All about Failure Mechanisms of C-steels according to API 571 Eng/ mohamed fawzy

Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Creep and Creep at Temperature 1. All metals 1. Material 1. Heater tubes 1. Hardening 1. Design Visual API 571:
Stress >370˚C depending on 2. Low creep 2. Load in fired heaters 2. Creep voids 2. Material UT,RT,EC, Chapter: 4.2.8
Rupture material. Deformation ductility 3. Temperature 2. Tube support at grain bound. Selection WFMT Table 4-2
(API 571/ may lead to a rupture 3. Cut of 3. Other furnace 3. fissures 4. PWHT Figure:4-9, 4-10
GALIOM) Related Mechanism: remaining internals 4. cracks API 579: G.3.5
1.Short term overheat. life 4. HAZ (bulging) Subsurface Crack.
Stress Rupture and Microfissuring
2. Reheat cracking Microvoid Format.
in heavy wall equipm.

Mechanical sudden, unexpected 1. All metals1. Geometrie 1. small concentric 1. Good Design PT, MT and API 571:
Fatigue failure exposed to 2. Stress level (Temp.) nozzles rings (waves) 2. Material SWUT Chapter: 4.2.16
(API 571) cyclic stresses for an 2. Fatigue 3. Number of cycles 2. rotating emanating Selection (shear wave Fig. 4-29 to 34
Corrosion extented period limit 4. Material strength shafts on from the crack 3. Minimize US testing)
Fatigue 5. Material Hardness pumps and initiation site weld defects Vibration API 579:
Cracking Related Mechanism: 3. Endurance 6. Material Mikrostruct. compressors 4. use of UIT Monitoring G.3.4 Surface
(GALIOM) Vibration induced limit 5. Min. Stress connected
consider fatigue,Thermal fatigue concentration cracking
also Therm.
Vibration
Fatigue(API
Erosion/ Erosion: 1. All metals 1.Velocity 1. Bends localized loss 1. Geometry 1. Visual API 571:
Erosion- mechanical removal 2.Hardness 2.Concentration of 2. Tees in thickness, 2. Material inspection Chapter:4.2.14
Corrosion of surface material of the impacting medium 3. Reducers in the form of Selection of suspected Table: 4-3
(API 571/ Erosion- Corrosion: surface 3. Size and hardness 4. Nozzles pits, grooves, 3. Surface areas Fig. 4-23,-24,-25
GALIOM) removing protective 3. Free of impacting particles 5. Valves waves, rounded Hardening 2. UT, RT
films corrosion 4. Hardness and 6. Pumps holes and 4.Inhibitors (metal loss) API 579:
Related Mechanism: potential corrosion resistance 7. Heatexch. valleys G.3.3 Localized
Cavitation, Fretting (V) 5. Angle of impact metal loss
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Reheat Cracking of a metal 1.Low alloy 1. Chemical composit. 1. Heavy wall Reheat cracking 1. Minimize 1. Surface API 571:
Cracking due to stress steels 2. Impurity elements vessels in areas is intergranular restraint during cracks:UT,MT Chapt.: 4.2.19
(API 571/ relaxation during 2. Loss of 3. Grain size of high restraint and can be welding and 2. Embedded API 579:
GALIOM) PWHT or in service toughness 4. Residual stresses including surface breaking PWHT. cracks: UT G.3.4./3.5.
at elevated temperat. 3. Intergran. (cold working, welding) nozzle welds or embedded 2. Small grain Surface and Sub-
It is most often cracking 5. Section thickness and heavy wall depending on size surface Cracking
observed in heavy wall 6. Notches and stress piping. the state of 3. UIT to weld
sections. concentrations 2. High strength stress and toe
low alloy are geometry.
very susceptible

Galvanic occur at the junction 1. Free 1. Electrolyte any unit 1. General 1. no contact 1.Visual API 571:
Corrosion of dissimilar metals corrosion 2. Two different where there metal loss 2. Coating inspection Chapter: 4.3.1
(API 571/ when they are joined potential materials is a 2. Crevice (the more noble 2. UT Table: 4-4
GALIOM) together in a suitable (anode/cathode) conductive 3. Groove material should Thickness Fig. 4-36/-37
electrolyte. 3. Electrical connection fluid and 4. Pitting be coated)
Related Mechanism: between the anode and alloys are 3. electric API 579: G.3.3
Soil corrosion cathode coupled. insulating General or local
4. cathodic metal loss, Pitting
protection
Atmosph. occur from moisture 1. Free 1. Physical location 1. any unit 1. general or 1. Surface 1.Visual API 571:
corrosion associated with corrosion (marine) 2. under poor local metal loss preperation inspection Chapter: 4.3.2
(API 571/ atmospheric potential 2. Moisture coating 2. Localized and proper 2. UT
GALIOM) conditions. (humidity) system coating failure coating Thickness API 579: G.3.3
Marine environments 3. Temperature 3. low temp. will tend to application General or local
are most severe. 4. not used promote metal loss, Pitting
component corrosion
Related Mechanism: 5. open to
Corrosion under atmosphere
isulation
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Corrosion resulting from water 1. Free 1. Design of insulation 1. any unit often appears 1. High quality 1. Partial or API 571:
under trapped under corrosion system as loose, flaky coating full stripping Chapter: 4.3.3
Insulation insulation potential 2. Insulation typ scale covering 2. Selection 2. UT-Thickn. Fig. 4-38/-39
(CUI) fireproofing 3. Temperature the corroded of insulation 3. Real-time
(API 571/ 4. Environment component material Profile X-ray API 579: G.3.3
GALIOM) Humidity, rainfall, (closed-cell for small bore General or local
Related Mechanisms: chlorides from marine foam glass piping metal loss, Pitting
1. Atmospheric environment better than 4. Neutron
corrosion 5. Operating below the mineral wool) backscater
2. Crevice/Under water dew point 3. Calcium or IR
Deposit Silicate insul. termography
contain identifying
chlorides wet insulation
4. inspection 5. Guided
plan wave UT
6. Deep
penetrating
Eddy-current

Cooling General or localized 1. Free 1.Fluid Temperature cooling water cooling water 1.Proper design Inspection API 571:
Water corrosion caused by corrosion (increasing temp. tend corrosion is corrosion can 2.Operat. Data depending Chapter: 4.3.4
Corrosion dissolved salts, potential to increase corr.-rate a concern result in many 3.Chem.treatm. on the Fig. 4-40
(API 579/ gases, organic and fouling) with water- different forms 4.Water velocity Morphology
GALIOM) compounds or 2. Type of water cooled heat of damage incl. 5.Periodic of Failure API 579:
don't use microbiological (fresh, brackish, salt) exchangers 1. General corr. mechanical G.3.2. General
activity >60˚C for fresh, >46˚C and cooling when dissolved cleaning of tube G.3.3. Localized
for brackish and salt towers in all oxygen is ID's and OD's Metal Loss
Related Mechanisms water cause scaling applications present. 6. Minimize
1. Microbiologically 3. Type of cooling syst. 2. Local corr. stagnant areas
induced corrosion (once-through, open from under-
(MIC) circulating, closed circ.) deposit, MIC
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
continue 2. Chloride stress 4. Oxygen content 3. Pitting corr.
Cooling corrosion cracking (increasing oxygen 4. MIC
Water 3. Galvanic corrosion content tends to 5. SCC
Corrosion increase corr.-rates) 6. Fouling
(API 579/ 5. Fluid velocities
GALIOM) <1m/s are likely to
don't use result in fouling,
sedimendation and
increased corr.-rates.
6. Fouling occur from
mineral deposits, silt,
suspended organic
materials, corrosion
products, mill scale,
marine and mircro-
biological growth

CO2 CO2 Corrosion results 1. Free 1. Partial Pressure of 1. Welds 1. Localized 1. Optimizing 1.VT, UT and API 571:
Corrosion when CO2 dissolves corrosion CO2. Increasing partial 2. Bends thinning and/or Process data RT inspection Chapter: 4.3.6
(API 571/ in water to form potential pressure of CO2 3. Reducer pitting corrosion 2. Corrosion techniques Fig.: 4-41 to 44
GALIOM) carbon acid (H2CO3) result in lower pH 4. Tees 2. deep pitting inhibitors should focus API 579:
The acid may lower condensate and higher 5. Nozzles and grooving in steam on general G.3.2 General
the pH and sufficient rates of corrosion. (1.-5 are in areas of condensate or local loss G.3.3 Localized
quantities may 2. Corrosion occurs in turbulent turbulence systems. in thickness Metal Loss
promote general the liquid phase, often areas of flow 3. material where water
corrosion and/or at locations where CO2 regime) selection wetting
pitting corrosion condenses from the 6. Bottom of (300 series SS is anticipated.
vapor phase. pipe/ are highly 2. Preferential
3. Increasing equipment resistant) corrosion of
temperature increase (as the 4. increase of weld seams
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
continue Related Mechanisms corrosion rate up to the density of PH >6 may require
CO2 1. Boiler water point where CO2 is water is angle probe
Corrosion condensate corrosion vaporized. larger than UT or RT.
(API 571/ 2. Carbonate cracking 4.In absence of of oil).
GALIOM) moisture is CO2 a non- 7. Dead legs
corrosive gas. 8. Top surface
5. Whether or not free of the pipe if
water will be present condensation
in crude oil and gas in wet gas
depends upon factors systems is
as the water cut, flow anticipated
regime and process
parameters.

Flue-Gas 1. Sulfur and chlorine C-Steel, 1. Concentration of 1. All fired 1. General 1. Wall thick- API 571:
Dew-Point species in fuel will C-Cr-Mo-St. contaminants (sulfur and process heaters wastage often ness: UT Chapter: 4.3.7
Corrosion form sulfur dioxide, chlorides) in the fuel and boilers that with broad,
(API 579/ sulfur trioxide and 2. Operating Temp. burn fuels shallow pits, API 579:
GALIOM) hydrogen chloride 3. Dewpoint of sulfuric in the econo- depending on G.3.3 Localized
within the combustion acid depends on the mizer sections the way the Metal Loss
products. concentration of sulfur and in the sulfuric acid
2. At low enough trioxide (about 138˚C). stacks. condenses.
temperature, these 4. Dewpoint of hydro-
gases and the water chloric acid (about 54˚C)
vapour in the flue gas
will condense to form
sulfurous acid, sulfuric
acid and hydrochloric
acid which can lead
to severe corrosion.
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Micro- corrosion caused by 1. Free 1. Where water is 1. Heat 1. localized 1. Application 1. Measuring API 571:
biologically living organisms such corrosion present exchangers pitting under of biocides biocide Chapter: 4.3.8
Induced as bacteria, algae or potential 2. stagnant or low-flow 2. Bottom water deposits or 2. minimize residual, Fig.: 4-45 to -50
Corrosion fungi. It often 3. Organisms can of storage tanks tubercles that low flow or microbe API 579:
(MIC) associated with the survive and grow under 3. Piping with shield the stagnant zones counts and G.3.3 Localized
(API 571) preence of tubercles severe conditions incl. stagnant or organisms. 3. Wrapping visual Metal Loss
or slimy organic a. lack of oxygen low flow 2. cup-shaped and appearance.
Biological substances b. light or dark 4. Piping in pits cathodically 2. Special
Corrosion c. high salinity contact with protecting probes have
(GALIOM) Related Mechanisms: d. PH range: 0 to 12 some soils underground been designed
Cooling water e. Temperature: 0˚ to 5. Open and not structures to monitor for
corrosion 235˚F (-17˚ to 113˚C) used component have been evidence of
4. Organisms thrive on 6. Product effective in fouling which
different nutrients incl. storage tanks preventing may precede
inorganic substances and water MIC. or coincide
(e.g. sulfur, ammonia, cooled heat with MIC
H2S) and organic exchangers damage
substances (e.g. in any unit 3. An increase
hydrocarbons, organic where cooling in the loss of
acids). In addition, all water is not duty of a
organisms require a properly treated heat exchang.
source of carbon, 7. Fire water may be
nitrogen and phosphor. systems indicative of
for growth. fouling and
5. In-leakage of process potential MIC
contaminants such as 4.VT, UT and
hydrocarbons or H2S RT
may lead to a massive
increase in biofouling
and corrosion
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Soil The deterioration of 1. Free 1. Temperature 1. Bottom of 1.localized loss 1. Coating 1.Visual API 571:
Corrosion metals exposed to corrosion 2. Moisture storage tanks due to pitting 2. Cathodic inspection Chapter: 4.3.9
don't use soils is refered to as potential 3. Oxygen 2. Production 2. Poor protection 2. UT, RT Fig.: 4-51 to -53
soil corrosion. 4. Soil resistivity Separator condition of a
5. Soil type protective
6. Cathodic protection coating is a
Related Mechanisms 7. Coating type,age, tell tale sign of
Galvanic corrosion condition potential
8. Soils having high corrosion
moisture content, high damage.
dissolved salt concentr.
and high acidity are
usually the most
corrosive.
9. Soil-to-air interface
areas are often much
more susceptible to
corrosion than the rest
of the structure because
of moisture and oxygen
availability.
10. corrosion rates
increase with increasing
metal temperature
11. Other factors
a. galvanic corrosion
b. dissimilar soils
c. stray currents
d. differential aeration
corrosion cells
e. MIC
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Caustic Localized corrosion 1. Free 1. Presence of caustic 1. Boilers 1.Localized 1. Design 1.For process API 571:
Corrosion due to the corrosion (NaOH or KOH) 2. Steam metal loss 2. Process equipment, Chapter:4.3.10
(API 579) concentration of potential 2. Caustic is sometimes generating which may 3. In process UT thickness Fig.: 4-54 to 55
Caustic caustic or alkaline added to process equipments appear as equipment, gauging is
Corrosion salts streams for neutralizat. incl. heat grooves in a caustic useful to API 570:
and SCC 3. Caustic solutions exchangers boiler tube or injection detect general Chapter:5.3.1
(GALIOM) Related Mechanisms: for removal of sulfur 3. Where locally thinned facilities should corrosion. Injection points
consider Steam Blanketing compounds caustic is added areas under be designed Localized
also 4. A concentrating to crude unit insulating to allow proper losses may
Caustic mechanism must exist charge deposits mixing and be difficult
SCC to built up the caustic 4. Accelerated 2. Deposits may dilution to locate.
(API 579) strength localized corr. fill corroded of caustic in 2. Injection
5. Caustic may become in preheat depressions order to avoid points should
concentrated by exchangers, and mask the be inspected
evaporation and furnace tubes damage below. concentration in acc. with
deposition and transfer Probing suspect of caustic on API 570
6. Exposure to high lines, unless areas with a hot metal 3. UT scans
solution strength caustic the caustic is sharp instrument surface and RT
can result in general effective mixed may be required 4. Steam
corrosion above 175˚F in the oil stream 3. Localized generation
(79˚C) and very high 5. units use gouging may equipment
corrosion rates above caustic for result along a may require
200˚F (93˚C) removing waterline where visual inspect.
sulfur corrosive with the use a
compounds. concentrate. boroscope.
In vertical tubes
circumferential
in horizontal at
the top or
longitudinal.
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Oxidation Oxygen reacts with C-Steel, 1. Temperatur >538˚C fired heaters and 1. General 1. Material UT API 571:
(API 571) C-steel at high temp. C-Cr-Steel 2. Alloy Composition. boilers as well 2. covered out- selection Chapter 4.4.1
High converting the metal as other side surface Table 4-6:
Temperat. to oxide scale. combustion with oxide scale Corrosion Rates
Corrosion It is most often equipment Fig. 4-62 to 4.64
(GALIOM) present as oxygen in
the surrounding air API 579:
used for combustion G.3.2. General
in fired heaters/boilers metal loss

Sulfidation Corrosion of C-steel C-Steel, 1. Temperatur >260˚C 1.Heaters fired 1. General 1. Material UT,RT API 571:4.4.2
(API 571) resulting from their C-Cr-Steel 2. Alloy Composition. with oil, gas 2. localized selection Fig. 4-65/66
High Temp. reaction with sulfur 3. Concentration of 2. Boilers 3. high velocity Corr.-Rates
H2 S compounds in high corrosive sulfur comp. 3. Piping erosion-corr. Fig. 4-67
Corrosion temp. environments. 4. Sulfidation is primarily 4. sulfide scale API 579/G.3.2/3
(GALIOM) caused by H2S General/Localized
Metal loss
Carburi- Carbon is absorbed 1.C-Steel, 1. Temperatur >593˚C 1.Fired heater 1. Increase of 1. Material Initial stage: API 571: 4.4.3
zation into a material at C-Cr-Steel 2. Alloy Composition. tubes hardness selection Hardness Fig.4-68/69
(API 571/ elevated temp. while 2.loss of high 3. Carburizing environm. 2. loss in EC
GALIOM) in contact with a temperature or carbonaceous mater. ductility Advanced API 579/G.3.6
carbonaceous mater. creep 4. Hydrocarbons, CO, 3. volumetric stage:cracks Metallurgical
or carburizing environ. ductility; CO2, methane,ethane increase RT,UT,MP Changes
Initially, carbon diffuse 3.loss of 5. Low O2 or steam
into the component at ambient temp
a high rate and then mech. Prop.
tapper off as the depth 4. loss of
of carburization weldability
increases. 5. loss of
Related: Metal dusting corros. resis.
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Decarbu- A condition where 1.C-Steels 1. Time 1. Components 1.The decarbur. 1. Material Hardness API 571:
rization steel loses strength C-Cr-Steels 2. Temperature exposed to layer will be free selection Chapter 4.4.4
(API 579/ due the removal of 2. loss in 3. Carbon activity of the elevated temp., of carbide
GALIOM) carbon and carbides room temp. process stream; gas heat treated or phases. API 579: G.3.6
leaving only an iron tensile phase (H2, CO2 ) that exposed to Metallurgical
matrix. Decarburizat. strength has a low carbon activity fire. Changes
occurs during 3. loss in so that carbon in the 2. Piping in hot
exposure to high creep steel will diffuse to the hydrogen service
temperatures, during strength surface to react with gas 3. fired heater
heat treatment, from phase constituents. tubes
exposure to fire, or 4. Pressure
from high temperature vessel comp.
service in a gas envir. hot formed

Related Mechanism:
High temperature
Hydrogen Attack
(HTHA)

Metal Metal dusting is a see see see see see see see
Dusting form of carburization Carburization Carburization Carburization Carburization Carburization Carburization Carburization
(API 571/ resulting in accelerat.
GALIOM) localized pitting which
don't use occurs in carburizing
gases and/or process
streams containing
carbon and hydrogen.
Pits usually form on
the surface and may
contain soot or
graphite dust.
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Corrosion A form of fatigue 1. Free 1. Corrosive environment 1. Rotating 1. The fatigue 1. Using 1. cracking API 571:
Fatigue cracking in which corrosion 2. Cyclic stresses Equipment fracture is brittle coatings and is generally Chapter: 4.5.2
(API 571) cracks develop under potential 3. Cracking is more 2. Deaerators and the cracks and/or detected with Fig.: 4-83 to 84
Corrosion the combined affects 2.Endurance likely to occur in 3. Cyclic Boilers are most often inhibitors WFMT (wet
Fatigue of cyclic loading and limit environments that 4. any equipm. transgranular, 2. Minimize fluorescent API 579:
cracking corrosion. promote pitting or subjected to as in stress- residual magnetic G.3.4 Surface
(GALIOM) Cracking often localized corrosion cyclic stresses corrosion welding and particle testing connected
consider initiates at a stress under cyclic stress due cracking, but not fabrication 2. Many of the cracking
also concentration such as to thermal stress, branched, and stresses cracks are
Thermal a pit in the surface. vibration or differential often results in through PWHT. very tight and
and Cracking can initiate expansion propagation of 3. Minimize difficult to
Mechanical at multiple sites. 4. Contrary to a pure multiple weld reinforce- detect.
Fatigue mechanical fatigue, parrallel cracks. ment by 3. Cracking
of API 571 Related Mechanisms: there is no fatigue limit 2. Fatigue grinding weld may occur at
Mechanical fatigue load in corrosion- cracking will be contours the
Vibration induced assisted fatigue. Corr. evidenced by smooth. membranes
fatigue promotes failure at a very little plastic Better is in the highly
lower stress and number deformation Ultrasonic stressed
of cycles than the except that final Impact Treatm. regions,
materials' normal fracture may (UIT) or WIG- particularly
endurance limit in the occur by dressing corners at
absence of corrosion mechanical buckstays.
and often results in overload
propagating of multiple accompanied
parallel cracks. by plastic
5. Cracks initiation sites deformation.
include concentrators
such as pits, notches,
surface defects,
changes in section or
fillet welds.
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Caustic Caustic embrittlement 1. Free 1. Caustic Strength 1. Equipment 1. cracking 1. PWHT 1. Although API 571:
Stress is a form of stress corrosion Cracking can occur at that handles typically 2. Steamout cracks may Chapter: 4.5.3
Corrosion corrosion cracking potential low caustic levels if a caustic, incl. propagates of non-PWHT'd be seen Fig.4-85 to 92
Cracking characterized by concentrating mechan. H2S removal parallel to the carbon steel visually, crack
(Caustic surface-initiated is present. units. weld in adjacent piping and detection is API 579: G.3.4
Embrittle- cracks that occur in Concentration can occur 2. Equipment base metal but equipment best perfored Surface connect.
ment) piping and equipment as a result of alternating that uses can also occur should be with WFMT cracking
(API 571) exposed to caustic, wet and dry conditions, caustic for in the weld avoided. (wet flouresc.
Caustic primarily adjacent to localized hot spots or neutralization deposit or HAZ Equipment magnetic
Corrosion non-PWHT'd welds high temperature steam- in sulfuric acid 2. sometimes should be particle test.),
and SCC out. and HF described as a water washed RT, ACFM
(GALIOM) In such cases, caustic alkylation units. spider web of before steam- (alternating
consider Related Mechanisms: concentrations of 50 to 3. Caustic is small cracks. out. current
also Amine cracking 100 ppm are sufficient sometimes 3. oxide-filled 3. Proper magnetic
Caustic Carbonate cracking to cause cracking. injected into the cracks design and flux leakage
Corrosion 2. Metal Temperature feed (Inlet) to the operation of the testing).
(API 571) Crack propagation rates crude tower injection 2.PT (Liquid
increase dramatically for chloride system is penetrant
with temperature. control. required to testing) is not
3. Stress Level ensure that effective for
Stresses that promote caustic is finding tight,
cracking can be residual properly scale-filled
that result from welding dispersed cracks and
or from cold working before should not be
(such as bending and entering the used for
forming) as well as high-temp. detection.
applied stresses. crude preheat 3. Crack
(Temp. and Stress system. depths with
causing caustic embritt. shear wave
see Fig.4-85). UT (SWUT)
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
Ammonia Carbon steel is 1. Harness 1. Anhydrous ammonia 1. Ammonia is 1. Cracking will 1. PWHT 1. WFMT API 571:
Stress susceptible to SCC > 225 BHN with < 0.2% water will present as a occur at 2. Addition of welds inside Chapter: 4.5.4
Corrosion in anhydrous cause cracking in process exposed non- small quantit. tanks Fig.: 4-93 to 95
Cracking ammonia. C-Steels. contaminant PWHT welds of water to the 2. External
(API 571) 2. PWHT eliminates in some and HAZ ammonia (0.2% UT Shear API 579: G.3.4
Ammonia Related Mechanism: susceptibility of most services or may 3. Hardness wave Surface connect.
Corrosion not applicable common steels (< 70 be intentionally ≤ 225 BHN cracking
and SCC ksi =482 Mpa) added as an 4. prevent
(GALIOM) 3. Contamination with acid neutralizer ingress of
air or oxygen increases2. ammonia oxygen into
tendency toward storage tanks, storage
cracking piping and facilities.
equipment in
ammonia
refrigeration
units.
Hydrogen A loss in ductility of 1.Loss of Three conditions must 1.Mild steel 1.Cracking due 1. Use lower 1. For suface API 571:
Embrittlem. high strength steels ductility be satisfied: for vessels and to HE can strength steels cracking Chapter: 4.5.6
(HE) due to the penetration 2. C-Steel 1. Critical concentration piping in most initiate sub- 2. PWHT use PT Fig. 4-99
(API 571/ of atomic hydrogen with ≥22 HRC of hydrogen within steel. refining, process surface, but in 3. Use low (liquid penetr.
GALIOM) can lead to brittle Hydrogen can come from applications most cases is hydrogen, dry testing), MT ISO 15156-1/2
cracking. HE can Welding-if wet electrode have low hard- surface breaking electrodes and (magnetic Petroleum and
occur during are used. ness and are 2. HE occurs preheating particle test.) natural gas
manufacturing, High temper. Hydrogen usually not at locations of methods. or WFMT industries-
welding, or from gas atmospheres. susceptible to high residual or (wet flouresc. Materials for use
services that can Wet H2S or HF acid. HE (Pipe and tri-axial stresses magn. Part. in H2S containing
charge hydrogen into If the partial pressure Pressure vessel (notches, testing) environments in
the steel in an of H2S in the gas is steels classified restraint) and 2. UT may oil and gas
aqueous, corrosive, ≥ 0,3 kPa (0,05 psi) as P-No.1, where the also be useful production
or a gaseous SSC (Sulfide stress Group 1 and 2. microstructure in finding HE Part 1:
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
continue environment. cracking)- resistant in Section IX of is conducive, cracks. General principles
Hydrogen steels, selected using ASME Boiler a. such as in weld 3. RT often is for selection of
Embrittlem. Related Mechanisms: Annex A.2 of ISO 15156 Pressure vessel HAZ's (≤22 HRC not sufficiently cracking-resistant
(HE) 1. hydrogen flaking Part 2, shall not show code. is acceptable). sensitive to materials.
(API 571/ 2. underbead cracking HE. 2. HAZ of welds detect HE Part 2:
GALIOM) 3. delayed cracking 2. Strength level and if not PWHT is cracks cracking-resistant
4. hydrogen assisted microstructure must be done. carbon and low
cracking susceptible to 3. Bolts and alloy steels, and
5. hydrogen induced embrittlement. SSC- springs made the use of cast
cracking. resistant steels shall of high stength irons
6. Sulfide stress not show HE. steel are very
cracking 3. A stress above the prone to HE. API 579:
7. Hydrogen stress threshold of HE must be G.2. Pre-Service
corrosion cracking present from residual Deficiencies
stresses and/or applied G.3.5 Subsurface
stresses. Cracking

Amine general and/or local Primarily 1. Type of amine used 1. all units to General uniform 1. proper 1. visual and API 571:
Corrosion corrosion that occurs C-steel From most aggressiv to remove H2S, thinning, operation UT Thickness Chapter: 5.1.1
(API 571/ principally on carbon least: MEA,DGA,DIPA, CO2 and localized 2. temperature 2. UT scans Fig. 5.1
GALIOM) steel in amine treating DEA,MDEA mercaptans corrosion or limits or profile
processes. 2. Amin-Concentration (a sulfur-contain localized 3. Oxygen radiography API 579: G.3.3
Corrosion is not >2% HSAS organic comp.) underdeposit inleakage are used for Localized metal
caused by the amine 3. Temperature 2. Regenerator attack. causes high external loss
itself, but results from Corr. Rates increase reboiler and Localized if the corrosion rates inspection.
dissolved acid gases with Temperature regenerator velocity is high and contributes 3. hot areas
(CO2 and H2S), amine 4. Process stream 3.The rich amine or with to HSAS. such as the
degradation products, velocity. Corrosion is side of the lean/ turbulence. 4. Filtration reboiler feed
Heat Stable Amine generally uniform reach exchanger of solids and and return
Salts (HSAS) and however high velocities hot lean amine hydrocarbons line, the hot
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
continue other contaminants. (>2 m/s for rich amine piping, hot rich from amine lean/rich
Amine and >6 m/s for lean amine piping, solution. amine piping,
Corrosion Related Mechanisms: amine) and turbulence the amine 5. Corrosion the stripper
(API 571/ Amine stress corr. will cause localized solution pumps, inhibitors overhead
GALIOM) cracking thickness loss. reclaimer condenser
piping.

Ammonium Aggressive corrosion Carbon 1. NH4HS-concentration 1. NH4HS salts 1.General 1. Flow regime 1. UT scans API 571:
Bisulfide occuring in hydro steel is < 2 wt% solutions not precipitate in metal loss with 2. Relation and/or RT Chapter: 5.1.1.2
Corrosion processing reactor less generally corrosive. the reactor potential for between profile thickn. Fig.: 5-2
(Alkaline effluent streams and resistant 2. NH4HS salt deposits effluent streams extremely high concentration of high and
Sour in units handling lead to underdeposit when temperat. localized rates and velocity. low velocity API 579:G.3.3
Water) alkaline sour water corrosion and fouling. drop to within of wall loss if 3. velocity areas. Localized Metal
(API 571/ (localized corrosion). 3. Oxygen and iron in the range of turbulent flow between 2. UT Loss
GALIOM) the wash water injected 49 to 66˚C. > 2 wt%. 3 and 6 m/s. downstream
Related mechanisms: into hydroprocessing 2. Fouling and/ 2. Low velocity 4. C-steel may of control
Erosion/Erosion corr. reactor effluent can lead or velocity may result in be suceptible valves at high
to increased corrosion accelerated extremely to high corr. NH4HS
and fouling. corr. may be localized under- rates >8 wt% concentrat.
found at: deposit corr. if 5. Properly 3. RFEC
air cooler head insufficient design and (remote field
exchanger tubes water is maintain water eddy current
inlet and outlet available to wash injection testing) and
piping. dissolve the with low oxygen flux leakage
3. Piping into NH4HS salts content. inspection of
and out of the that precipitated steel air
reactor effluent 3. Heat cooler tubes.
separators. exchangers
4. Vapor line may show
from the high plugging and
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
continue pressure loss of duty due
Ammonium separators. to fouling.
Bisulfide 5. Hydrocarbon
Corrosion lines from
(Alkaline reactor effluent
Sour separators due
Water) to entrained
(API 571/ sour water.etc.
GALIOM)
Ammonium General or localized 1. Free 1. Concentration: 1. Crude tower 1.The salts have 1. Crude Unit: 1. Accumulat. API 571:
Chloride corrosion, often corrosion (NH3, HCl, H2O or overheads: a whitish, a.Limit salts by of ammonium Chapter: 5.1.1.3
Corrosion pitting, normally occur potential amine salts) tower top, top greenish or limiting chloride salts
(API 571) under ammonium 2. PRE 2. Temperature: trays, overhead brownish chlorides in the can be very
chloride or amine salt (Pitting Ammonium chloride piping, exchang. appearance. tower feed localized and
don't use deposits, often in the resistant salts may precipitate may be subject Water washing through the resulting
absence of a free equivalent) from high temperature to fouling and and/or steamout desalting and/ corrosion may
water phase streams as the they are corrosion. will remove or the addition be difficult to
cooled, and may corrode Deposits may deposits so that of caustic to detect.
Related Mechanisms: piping and equipment occur in low evidence of the desalted 2. RT, UT
HCl corrosion at temperature well flow zones due fouling may not crude. tickness
above the water dewpoint to ammonia and be evident b. A water Monitoring
(149˚C). or amine during an inter- wash may be
3. Ammonium chloride chloride salts nal visual required in the
salts are hygroscopic, condensing inspection. crude tower
and readily absorb water from the vapor 2. Corrosion overhead line
A small amount of water phase. underneath the to flush the
can lead to very 2. Hydroprocess salts is typically salt deposits.
aggressive corrosion Reactor effluent very localized c. Filming
(>100mpy or >2,5 mm/y streams. and results in amine inhibitor
4. Some neutralizing pitting. are often added
amines react with 3. Corrosion to control corr.
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
continue chlorides to form amine rates can be 2.Hydroprocess
Ammonium hydrochlorides that can extremely high a.Limit
Chloride act in a simular fashion. chlorides in the
Corrosion 5. Corr. Rates increase hydrocarbon
(API 571) with increasing temp. feed to the
reactor and the
make-up
hydrogen
supply.

High Temp. The presence of C-Steel, 1. Temperatur >260˚C 1. Hydro- 1. General 1. Material UT,RT API 571:5.1.1.5
H2/H2S hydrogen in H2S C-Cr-Steel 2. Alloy Composition. processing selection Fig. 5-3/4
Corrosion streams increase the Cr-Mo-Steel 3. Prensence of H2 Corr.-Rates
(API 571/ severity of high temp. 4. Concentration of H2S Tab. 5-1
GALIOM) sulfide corrosion. When H2 is present in API 579/G.3.2
don't use significant quantities, General
Related Mechanism: corrosion rates are Metal loss
Sulfidation higher than those
associated with high
temp. sulfidation in the
absence of H2.

Sour Water Corrosion of steel due C-Steel 1. H2S content 1. General 1. Material UT,RT API 571:5.1.1.10
Corrosion to acidic sour water 2. pH Thinning selection
(Acidic) cointaining H2S at a 3. Velocity 2. Localized API 579:G.3.2/3
(API 571/ pH between 4.5 and 7. 4. O2 concentration 3. under deposit General and
GALIOM) CO2 may also be 5. <4.5 pH corrosion Localized metal
present. Sour water 6. >4.5 pH thin FeS loss
containing significant layer limits corr. Rate
amounts of ammonia, a thicker, porous FeS
Failure Description Affected Mat. Critical factors Affected Appearance Prevention Inspection Remarks acc. to
Mechanism Properties related to service Units Morphology Mitigation Monitoring API 571 and 579
continue chlorides or cyanides layer can promote
Sour Water may significantly pitting under sulfide
Corrosion affect pH but are out- deposits.
(Acidic) side the scope of this 7. HCl and CO2 lower pH
(API 571/ mechanism. 8. Ammonia significantly
GALIOM) increases pH (alkalin
sour water and ammonia
bisulfide corrosion)
9. The presence of air or
oxidants may increase
the corrosion und
usually pitting or under
deposits.

Eng/ mohamed fawzy

1027004881