plEu|EM
Mrr6hl
Duplq
33 ui
Wnrthi
rd
C.tk.l
:lx) Sds
SS coddning
tiniq
Ff,i@Lrt
trrt-l
\tlq
lmruint
DuuS!
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 $rnrlrtiw.
,lppaffiof
.
t {)
M-DlFLOf
rdnpcrturo
cxFicnod
&rr{
cf Du{t
rpguer
whh ffidlofrryary,
ht ry
bc qnfrnod
ttru3h
bod r
?scth
tl5 F Finb.inlccd
qF..d
lo th. m
it rlwiltlc
qrditiool
bt hal lffitrd
it *ill Gobfitlc
(q-ti.Jly
/er
lh.r
I I m f ) to dilolvc
n did itritirlly
Fcipnr6
- tilt|(sql
by rqrd urlir4.
lftm,
if
Which
o
o
o
o
o
Ai
fourd?
Carbonrted
TyF 3oa Skin csr Stcl
TlDc4o5.9tainlcoSta{
Tcllon lincd pipc
facton led a mttcrid to bc rure prce to 88t,P embrittlmat?
Thicksmll
A ffiitic rtainls ltEl with roi chrcoim
A ferltic stainl6 ncl with r3.SX chmim
A! aurtmitic stainls rtql with 161 chmiuo
Expocw to 80'F cm|EEd to 60o'F
(clxru
ttr. n* i*,"*
t -'
18
:':;'
816/2010
(\
Embrinl.mcnt
1.2.5
__::'
l).icrlptlD.
Sigms phascrr a har4 bnttle, intermelalliceompound,Fd'r, which cm lbrm in ccrtainhigh chromium and
ehromrum-nrckel
SS'sfbllowrngerposurEin thc temperature
rangeof l(nO - t 750F
.{tt .t.d Mrtcrlrb
o Wroughl and castl(lo ScriesSS containlngllrrite, portrcularlywcldr. Alloy-swith high ( | 0 - l4% fcnitc
areespocrally
suscepnrble.
. ltX) ScriesSS and other lerritic/rnartcmiticSS wtth | 7qloCr or morc (.{3Oand ,l,l0)
o DuplcxSS suchar Alkrys 2205.2lO4arxl25O7
.
M a le ttr lswlth lT ' /o Cr o r m o r e u e lhcmosl susceptabl (thi smean3l mtcrrc3S S -mosl ofthcl l rne)
{h
f,mbrittlcncat
{.2.6
(PS a - t6)
i'?
19
816/2010
4.2.6
e\,
i '- . t
J
t6)
(lrltlcrl !'rcton
. Alkry comp($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.
,q h "
''.9
4.2.6 (Pg4-16)
to Pfll6
Rat
ir thc lart
by vtrud tntFction.
of wfiich eLml
tlitb qwtiti6
o Niclcl
o Nitrogs
o Carbon
o Chmmiu
]}lc
fomtid
BurteF
i *1
2C
8/6120ro
fe
{.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$idcrcd.
. Brislc li,arturc can abo occur during autorcfrigcration.
Appcrnncc of Morpbol4y ol lhrrgc
. Cra:kr arc tlpio:olty strright ad noo-branching.
(M
Module 4 High Temperatrrre Corrosion (4oo+ F)
BrltdcFrrctrrc
4.2.7 (Pt1-19)
#e
2L
8/5/70rc
1.2.7 (PB+19)
.aB,
2-
.,.:r.v.
1,...,,
*
8/6/2010
(*
1.2,
(PS+23)
Dcrcrlptlor
. Al hidr lcmperaturc$,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
Module 4 High Temperature Corrosion (4oo+ F)
(lrcep/ Strcrr nrptlrr
4.2t
(PS+af)
f':h
23
8/6l70rO
\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'
Prcrantion / mitigation
. Doo't ure titanium in known newicts for bydriding.
lnepeetion/ Mooitoring
. A specializedEddy currcnt was noted ar beiog succtssfirl
. Uctdlo$apby
TH\
'g
25
Module 4
High Temperature
Corrosion
OpenBook
1. Are nickelbasedalloysresistantto sulfidation?Explain.
2.
3.
4.
5.
6.
7.
8.
9.
Monitorprocesstemperatures(watchfor processcreep)
Monitortemperatureswith infrared
UT materialduringS/D
Copyright@2008 TheRustBusters
Page4
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'
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.
2o/o.
l0 o/o
15 o/o
20 o/o.
25 o/o
Copyright@2008TheRustBusters
Page1
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)
10 Revised
- Whichelementcanbe addedto steelto reducemetaldustinetendencies?
I ilil;'"'
c.
d.
"t^.,\rnY
Molybdenum I r r*'.
Sulfur
\J
copyright@2008TheRustBusters
PageZ
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
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.
Copyright@2008TheRustBusters
Page3
w/
.&
8/6lZOLO
Module
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
.'4
Module
- 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.
-+\
...1
8/6/?ALO
r'+l\L
,i
t
Module
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-
,'',lt'.
Module
- All Industries
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
f+
8/6/2010
{.2.13
- AII It dtr"t"io
(Pg.{-12)
|lspcctbr md Moritor|ll
. lhrs tlpc of damagcrs highly l<xalizedand riilfrcult to locatc.
o PT & MT can bc usgl ro conlirm crackrng.
.*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.
t:)
8/6/2010
Module
- All Industries
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.
Module
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
'-3
4.2.15 (Pg.&19)
T!t"
*t
4.2.1t
Nl Industries
'h!
tt1n{-C\ 1r
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
(*
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.
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.
CopyrightO 2008TheRustBusters
Page5
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.
38)
a,
b.
d.
5.
Above500
A b o v e5 1 0
Above1000F
Noneofthe above.
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.
CopyrightO 2008TheRustBusters
PageL
CopyrightO 2008TheRustBusters
Page2
8l61ZOLO
(''}i
Module 6 - Uniform
.rtt
(iolvanrc Corrosron
I
't
AtmosphcrrcCfiroslon
432
4l ]
CmlingWatcrCorrooion
MicrobrokrgrcallyInducrxlCormsion { MIC)
{14
l)ealloying
(;raphrtK C()frosion
43 i l
4 t.t2
{ 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
{"3a
Module
6 - Uniforrn
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
-\
f
(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'
cathodeih-
^ri"u, fr
c"tl"a"
,'nwr
-i,F.i.
816l2OtO
{3
Module
6 - Unifonn
Grlvrnic Corrosioo
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.
816/20tO
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
--T'ir,
il
Crltkrl Frcton:
. Madnc cnvironmenB
. Industrnl envirunmGnb
. lnlmd locatioot
20 mpy
5 to l0 mpy
I to I mpy
i^lT.'-h,
t'
1
816/20t0
r"{?\
('-'a
Dtscrlpflor
Corrosrrn that resultstiom wucr rnppcr.lundcr insulotim tr tireprooling conditions
Vc$al
Insuhllo! Rint
n r Ru t&r td
{'*
-o
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.
i-'&
5
8/6l20rO
-o
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
Inrpcctlol ud Molllorirg
. Visual is dwup th best.
. t.fl fin thrcknesr.
. X-Ray.
TlERurButd
;'\
*;i
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
{J.a
{Pt }7S)
Module
6 - Uniform
::______o
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.
81612Or0
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.
T\
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lPS.,l.t5)
,d .
Ttre Rut
ll6te6
't!
8/6/20LO
{'n
lJa
(Pg. +{6)
(da
Module
6 - Uniform
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.''\
,.
(Pg.+l0l)
ThcRurBut6
{k
Module
6 - Uniform
'-''_-o*---
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
,.*\
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
(e
Module
6 - Uniform
_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.
{:"h
13
8l612OrO
\
F
(Pg.+t4t
{.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.
14
.l
olvl
r'
LvLv
:-\,
ilIodule 6-Uniform<rr
Soil ('orrmiot
lJ.t
1Pg.{-91) cont'd
('\
Module
6 - Uniform
Crusilc ('orroalor
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
{J.9
II
I
Ttrfu[{8ut6
(.^
Module
6 - Uniform
(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
{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
':;!
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.
\Ra\
r'^Y
Vv
.s
E
\a_t-
,,}
t
16
vt
vt
Lv
-v
rt%
t
Module
6 - Uniform
(-aurtic (lorrosioo
'fh. Rusr!urt6
(ta
Module
6 - Unifonn
('rurtlc (;orrorio!
h
r''
1.'
L7
Module 6
GeneralDamageMechanisms
OpenBook
1.
2.
3.
4.
5.
What is carbonicacid?
6.
Can carbonsteeland 300 SeriesSS be usedin highstrengthcausticsolutionsthat are above 150 F (66 C)??
7.
8.
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.
Copyright@2008 TheRustBusters
Page5
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.
yes
b.
No
c.
Dependson thetemperature.
Dependson the levelof nutrients
available.
d.
5.
a.
130F
b.
140F
c.
220 F
d.
280F
not
b.
more
c.
less
d.
barely
-affected
thanthesurrounding
material?
Faster
b.
Slower
c.
d.
Undetermined
because
of thelargecathode/anode
ration,
Copyright@2008TheRustBusters
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.
Copyright@2008TheRustBusters
PageZ
b.
GalvanicCorrosion
c.
MIC
d.
CO2 Corrosion.
b.
Specialbackfilland cathodicprotection
c.
Flameappliedcoatingand oxygencontentmonitoring.
d.
15. Revised
- For galvaniccorrosionto occur,certaincriticalfactorsmust be met. (pg 4-65) They are:
a.
b.
An electrolyteand a cathode
c,
d.
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.
c.
Graphiticcorrosion.
d.
CO2 corrosion.
17. Revised
- Generalor localizedcorrosionof carbonsteelsand other metals caused by dissolvedsalts, gasses,
organiccompoundsor microbiologicalactivitiesis called
a.
AtmosphericCorrosion.
b.
c.
Coolingwater Corrosion.
d.
18. Revised
- What structureis 410 stainlesssteel ?
a.
Martensitic.
b.
Austenitic
c.
Duplex.
d.
Ferritic
Copyright@2008 TheRustBusters
Page3
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.
b.
A relatedcorrosionmechanismis carbonatecracking.
Corrosionis selectiveto the HAZ of welds.
d.
22. Revised
withwhichof thefollowingunits?
- Causticcorrosionis mostoftenassociated
a.
b.
c.
d.
Crudeunitsand FCCUunits.
Causticgenerators
andregenerators.
Crudeunitsandwastewatertreatingunits.
Boilersandsteamgenerating
equipment.
Copyright@2008 TheRustBusters
Page4
8/6l20rO
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
Module
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
Module
, r\
t.
t.t.t.l
(P 9,5-l )
- Reffnery Induag
a
Modulc
(P 3.5-l )
5.l .l .l
Arn'inadonotcoda.
It't tho annhu c.orrtcmlnan|rthat
cattodo
Module
- Refincry
Industry
(Pg.!l)
5.l.l.l
.r
ln ls,;r r lr - J
t-.
lrr1r11j
lL----J
{\J
; 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
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
.
.
{}
.
.
.
.
.
MEA
t)(GA
DIPA
DEA
MDEA
vI
avLv
8/6l20rO
f%
Module
{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
'"3
Modulc
7 - Gcncrd
Arnmonlurn
Demage Mechanismc
- 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.
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)
Thc Ruli
Bstc6
(n
Module
Arnmonlum
Blsultldc (Allallne
o;
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:
NllrllS txnrcentratioo is usually L"rs than 2 wflr, buf high vclourtrrs anVor thc prcscncc of cyanidcs can
rcnrovc protcctivs iron sulli& scd6.
r
.
.'Fir',,
Propcrdcsi$ofwarhwatcrinjcclionleoiliticaiscritical. Providesufficientcxccaswalcrtoensurethat
an adcquatcarnountof waicr rcmlios I liquid to dilutc thc NHrHS salts.
Ilspctbr
ud Modtorirg
. LJTscanningand/orRT profilc.
o UT dormstrerm of control valvcr due to incrcasod vclocitv.
TheRurt &'[t rt
rh
l.l
8l6l20to
r't"L
t'.+;
Module
It drxxn't take much NH. and HCl. HCI is a contarninant prsent in lery small
qruntities, usrr"lty parb per million (ppm). NH, originatcs with the small amount of
nitmgen pFesentin oil. With thonqandsand thou.sandsof other molecrrlrx presnt,lik
hydrocarbons, hydmgen and thc like, onc may think there is littb chance of NH. seeing
HCl. But that L3not tnre; and NH.CI salt can readily form and can be a big problem.
Modulc
-o--
- Refrnery Industry
Clrloride
C;orr.oclon Occur?
Distillint column upper scctions and oerheads. Fe.ds have ammonia and there are
chlorides from desalter carrysver. There are signifirnnt amountg of water vapor.
Deadle8sthat collect water and salts, Deadte$ 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.
'r"h
8l6l2OrO
Module
o-- -
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
Th Rurt 8ust6
Module
- Refrnery IndusFy
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
l':.r?h
9
8/6l70rO
Module
- Refinery
Industry
o--
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
- 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!.
.
.
.
l{ydroprocessing
r l-imh chloridcs in thc MAJ Hl!.
.
try,
l.l
10
8/6/20Lo
./
o'-"__
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.
.
Module
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.
Prncndon
/ Mitigattoo
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.
.
Module
Dcrcrlptlor
Frlon
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.
Th Rud Bst6
?.t
t2
8/6/?OLO
Module
('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
{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.
.
13
8/6l2O1O
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
.
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
.
\
l
Cormlon
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
Dccriptbr
-l'hi3i3 uscda!
'
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.
(,
Module
- Refinery Industiy
15
8/6/za1o
Module
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.
a.
ra
Module
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
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.
r^
Module
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
t7
8/6l20to
Module
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
Module
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 $lgnant areassuch as in a storagc tanl.
I[ thc corrcsion rdlc Bnd velosity are hig[ tltcrc will bc no ccalc.
Corrosronof ltecl by dilutc acid ir usually rn llrc tbrm ofovcrall metatloosor pitling and bccomcr morc
scverewith rncreasingtemperatureand velocity.
Prwcuti'or i Mlt[rtlor
. ( lsc alloys that arc more resistant
o Acrdrfied prxluct streamscan bc wuhed wilh causticto neutralizcthe at,id.
I nsDcctlonrld Monltorlng
o tJT / RT suspcrutcdareas.
"\{
J
18
8/512070
c'
V
Efiect of Velocity on Sulfurtc Acid Carbon Steel Conoclon
tatec
ttrai6&fi.dcAotdnhn*d
; ; i,
o12345a
8910'17l ?i
H\rrdgfr.
e
.fhe
a1" '"
n1" _* i 6.
r gr l
Rurt Butm
S.t. r. lt (p*
S-zZl cont'd
Ily&ogclrnGraoalrng:
when carbon steel corrodee in sulfuric acid servitr, hydrcgen gar is formed.
The
hydrygen gar riseg and the ngrr.of
hydmgen can disrupt the ferrou.r sutfate film,
lhe
causing increased corroeion in the form of groove. A normal location for hvdmcen
grocrvingis the inside surfa<x on the top of a horimntal pipe.
,'"?}-'t
19
8l6l2OLo
l).'rriDilor
Hydriding5.l.3.z
o-
1[ dmgen dilfi$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.
'\,
v
Module
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?
CopyrightO 2008TheRustBusters
Page4
Module7 GeneralDamage
Mechanisms
- Refining
Industry
Revised
August,
2009
1'
2.
a.
3%
b.
5%
c.
7%
d.
15 %.
b.
c.
d.
Lesssulfuris alwaysbetter
More sulfur is better
Dependson the TANcorrosivity.
d.
s%.
7 . Wha tisDNB ?
a.
Department
of Non-Binding
Refractory
b.
DoesNotBelong
c.
DyneNuclear
Bonding
d.
Departure
Nucleate
Boiling
CopyrightO 2008TheRustBusters
Page1
Copyright
O 2008TheRustBusters
PageZ
3161.
Alloy20
Titanium
c276.
lt depends.
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
Copyright@2008TheRustBusters
Page3
6b*rfl{}ll'o'o
/",\
Module I Refrning U
'}F?eB
-0
@
Hffi
zt|E
il'
{14
I J!<,-
r'--.etJ
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The RNt
1":
Bwtd
816laOLO
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
FCCU- CatalyticCracker
The Rut Bulta
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'l
8/6/2070
FCCU- CatalyticCracker
Thc Rut Brstcrr
Tbqlurynrnh
ryil@.d
qtu.tur*I
ffitqbecryi
r'",.&
{.;
DCU - (thermalcrackins)
8/6l2OrO
It
\
4C
AlkylationUnit
fF,
r-t
5.'
4
8/6/zorc
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
R.qcL
O-
;*-6ql
l-*-.
.=i?
i
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SulfurRecovery
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8/6/20rO
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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.
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
816lzArc
Don'tPanic!
Remember
to fill in you answerkey last.
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
to fill in you answerkey last.
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
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
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
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
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
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
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.
SampleQuestion
Whichof thc followingaresusceptible
to thermalfatigue?
A. sA-51G70
B. SA-182Cr B
C. SA-53Gr B
gPNt
theabove.
8l6l20rO
SampleQuestion
For tumaceg to prevent PASCC, keep the firebox heatedabove the dcwpoint to keep _
from tbrming.
h'tr\P{
SampleQuestion
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 $t\.-,:.ta5t
'Alky reactor
. Crudeunit desalter
oL_
SampleQuestion
Ametallurgical treatmentwhich has worked well to prevent{
./
or@plantsis:
ld heat treatment(P
fzt'r\hltEt
(-\
11
8l6lzOtO
o,
SampleQuestion
What is the best NDE method to use to detect Creep in the
advancedstage?
'Cali
. WFMPT
.D P
.ACFM
Thc Rrst 8ute6
SampleQuestion
Whatmaterialwould the liner be madeout of in an sulfuricacid
reactor?
rf
SeriesSS
.100 SeriesSS
. 2.25Cr
-s
L2
81612OrO
n'
\-ll
SampleQuestiorlr*'
For CUI. corrosionbecomesmore severeat what metal
temperatures?
@.l 8- 0 F to 2 6 0 F
.l 9 0 F to 2 5 0 F
. 1 7 5F to 2 7 5 F
O'F
Lets Review
Dealloying - What color will bronze turn?
. Green
ffi
.Black
ThRurt But6
{"q
13
8/61zarc
Lets Review
LME
Surccpdblc
Alloy
3oo SeriesSS
CopperAlloys
Alloy 4oo
Aluminum Allow
High Slrength Steels
The R$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
Cadmium. tead
f,f
L4
8l6l2OLO
Lets Review
SS
'300 Series
t
\lickel basedalloys
n
Module 9 - Test Preparation
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
O,,*-LetsReview
What is another term for erosion?
:Eb
t6
816lzOtO
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?
n
Module 9 - Test Preparation
Qr
Lets Review
What is not an Inspection and Monitoring method for Cavitation?
19
8/61zOtO
o
LetsReview
What material is least resistantto HCI corrosion?
. 300SeriesSS
.400 SeriesSS
'Nickel basedalloys
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
DkcefulrllicrrQor*o
Thc REt ErEtcr
f^
Module 9 - Test Preparation
LetsReview
Strain aging effects are observedin what type of material?
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
LetsReview
Which of the following are related to poor techniquesthat could
lead to Steam Blanketing'l.
.Maintainburners
23
8/6l20Lo
"?1
-;te
Lets Review
Which of the followins statementsis not true about Reheat
cracking?
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
"b"
1;
./
24
8l6laOtO
LetsReview
a resultfrom dissolvedacidgases(CO2and
I
25