Damage Mechanisms Affecting Fixed Equipment in the

Refining Industry
ANSI/API RECOMMENDED PRACTICE 571 THIRD EDITION, MARCH 2020
 Content

Exam questions will be based on the following portions of the document API
571 only:

Section 2 Definitions
3.3 Amine Stress Corrosion Cracking
3.8 Atmospheric Corrosion
3.9 Boiler Water and Stream Condensate Corrosion
3.14 Caustic Corrosion
3.15 Caustic Stress Corrosion Cracking
3.17 Chloride Stress Corrosion Cracking
3.22 Corrosion under Insulation
3.27 Erosion/Erosion – Corrosion
3.31 Galvanic Corrosion
3.37 Hydrochloric Acid Corrosion
3.43 Mechanical Fatigue (Including Vibration-induced Fatigue)
3.45 Microbiologically Influenced Corrosion
3.57 Soil Corrosion
3.58 Sour Water Corrosion (Acidic)
3.61 Sulfidation
Stress corrosion cracking:
1. Amine Stress Corrosion Cracking
2. Caustic Stress Corrosion Cracking
3. Chloride Stress Corrosion Cracking

Corrosion:
1. Atmospheric Corrosion
2. Boiler Water and Stream Condensate Corrosion
3. Caustic Corrosion
4. Corrosion under Insulation
5. Galvanic Corrosion
6. Hydrochloric Acid Corrosion
7. Microbiologically Influenced Corrosion
8. Soil Corrosion
9. Sour Water Corrosion (Acidic)

Mechanical
1. Mechanical Fatigue (Including Vibration-induced Fatigue)
2. Erosion/Erosion – Corrosion

High temperature corrosion

1. Sulfidation
 Mechanical Fatigue (Including Erosion/Erosion –
Vibration-induced Fatigue) Corrosion
Mechanical Fatigue Vibration-induced
Cracks occur due to
cyclical stresses
exposed for an
Erosion: Accelerated mechanical
extended period, often Form of mechanical
removal of surface material as a
resulting in sudden, fatigue caused due to
result of relative movement
Description unexpected failure, dynamic loading due to
between, or impact from solids,
either by mechanical vibration, water hammer
liquids, vapor or any combination
loading or therm or unstable fluid flow.
thereof.
cycling typically well
below yeild strenght
of the material
Affected All engineering
All engineering material All metals, alloys & refractories
Materials material
Temperature is a factor which
Temperature contributes to increase in metal loss
range along with other parameters of pH,
velocity and angle of impact.
Increasing hardness of the metal
Geometry, stress level, Amplitude and substrate is not always good
number of cycles, and frequency of vibration indicator of improved resistance
Critical Factors material properties, and fatigue resistance of where corrosion plays a sigf role. &
(Strength hardness & material are critical Increasing velocities above
Microstructure factors. threshold velocity limits will
increase metal loss
Socket welds and small
bore bypass lines and
flow loops around
rotating and
Equipments affected
reciprocating eqpt + All types of equt exposed to moving
by THERMAL
Affected Units Safety relief valves + fluid and/or moving catalyst are
CYCLING &
or Equipment subject to chatter, subject to erosion and erosion-
MECHANICAL
premature pop-off, corrosion
LOADING
fretting and failure to
operate, + HE tubes
susceptible to vortex
shedding.
CLAM SHELL type
finger print that has
concentric rings called
Crack initiating at a Localized loss in thk in form of pits,
"BEACH MARKS"
Appearance or point of high stress such grooves, gullies, waves, rounded-
results from the
Morphology of as a thread or weld joint. holes, and valleys. Often occur a
"WAVES" of the
Damage For Refractory damages, directional pattern and may fail with
crack propagation that
skin temp measurement in a short period.
occur during every
cycle above the
threshold loading.
 PT,MT & SWUT , VT
of small dia piping to
detect oscillation or
Visual inspection &
cyclic movement, +
Vibration montg, Visual +UT + RT +Corrosion
Vib montg of rot equpt
Damage to jacketing can montg like corr coupons and ER
Inspection to help detect shafts
cause wet insualation probes + IR scans for refractory
out of balance, IN
resulting corrosion erosions.
HIGH CYCLE
below insulation. (CUI)
FATIGUE, CRACK
INITIATION MAKE
DIFFICULT
Good design that
minimize stress
Supports & Vibrations
concentration of
dampening, proper side
components + allow
branching of safety
for a generous radius
Prevention/Miti valves, Vibration has to
along edges and
gation be removed from the
corners + mimimize
source as the effect may
grinding marks, +
shift is anchors are
good fit-up , mimize
provided,(design to be
weld defects + use low
studied)
stress stamps and
marking tools.
Specialized terminology :
Related Vibration induced Mechanical fatigue &
Cavitation, liquid impingement
Mechanism fatigue. Refractory degradation
erosion, fretting etc.,
 Hydrochloric Acid Sour Water Corrosion
Caustic Corrosion
Corrosion (Acidic)
Damage in refineries is
most often associated with
dew point corrosion in
Localized corrosion due to Corrosion of steel due to
which vapors containing
concentration of caustic or acidic sour water containing
water & HCL
alkaline salts that usually H2S at a pH between 4.5 and
condense from the
occurs under evaporative 7.0. (CO2) may also be
overhead stream of a
Description or high heat transfer conditions. present.+ Sour waters
distillation, fractionation or
However, general corrosion can containing significant
stripping
also occur depending on alkali amounts of NH3, chlorides
tower. First water droplets
or caustic or cyanides may
that condense can be highly
solution strength significantly affect pH
acidic (low pH) and
promote high corrosion
rates.
Primarily affects carbon
All common materials
steel.
Affected Primarily carbon steel, low constructed in refineries
b) Stainless steels, copper
Materials alloy steels and 300 Series SS. (Alloy400, Ni base & Ti
alloys and nickel base alloys
resistant to dilute HCL)
are usually resistant.
Exposure to high solution
strength caustic can result in
general corrosion of carbon
steel above 175F The severity of corrosion At a given pressure, the H2S
Temperature and very high corrosion rates increases with increasing concentration in the sour
range above 200 F + also Carbon steel HCl concentration and water decreases as
and 300 Series SS have serious increasing temperature. temperature increases
corrosion problems in high
strength caustic solutions above
about 150F .
Major contributing factors are H2S content, pH,
HCl acid concentration,
the presence of caustic (NaOH temperature, velocity and
Critical Factors temperature and alloy
or KOH) strength & oxygen concentration are all
composition.
temperature critical factors
Boilers, heat
exchangers. HCl corrosion is found in Acid sour water corrosion is
crude unit charge where caustic several units, especially a concern in overhead
Affected Units is added + preheat exchangers, crude and vacuum units, systems of FCC and coker
or Equipment furnace tubes and transfer hydroprocessing units and gas fractionation plants with
lines+ Units that use caustic for catalytic reformer high H2S levels and low
removing sulfur compounds units.REFER NH3 levels.
from product streams
CS & LAS suffer general General thinning. localized
Appearance or uniform thinning, localized corrosion or localized
Metal loss, Metal gouging,
Morphology of corrosion or underdeposit underdeposit attack can
deposits, grooving
Damage attack.+ 300 Series SS and occur, especially if o2 is
400 Series SS will often present. Corrosion in CO2
 suffer pitting attack and 300 containing environments
Series SS may experience may be accompanied by
chloride stress corrosion carbonate SCC + 300 SS are
cracking. susceptible to pitting attack
and may experience crevice
corrosion and/or chloride
SCC
UT thickness gauging +
Injection points should be UT for general thinning and
inspected in accordance with localised corrosion + pH &
UT& Profile RT + Process
API 570.+ UT scans and Corrosion monitoring +
Inspection and Corrosion montg of pH,
radiography can be used.+ Water sampling +
+ Provide corrosion coupons
Steam generation equipment Corrosion probes or
may require visual inspection coupons
with the use a boroscope.
Proper design + reducing the
amount of free caustic, by
ensuring adequate water
300 Series SS can be used at
flooding and water flow +
Water washing + Caustic temp below about 140F
ensure proper burner mangment
injection + Chloride control where Chloride SCC is not
to minimize hot spots on heater
genrally below 20 PPM in likely.+ Cu alloys and Ni
Prevention/Miti tubes, and by minimizing the
overhead accumulator alloys are generally not
gation ingress of alkaline producing
water + NH3, amine, susceptible to acid sour
salts into condensers+ caustic
neutralization into water + water corrosion.
injection facilities should be
Minimize HCL in H2 However,copper alloys are
designed to allow proper
streams vulnerable to corrosion in
mixing and dilution of caustic
environments with NH3
in order to avoid the
concentration of caustic on hot
metal surfaces
Caustic corrosion is also
referred to as caustic gouging or
ductile gouging. A related Ammonium chloride
Related Wet H2S damage and
mechanism is known as corrosion + Chloride SCC
Mechanism Carbonate SCC.
Departure from Nucleate & Localized corrosion
Boiling (DNB) as discussed in
steam blanketing
 Atmospheric Corrosion Galvanic Corrosion Soil Corrosion
A form of corrosion that occurs
A form of corrosion that
from moisture associated with
can occur at the junction of
atmospheric conditions. Marine
dissimilar metals when they
environments and moist The deterioration of metals
are joined together in a
Description polluted industrial environment exposed to soils is referred
suitable electrolyte, such as
with airborne contaminants are to as soil corrosion.
a moist or aqueous
most severe. Dry rural
environment, or soils
environments cause very little
containing moisture.
corrosion.
All metals with the
Affected Carbon steel, low alloy steels Carbon steel, cast iron and
exception of most noble
Materials and copper alloyed aluminum. ductile iron.
metals.
many factors including
operating temperature,
Corrosion rates increase with
moisture & O2 availability,
temperature up to about 250F.
Temperature soil resistivity, soil type and
Above 250F surfaces are
range homogeneity , cathodic
usually too dry for corrosion to
protection, stray current
occur except under insulation
drainage, coating type, age,
and condition.
Critical factors include the
physical location (industrial,
marine, rural); moisture For GC, 3 cond shall be
(humidity), particularly met, Presence of
Critical Factors designs that trap moisture or electrolyte, 2 different
when present in a cooling tower alloys & electrical
mist; temperature; presence of connection
salts, sulfur
compounds and dirt.
HE tubes of different
Underground piping and
materils of TS and / or
equipment as well as buried
baffles particularly if salt
Affected Units tanks and the bottoms of
water cooling is utilized.+
or Equipment above ground storage tanks
Buried pipelines, electrical
+ Ground supported metal
transmission support towers
structures
and ship hulls
general or localized, depending
upon whether or not the
moisture is trapped.+ If there is external thinning with
no coating or if there is a localized losses due to
Appearance or crevice, groove or pitting
coating failure, corrosion or pitting. + Poor condition of a
Morphology of corrosion, at the bolts or
loss in thickness can be protective coating is a tell
Damage welds of different materials
general.+ Localized coating tale sign of potential
failures will tend to promote corrosion damage.
corrosion.+
Metal loss may not be visually
 evident, although normally a
distinctive iron oxide (red rust)
scale forms.
measure soil potential using
dedicated reference
electrodes near the structure
VT and UT are techniques that Visual inspection & UT + Cathodic protection
Inspection
can be used. gauging (NACE RP 0169.)+
guided ultrasonic thickness
tools, pressure testing, or
visually by evaluation.
Soil corrosion of CS can be
minimized through the use
Good design + Coating but
Surface preparation and proper of special backfill, coatings
more the noble materal
Prevention/Miti coating application are critical and cathodic
shall be coated + For
gation for long-term protection in protection. The most
piping, electric insulating
corrosive effective protection is a
bolt sleeves and gaskets +
environments. combination of a corrosion
galvanized steel
resistant coating and a CP
system.
Related
Corrosion under insulation Soil corrosion Galvanic corrosion
Mechanism
 Corrosion under Insulation

Corrosion of piping, pressure vessels and structural components resulting from water
Description
trapped under insulation or fireproofing.

Affected
Carbon steel, low alloy steels, 300 Series SS and duplex stainless steels.
Materials
more severe at metal temps between the boiling point 212F & 250F where water is less
Temperature likely to vaporize and insulation stays wet longer.+ In marine environments or areas
range where significant amounts of moisture may be present, the upper
temperature range where CUI may occur can be extended significantly above 250F
Design of insulation system, insulation type, temperature, environment (humidity,
Critical Factors rainfall and chlorides from marine environment, industrial environments containing high
SO2) are critical factors.
Affected Units CS, LAS & 300 SS + 300 SS are also subject to SCC if chlorides are present, while the
or Equipment duplex SS are less susceptible.+ Location issues and Design issues
Appearance or
CS & LAS : loose, flaky
Morphology of
scale covering the corroded component. highly localized,
Damage
Visual inspection, Profile Radiography & Thermography (Generally appearace will be
Inspection
loose flaky corrosion )
Prevention/Miti
gation

Related
Atmospheric corrosion + Oxidation + Chloride SCC
Mechanism
 Boiler Water and Stream Condensate Corrosion

Description General corrosion and pitting in the boiler system and condensate return piping.

Affected
Primarily carbon steel, some low alloy steel, some 300 Series SS and copper based alloys
Materials
Temperature
No specific temp, depends on various factors of pH, O2 , quality of feed water and temp
range
concentration of dissolved gas (oxygen and carbon dioxide), pH, temperature,
Critical Factors
quality of the feedwater and the specific feedwater treating system.
Corrosion can occur in external treatment sys + deaerating equp + feedwater lines,
Affected Units
pumps, stageheaters and economizers as well as the steam generation system on both the
or Equipment
water and fire sides and the condensate return system.
Corr from O2 tends to be pitting type particularly aggressive in equip such as closed
Appearance or
heaters and economizers where there is rapid water temp rise.
Morphology of
+ Corr in cond return syst tends to be due to CO2 CO2 corr tends to be a smooth
Damage
grooving of the pipe wall.
Water analysis for pH, conductivity, chlorine or residual biocide, and total dissolved
solids to check for leaks in the form of organic compounds.
Inspection
+ NO proactive insp methods + Deaerator cracking problems can be evaluated by
WFMPI
Prevention/Miti O2 scavenging in deaerator + If the scale/deposit control/magnetite maintenance
gation treatment scheme does not minimize CO2 in cond return system, an amine inhibitor
treatment might be required.
Related
CO2 corrosion, corrosion fatigue and erosion/erosion-corrosion
Mechanism
 Microbiologically Influenced Corrosion

A form of corrosion caused by living organisms such as bacteria, algae or fungi. It is

Description often associated with the
presence of tubercles or slimy organic substances.

Affected Carbon and low alloy steels, 300 Series SS and 400 Series
Materials SS, aluminum, copper and some nickel base alloys.
Temperature 0F to 235F (–17 C
range to 113C).
MIC is usually found in aqueous environments or services where water is always or
Critical Factors sometimes present,especially where stagnant or low-flow conditions allow and/or
promote the growth of microorganisms.
heat exchangers, bottom water of storage tanks, piping with stagnant or low
flow, and piping in contact with some soils.+ equipment where hydrotest water has not
Affected Units been removed or equipment has been
or Equipment left outside and unprotected.+ Product storage tanks and water cooled heat exchangers in
any unit where cooling water is not properly
treated can be affected. + Fire water systems can be affected.
MIC corrosion is usually observed as localized pitting under deposits or tubercles that
Appearance or
shield the
Morphology of
organisms + Damage is often characterized by cup-shaped pits within pits in carbon steel
Damage
or subsurface cavities in SS
In CW systems, effectiveness of treatment is monitored by measuring biocide residual,
microbe
counts & visual appearance.+ Special probes have been designed to monitor for evidence
Inspection of fouling which may precede or coincide
with MIC damage.+ An increase in loss of duty of a heat exchanger may be indicative of
fouling and potential MIC
damage.+ Foul smelling water may be a sign of trouble.
Prevention/Miti Microbes require water to thrive. Systems that contain water (cooling water, storage
gation tanks, etc.) should be treated with biocides such as Cl, bromine, ozone, ultraviolet light or
proprietary compounds
Related
Cooling water corrosion
Mechanism
 Amine Stress Corrosion Caustic Stress Corrosion Chloride Stress Corrosion
Cracking Cracking Cracking
1. Amine cracking is a common
term applied to the cracking of
steels under the combined action
of tensile stress and corrosion in Surface initiated cracks casued by
aqueous alkanolamine systems Form of SCC charecterozed by surface environmental cracking of 300 series SS and
used to remove/absorb H2S initiated cracks that occur in piping & some Ni base alloys under combined action
Description
and/or CO2 and their mixtures equpt exposed to caustic, primarily of tensile stress temp and aqueous cl en, the
from various gas and liquid adjacent to non PWHT'd welds presence of dissolved O2 increases
hydrocarbon streams. propensity for cracking
2. Amine cracking is a form of
alkaline stress corrosion
cracking (ASCC).
1. Carbon steels
Affected 1. Carbon steels All 300 Series are highly susceptible. CS,
2. Low alloy steels
Materials 2. Low alloy steels LAS, 400 series are NOT susceptible.
3. 300 SS are susceptible
Cracking has been reported down to
ambient temperatures with some amines. Increase in caustic concentrations with
Temperature Usually occurs above 140F, increase in temp
Increasing temperature and stress levels increase in temp increase likeihood of
range increases susceptibility.
increases the likelihood and severity of failures
cracking.
The critical factors are the level of
1. caustic concentration,
1. tensile stress,
Critical Factors 2. metal temp Cracking in stainelss steel 300 series,
2. amine concentration
3. stress levels
3. Temperature.
All non-PWHT carbon steel piping and
equipment in lean amine service 300 series components+ water-cooled
Equpt handling caustic, H2S & mercaptan
including contactors, absorbers, condensers and in the process side of crude
Affected Units removal units, equts uses caustic for
strippers, regenerators and heat tower overhead condensers + drains in
or Equipment neutralalization in sulfuric acid
exchangers as well as any equipment hydroprocessing units are susceptible during
alkalyation untis and HF alkylation units
subject to amine carryover.MEA,DEA, start-up or shutdown if not properly purged.
DIPA
 Surface breaking cracks initiating at ID
typically propagates parellel to the weld Surface cracks on processside or externally
of pipe primarly at HAZ and stress areas,
in adj to basemetal and also in weld under insulation + no visible signs of
Appearance or + typically parelell to welds+ Nozzles +
deposits/HAZ+ spider web of small corrosion + branch and craze crack
Morphology of similar to H2S cracking + found on
cracks + Inergrannular + as-welded CS appearance + INTERGRANULAR cracking
Damage process side opposite to external
fabrications as very fine and oxide-filled of sensitized SS 300 + brittle appearance of
attachment welds + INTERGRANULAR
cracks fractured surfaces.
(Oxide filled & branching)
WFMT+EC+RT or ACFM , surface prep Visual + PT + Phase analysis ECT + fine
by blasting is required, + NO PT for scale cracks with PT after specail surface cleaning
Inspection WFMT + ACFM + Less PT + AET
filled cracks+ UT/SWUT + AET for methods + UT + NOT RT unless cracks are
Crack growth. at advanced stage.
PWHT, for CS consider SR @
PWHT all CS welds in accordance with 1150F+300SS litle advantage over CS +
API RP 945. also to repair welds and to Ni base alloys more resitant + Avoid Duplex + Nickel base + when hydrotesting
Prevention internal and external attachment welds.+ Steam out of Non PWHT, where requd use low chloride content and allow to dry
/Mitigation Use solid or clad SS Alloy 400 or other water wash before, use LP steam for short thouroughly and quickly + coatings under
corrosion resistant alloys in lieu of CS + periods. + proper dsgn * oprtn of Inj sys insulation + avoid design where Cl can
Water wash non-PWHT CS prior to requd to ensure caustic is properly deposit or stagnate. + SR for 300 SS
welding, heat treatment or steamout. dispersed before entering high temp crude
preheat system
Amine stress corrosion cracking and is a
Related form of Alkaline SCC. Caustic SCC and
Amine cracking & Carbonate cracking Caustic SCC & PASCC
Mechanism carbonate SCC are two other forms of
ASCC that are similar in appearance.

1. In aqueous alkanolamine systems used to remove/absorb H²S and/or CO² and their mixtures from various gas and
liquid hydrocarbon streams, Amine SCC is a term applied to the cracking of steels under the combined actions of:
A) Temperature and pressure B) Pressure and stress
C) Temperature and corrosion D) Tensile stress and corrosion

Answer: D … Ref: 5.1.2.2.1.a … Amine SCC → Description of Damage

2. Which of these materials is not susceptible to amine cracking?

A) Carbon steels B) Low alloy steels
B) Both CS & LA Steels D) Both 300 & 400 Series SS
Answer: D … Ref: 5.1.2.2.1.c & 5.1.2.2.2 … Amine SCC → D of D & Affected Materials

3. Amine cracking (form of Alkaline SCC) is more likely to occur in which services?

A) MDEA & ADIP B) ADIP & DIPA C) MEA & DEA D) DIPA & MEA

Answer = C … See Para. 5.1.2.2.3.c → Amine SCC … (Critical Factors)

4. Regarding amine cracking (reported down to ambient temps with some amines), which of the following statements are
TRUE:
A) Decreasing temperatures & stress levels decreases the likelihood & severity of cracks
B) Decreasing temperatures & stress levels increases the likelihood & severity of cracks
C) Increasing temperatures & stress levels decreases the likelihood & severity of cracks
D) Increasing temperatures & stress levels increases the likelihood & severity of cracks

Answer: D … Ref: 5.1.2.2.3.d → … Amine SCC → Critical Factors → API style Q

5. Amine stress corrosion cracking is most often associated with lean amine service and pure alkanolamine does not cause
cracking. Rich amine service cracking is most often associated with which of the following?

A) H²S B) Wet H²S C) Stress D) Temperature

Answer: B … Reference: 5.1.2.2.3.e … … Amine SCC → Critical Factors

6. Amine stress corrosion cracking can occur in non-PWHT’d piping & equipment when:

A) Exposed to steamout or short-term amine carryover

B) Exposed to wet H2S environment or CO2 carryover
C) Exposed to steamout or organic acid carryover
D) None of these are correct
Answer: A … Reference: 5.1.2.2.3.f … Critical Factors
7. Which of the following materials is susceptible to Chloride SCC?

A) Carbon steel B) 300 Series SS C) Low alloy steel D) 400 Series SS

Answer: B … Ref: 4.5.1.1 & 4.5.1.3.L … Chloride SCC → D of damage & Critical Factors
8. Critical factors for Chloride SCC include all of the following EXCEPT:

A) Chloride content B) pH & temperature C) Alloy composition D) Stress & presence of CO² Answer = D … Para. 4.5.1.3.a …
Chloride SCC → Critical Factors → stress, O2 presence

9. Regarding Chloride SCC, which of the statements below is TRUE?

A) Increasing temperatures & chloride levels increase susceptibility for cracking

B) Decreasing temperatures all but eliminates the susceptibility for cracking
C) Decreasing temperatures increases the susceptibility for cracking
D) None of these are correct
Answer: A … Reference: 4.5.1.3.b/c … Chloride SCC → Critical Factors → API style Q
9. Chloride SCC usually occurs above what metal temperature and pH value?
A) Above 125º F (52ºC) and pH 3.0 B) Above 140º F (60ºC) and pH 2.0
C) Above 175º F (79ºC) and pH 2.5 D) Above 200º F (93ºC) and pH 3.0
Answer: B … Ref: 4.5.1.3.g/f … Chloride SCC → Critical Factors
10. Regarding Chloride SCC, which statements regarding nickel content are true?
A) Greatest susceptibility (≤ 3%), highly resistant (≥ 20%), nearly immune (≥ 30%)
B) Greatest susceptibility (3 – 8%), highly resistant (≥ 25%), nearly immune (≥ 35%)
C) Greatest susceptibility (8 – 12%), highly resistant (≥ 35%), nearly immune (≥ 45%)
D) Greatest susceptibility (12 – 20%), highly resistant (≥ 45%), no % immune from SCC
Ans: C … Ref: 4.5.1.3.j Chloride SCC usually above 140°F (60°C)… Critical Factors NOTE: AFFECTED MATERIALS
Nickel based alloys are highly resistant to CLSCC
11. Regarding the visual appearance (after PT) of Chloride SCC, which statement is true?
A) Parallel cracks in HAZ nearer to the fusion line
B) Parallel cracks in HAZ nearer to adjacent base metal
C) Spider web, branching and craze-cracked in appearance
D) None of these are correct

Answer: C … Ref: 4.5.1.5.c & Fig 4-136 → Chloride SCC → Appearance

12. What are the preferred methods of detecting Chloride SCC?
A) PT only
B) PT or WFMPT
C) PT or Phase Analysis EC techniques
D) UT shearwave and RT, because PT cannot locate extremely fine cracks

Answer: C … Ref: 4.5.1.7.b Chloride SCC Inspection & Monitoring

13. Caustic concentrations at what minimum ppm values can cause Caustic SCC?

A) 50-100 PPM
B) 100-150 PPM
C) 150-200 PPM
D) 200-250 PPM

Answer = A … Ref: 4.5.3.3.c → PWHT prevents Caustic SCC … Critical Factors

13. Caustic embrittlement cracking can be effectively prevented by means of PWHT at a temperature of:
A) 1100º F (593°C)
B) 1150º F (621°C)
C) 1200º F (649°C)
D) 1250º F (677°C)

Answer = B … Ref: 4.5.3.6.a PWHT temps for Caustic SCC … Prev/Mit NACE
SP0403 not requires a 1175 +25 F PWHT … So … C is correct in the field!!!

14. How can Caustic Stress Corrosion Cracking be prevented on Non-PWHT’d CS lines?
A) Upgrade to 300 Series SS
B) Upgrade to the nickel alloy
C) Avoid steamout cleaning
D) None of these

Answer = C … See Para. 4.5.3.6.d … Caustic SCC → Prevention/Mitigation

15. At higher temperatures and/or caustic concentrations, what material is more resistant to Caustic embrittlement (Caustic
SCC)?
A) Carbon steels that have received PWHT
B) Low alloy steels that have received PWHT
C) 300 Series Stainless steels
D) Nickel-based alloys

Answer = D … Reference: Caustic SCC Par. 4.5.3.2, 4.5.3.3.b & Fig 4-146, & 4.5.3.6.c

16. Another name for Caustic Stress Corrosion Cracking (SCC) is:
A) Alkaline SCC
B) Caustic Gouging
C) Ductile gouging
D) None of these

Answer = D … See Para. 4.5.3.1 … CAUSTIC SCC = CAUSTIC EMBRITTLEMENT

17. Caustic embrittlement is a form of stress corrosion cracking characterized by Surface- initiated cracks in piping and
equipment exposed to caustic and located:
A) In the HAZ of welds always
B) Most often in the HAZ of welds
C) Mostly adjacent to Non-PWHT welds
D) Mostly adjacent to zones of high stress

Answer = C … See Para. 4.5.3.1 … CAUSTIC SCC → Description of Damage

18. Susceptibility to Caustic SCC in caustic soda/caustic potash solutions is a function of:
A) Caustic strength, metal temp & stress levels
B) Metal temperature and stress levels
C) O2 content, caustic strength & stress levels
D) None of these

Answer = A … See Para. 4.5.3.3.a … CAUSTIC SCC → Critical Factors

19. Regarding caustic embrittlement, which of these statements are true about caustic concentrations and temperatures?
A) Decreasing concentrations & decreasing temps increases likelihood/severity of cracks
B) Decreasing concentrations & increasing temps increases likelihood/severity of cracks
C) Increasing concentrations & decreasing temps increases likelihood/severity of cracks
D) Increasing concentrations & increasing temps increases likelihood/severity of cracks

Answer = D … Ref: 4.5.3.3.b → Caustic Embrittlement = Caustic SCC … Crit Factors

Sulphidation

Sulfur compounds reacts with CS & other alloys at high temperature, Presence of H2 accelerates corrosion It is also
Description
called sulfidic corrosion

Affected
All Fe base alloys incl 300 & 400 SS + Ni base alloys if Cr content is less + Copper at lower temp than CS
Materials
Temperatur
Iron base alloys sulfidation occurs usually above 500 F
e range
Critical
Factors
Affected
Piping and equpt (contains sulfur at high temp.+FCC+Crude+vacuum + Boilers high temp where sulfur at high comp is
Units or
present
Equipment
Appearance
or Uniform thinning, localized+Sulfur scales depend on alloy, corrosiveness of stream, velocity & presence of
Morphology contaminats
of Damage
Process cond monitoring for increae in Temp & sulfur levels + Temp montg + UT & Profile RT for thinning + PMI for
Inspection
alloy comp check for any mixing of sulfur
Prevention/
Upgrading to higher Cr alloy + constructing with clad or solid 300/ 400 SS + Al diffusion treatment for LAS sometimes
Mitigation
reduce sulfidation rates and scaling
Related
 Mechanism
1. Sulfidation damage is accelerated by the presence of:

A) Hydrogen B) Sulfur C) Salts D) Corrosive Water

Answer = A … See Paragraph 4.4.2.1 (Description of Damage)

2. Which material is highly resistant to Sulfidation damage in most refining process environments?

A) Carbon steels B) Low alloy steels ≥ 7% Chrome

C) 400 Series SS D) 300 Series SS (304, 316, 321, 347)

Answer = D … Ref: 4.4.2.2.a & 4.4.2.3.d … Affected Materials & Critical Factors

3. Sulfidation of iron-based alloys usually begins at metal temperatures above:

A) 500°F (260°C) B) 700°F (370°C) C) 900°F (482°C) D) 1000°F (538°C)

Answer = A … See Paragraph 4.4.2.3.c (Critical Factors)

4. Increasing chromium content in Low alloys improves Sulfidation resistance. However, there is little improvement until
chromium content is increased to (what % Cr):

A) 3-5% B) 5-7% C) 7-9% D) 12%

Answer = C … Ref: 4.4.2.3.c & Fig. 4-65 McConomy Curves & 4.4.2.6.a … CF & P/M Par. 5.1.1.5.3.f & Fig 5.4 → 7 – 9% is
the given rule in High Temp H²/H²S Corrosion McConomy curves must be understood as well as the need to increase Cr%
& use IOWs

5.Which Curves are utilized to determine Sulfidation corrosion rates?

A) Couper-Gorman B) McConomy C) Nelson D) None of these

Answer = B … Ref: 4.4.2.3.c & Fig. 4-65 McConomy Curves & 4.4.2.6.a …

6. Sulfidation occurs at high temps and is primarily caused by:

 A) Sulfates & other reactions from decomposition of sulfur compounds at high temps
B) SO² & other reactions from decomposition of sulfur compounds at high temps
C) SO³ & other reactions from decomposition of sulfur compounds at high temps
D) H²S & other reactions from decomposition of sulfur compounds at high temps

Answer: D … Ref: 4.4.2.3.f … Critical Factors

7. When Sulfidation damage is found, it most often (usually) appears as:

A) Localized corrosion B) High velocity erosion-corrosion
C) Uniform thinning D) Under-deposit (scale) corrosion

Answer = C … See Paragraph 4.4.2.5.a below (Appearance)

8.Services susceptible to sulfidation will usually have component surfaces that are:
A) Covered with localized pitting B) Covered with sulfide scale
C) Uniformly corroded (general deep pits) D) Covered with under-deposit pitting

Answer = B … See Paragraph 4.4.2.5.b below (Appearance)

9.Resistance to Sulfidation is generally achieved by:

A) Upgrading to a higher chromium alloy B) Upgrading to a SS or nickel steel
C) Utilization of effective hi-temp coatings D) None of these
Answer = A … See Paragraph 4.4.2.6 below (Prevention)

10.Sulfidation occurs in piping and equipment:

A) In hi-temp environments where sulfur-containing streams are processed
B) In hi-temp environments where H2S exists regardless of percentage
C) In hi-temp environments where hydrocarbon steams are mixed
D) None of these are correct
Answer = A … See Paragraph 4.4.2.4.a (Affected Units or Equipment)
11.In services where sulfidation is anticipated, what is used to check for alloy mix-ups that can result in accelerated
corrosion rates?
A) Proactive and retroactive PMI programs for alloy verification per API 578
B) Retroactive PMI programs for alloy verification per API 578
C) Proactive PMI programs for alloy verification per API 578
D) Alloy verification checks (chemical analysis) per API 578
Answer = A … 571, Para. 4.4.2.7.d & Reference 7 … DM # 1 … Insp & Monitoring
12. Evidence of thinning from sulfidation is best detected using:
A) Shear wave UT due to preferential weld attack and weld metal loss
B) Alloy verification checks (chemical analysis) per API 578
C) UT thickness measurements and Profile Radiography
D) A combination of UT thickness and UT shearwave
Answer = C … 571, Para. 4.4.2.7.c … DM # 1 … Inspection & Monitoring