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The following mechanisms from API 571 are included on the exam

1. BRITTLE FRACTURE

2. MECHANICAL FATIGUE ( INCLUDING VIBRATION-INDUCED FATIGUE )

3. MICROBIOLOGICALLY INFLUENCED CORROSION (MIC)

4. ATMOSPHERIC CORROSION

5. SOIL CORROSION

6. SOUR WATER CORROSION

7. CORROSION UNDER INSULATION (CUI)

8. CAUSTIC CORROSION

9. CAUSTIC STRESS CORROSION CRACKING (CAUSTIC EMBRITTLEMENT)

10.CHLORIDE STRESS CORROSION CRACKING

11.SULFURIC ACID CORROSION

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 BRITTLE FRACTURE

Sudden rapid fracture under stress, no evidence of ductility or

plastic deformation

AFFECTED MATERIAL: - Carbon steel, Low alloy steel

CRITICAL FACTORS: - Size, Stress Concentration, temperature

AFFECTED EQUIPMENT: - Sand Polymer Plant, Storage Tank

APPEARANCE OF DAMAGE: - Straight, non-branching, chevron markings

PREVENTION / MITIGATION: - Special Heat Treatment, Impact testing

INSPECTION / MONITORING: - MT, PT, UT

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 MECHANICAL FATIGUE FALIURE

Components exposed to cyclical stresses, mechanical loading or

thermal cycling below yield strength.

AFFECTED MATERIAL: - All engineering Alloys

CRITICAL FACTORS: - material strength,Stress Level

AFFECTED EQUIPMENT: - Small nozzle, rotating shaft of pump

APPEARANCE OF DAMAGE: -“Clamshell” (“beach Mark”)

PREVENTION / MITIGATION: - Minimum stress Concentration,

INSPECTION / MONITORING: - PT, MT

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MICROBIOLOGICALLY INFLUENCED CORROSION

MIC caused by living organisms such as bacteria, algae, fungi, it

appears as a tubercles or slimy organic substance

AFFECTED MATERIAL: - Carbon steel, Low alloy steel,

Aluminum, Copper, Nickel

CRITICAL FACTORS: - Found in conditions of stagnant and low flow water,

lack of oxygen, high salinity

AFFECTED EQUIPMENT: -Heat exchangers, Storage tank bottoms, Stagnant or

Low flow piping systems

APPEARANCE OF DAMAGE: - Localized pitting,Cup shaped pits Subsurface cavities

PREVENTION / MITIGATION: - Water should be treated with biocides such as

chlorine, bromine, Cathodic protection,
Maintain flow velocities

INSPECTION / MONITORING: - Foul smell, VT

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 ATMOSPHERIC CORROSION

Atmospheric corrosion occurs from moisture associated with

atmospheric conditions

AFFECTED MATERIAL: - Carbon steel, Low alloy steel

Copper alloyed aluminum

CRITICAL FACTORS: - Location of plant, moisture,

presence of salts,Marine locations very
corrosive,
Dry rural location less corrosive

AFFECTED EQUIPMENT: - Water trapped under

pipe support , wind, rain

APPEARANCE OF DAMAGE: - Corrosion or loss in thickness

PREVENTION / MITIGATION: - Proper coating and surface preparation

INSPECTION / MONITORING: - VT

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 SOIL CORROSION
Deterioration of metals exposed to soils

AFFECTED MATERIAL: - Carbon steel, Cast Iron, Ductile Iron

CRITICAL FACTORS: - Moisture and oxygen in the Soil, Coating type,High moisture

AFFECTED EQUIPMENT: - Underground piping and equipment, Buried tanks

Ground supported structures

APPEARANCE OF DAMAGE: - Pitting Corrosion

PREVENTION / MITIGATION: - Most effective is a combo of is a coating

and cathodic protection

INSPECTION / MONITORING: - VT, UT

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 SOUR WATER CORROSION
Sour water corrosion occurs with H2S at a pH between 4.5 and 7.0

AFFECTED MATERIAL: - Carbon steel, Stainless steel

CRITICAL FACTORS: - Depends on H2S content, pH

AFFECTED EQUIPMENT: - Overhead systems of FCC and coker gas

fractionation plants that have a high H2S level

APPEARANCE OF DAMAGE: - General thinning,Pitting attack

PREVENTION / MITIGATION: - Copper and nickel are usually not

Susceptible (attacked)

INSPECTION / MONITORING: - UT

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 CORROSION UNDER INSULATION
Water trapped under insulation

AFFECTED MATERIAL: - Carbon Steel, Low alloy steel

CRITICAL FACTORS: - Design of insulating systems, insulation type

AFFECTED EQUIPMENT: - Units with a higher moisture content, cooling

towers, steam vents

APPEARANCE OF DAMAGE: - Appears as loose flaky scale covering the

Corroded component

PREVENTION / MITIGATION: - Maintain the insulation

Proper selection of insulation,
High quality coating

INSPECTION / MONITORING: - Neutron backscattering and

I R Thermography identifying wet
Insulation

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 CAUSTIC CORROSION

Caustic or alkaline salts occurs under evaporative condition

AFFECTED MATERIAL: - Carbon steel , Low alloy steel

CRITICAL FACTORS: - Presence of caustic (NaOH or KOH) ,temperature above

170ºF

AFFECTED EQUIPMENT: - Boilers, Steam generating equipment, Heat

exchanger

APPEARANCE OF DAMAGE: - Grooves in boiler

PREVENTION / MITIGATION: - Reduce the amount of caustic, control

temperature

INSPECTION / MONITORING: - VT, UT

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CAUSTIC STRESS CORROSION CRACKING
(CAUSTIC EMBRITTLEMENT)

Combination of tensile strength, temperature and caustic

environment

AFFECTED MATERIAL: - Carbon steel ,Low alloy steel , Nickel alloys

CRITICAL FACTORS: - Depends on caustic strength levels, metal temperature,

and stress levels

AFFECTED EQUIPMENT: - Piping Corrosion

APPEARANCE OF DAMAGE: - Cracks parallel to the weld in adjacent to the

Weld

PREVENTION / MITIGATION: - Proper heat treatment, control caustic,

temperature, stress

INSPECTION / MONITORING: - VT ,WFMT

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 CHLORIDE STRESS CORROSION CRACKING
Caused by the action of tensile stress, temperature, and an aqueous
chloride environment

AFFECTED MATERIAL: - 300 SS , Duplex SS ,Nickel alloys

CRITICAL FACTORS: - Chloride content, temperature, stress ,
alloy composition

AFFECTED EQUIPMENT: - All 300 SS piping and pressure vessel components ,

Water cooled condensers

APPEARANCE OF DAMAGE: - Cracks on the Surface

PREVENTION / MITIGATION: - Proper applied coatingsunder insulation

INSPECTION / MONITORING: - VT, PT, UT, EDDY CURRENT TEST

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 SULFURIC ACID CORROSION
Corrosion resulting from their reaction from sulfur compounds in high
temperature environment
AFFECTED MATERIAL: - Carbon steel , Alloy 20 ,

CRITICAL FACTORS: - Depends on acid concentration, temperature, Velocity

AFFECTED EQUIPMENT: - Waste water treatment plants,Boilers

APPEARANCE OF DAMAGE: - General and localized corrosion
PREVENTION / MITIGATION: - Alloys

INSPECTION / MONITORING: - UT

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