API-571 Damage Mechanism comparison Chart (API 570)

S.N Damage Affected Prevention/

O. Mechanism Description Material Critical Factors Affected Units Appearance of Damage Mitigation
Erosion/ Erosion- Corrosion contributes All Metals/ Alloys Velocity & Conc of Having Moving Localised loss in thk- pits, Best- More corrosion
Corrosion to erosion by & Refractories Particles, Softer Fluids,,downstree grooves, gullies, waves, resistant alloys or
removing protective Material (Cu, Al), m of pumps rounded holes & valleys, altering process,
films/scales Temp, PH Directional, Failure in Short Improved design,
time Hardfacing,
1 Impingement plate

Mechanical Fatigue Cyclic Mechanical or All Engineering Design, C-LAS below Daily Operation Clam Shell type fingerprint Best- Good Design
Thermal loading even alloys Endurance 0.4 to 0.5 having concentric ring called Low stress stamps
below Y.S. UTS, 300 & 400 series beach marks & marking
2 & Al 106 to 107 cycles

Galvanic corrosion corrosion that can all metals except conditions- condutive fluid crevice, roove or pitting good design, coating
occur at the junction noble metals anode,cathode, and alloys are corrosion depend on driving to more noble
of dissimilar metals electrolyte,electrical coupled force. material.
connection.farther the
3 table more protection
to cathode

Atmospheric Marine & moist CS, LAS Physical location, Poor paint/ Localized, If no coating then Surface Preparation
Corrosion polluted indutrial & Copper alloyed Marine 20mpy, coating General & Proper Coating
Al Industrial 5-10 , Rural
4 <1, Temp upto 250 oF

CUI Trapped water under CS, LAS, 300 series Intermittent all temp, All insulated C & LAS- Localised pitting, Proper Painting/
Insulation & Duplex Most severe 212oF to piping & 300 series SCC, Flaky scale Coating , good
350oF Equipment insultn, Al foil
wrapped SS piping,
5 Closed-cell foam
glass, Low Cl insl for
300
S.N Damage Affected Prevention/
O. Mechanism Description Material Critical Factors Affected Units Appearance of Damage Mitigation
Cooling Water Dissolved salts, gases, CS, All SS, Cu, Al, Ti Increase in cooling Water cooled HX General corrosion, Pitting, Proper design,
Corrosion organic compounds & Ni alloys water outlet temp, & Cooling towers MIC, SCC & fouling, ERW operation & chemical
or microbiological Fresh water above grooving treatment, Inlet
activity 140oF & Brackish Salt temp < 140oF,
water above 115oF, Periodic cleaning of
6 Low Velocities 3fps, Ti tubes
> 180oF hydriting
embrittlement

Caustic Corrosion Localised corrosion CS, LAS & 300 NaOH or KOH Boilers, Steam Localized metal loss, grooves Proper design, water
due to Alkaline salts series Generators in boiler tubes, Local flooding, Ni base
thinning under insulation, CS
corrosion >175oF very high>
7 200oF, 300 series > 150oF

Sulfidation or Sulfur at high temp, All Iron base Temp > 500oF . Crude, FCC, Uniform thinning or localized Upgrading to higher
Sulfidic Corrosion H2 Presence including SS, Ni Increased resistance Coker, Vacuum corrosion Cr Alloy
base & Cu base by Cr in 300 series & Ni
8 alloys

Cl SCC Surface initiated All 300 series SS, Temp > 140oF, PH >2, All 300 series Surface break cracks, Use resistant
cracks under stress, Duplex SS. Ni 8% to 12%. Ni above piping & Branches Material, Low Cl in
temp & aqueous Cl Ni alloys are highly 35% highly resistant, equipment hydro, High temp SR
envnmt resistant CS, LAS 7 400 series for 300 series
9 not susceptible

Caustic SCC or Surface initiated CS, LAS & 300 Caustic 50 to 100ppm Caustic & H2s on BM parallel to weld. Can PWHT >1150oF,Use
Caustic cracks exposed to series Ni alloys are Service also occur on WM or HAZ, Ni alloys, Avoid
embrittlement Caustic adjacent to resistant Spider web steamout of Non
non PWHT'd welds PWHT pipes
10

11 HCl Corrosion

12 Sour Water
Corrosion
S.N Damage Affected Prevention/
O. Mechanism Description Material Critical Factors Affected Units Appearance of Damage Mitigation
Amine Stress TS & corrosion in CS & LAS Residual stresses from All non PWHT'd Cracks parallel to welds, In PWHT, Use SS, Water
Corrosion Cracking aqueous welding, cold working, piping & WM transverse or wash
alkanolamine systems lean amine services & equipments in Longitudinal
to remoe H2S or CO2, Wet H2s lean Amine
Alkaline SCC, adjacent Services
13 to Non PWHT'd CS
welds

Wet H2s Damage Hydrogen Blistering- CS & LAS Minimum at PH7, Wet H2S service SOHIC & SSC associated with SSC eliminated by
(Blistering/ HIC/ Bulging, H2 generated Blistering, HIC & SOHIC throughout Weldments PWHT & SOHIC
SOHIC/ SSC) by Corrosion above ambient > refinery reduced
HIC- Stepwise 150oF, SSC below
Cracking 180oF SSC BHN <
SOHIC- Array of cracks 200HB less susceptible
stacked, through
thickness SSC-
14 Stress, corrosion, H2O
& H2S

HTHA CH4 formation. CS & LAS. 300 Series, Cr>5% are Hydroprocessing Metallographic Analysis Use of High Cr & Mo
Carbide loss, Increasing Cr not Susceptible Units or other Stabilizing
Methane pressure reduces elements Tungsten &
15 forms cracks Susceptibility Va,
Inspection/
Monitoring Remarks
Visual, UT, RT,
Corrosion coupons
IR
Scan for refractory
loss

PT, MT, SWUT

VT & UT

VT & UT

Stripping, UT, X-Ray,

Neutron backscatter,
Eddy-current, IR
thermography &
guided wave UT
Inspection/
Monitoring Remarks
Cooling water O2, PH,
outlet temp
EC or IRIS of
tubes

UT, RT

Monitoring process Fig 4-144

conditions, PMI for
programs Corrosion
Vs temp

PT or phase analysis
EC, UT

WFMT, EC, RT or Fig 4-146

ACFM PT not for
effective Caustic
Soda
Service
graph
Inspection/
Monitoring Remarks
WFMT or ACFM
PT not effective

WFMT, EC, RT or
ACFM PT not
effective
Surface prep by grit or
high pressure water
blasting

UT & AUBT